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BWTS 3

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0% found this document useful (0 votes)
34 views575 pages

BWTS 3

Uploaded by

bigidanzhekov
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Equipment Operations & Technical

Manual
ERMA FIRST BWTS FIT 800 for HN SEE VESSEL TABLE
P.1

Vol. III – Suppliers’ manuals

© ERMA FIRST ESK ENGINEERING SOLUTIONS


Schisto Industrial Park ( VIPAS ), Block 13, Keratsiniou–Skaramagas Ave,
188 63, Perama, Greece
Tel: (+30) 2104093000 / Fax: (+30) 2104617423
E-mail: [email protected]
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: Overall information and specifications HN SEE VESSEL TABLE
P.1

Overall information and specifications


Hull Number: SEE VESSEL TABLE P.1
BWTS model: ERMAFIRST BWTS FIT 800

ERMA FIRST BWTS Serial


Vessel Name Hull Number Project Number
Number
ECKERT OLDENDORFF JLZ9120417 002-000484 10-0800RF-1-0837
EMMA OLDENDORFF JLZ9120418 002-000497 10-0800RF-1-0878
ERNA OLDENDORFF JLZ9120425 002-001721 10-0800RF-1-0911
EIBE OLDENDORFF JLZ9120419 002-001722 10-0800RF-1-0912
EDWARD OLDENDORFF JLZ9120420 002-001723 10-0800RF-1-0913
ELSA OLDENDORFF JLZ9120421 002-001724 10-0800RF-1-0914
ERNST OLDENDORFF JLZ9120422 002-001726 10-0800RF-1-0915
ELISABETH OLDENDORFF JLZ9120423 002-001727 10-0800RF-1-0916
EDWINE OLDENDORFF JLZ9120424 002-001869 10-0800RF-1-0918

Document No: 2-1920-0801


Document Revision 01
Date 11/6/2019

BWTS capacity: 800 m³/h


Max. power consumption: 92.74 kW
Cooling Water flow: 1.2 m³/h

Ballast water temperature range: -2° – 40° C

Minimum intake water salinity: 1.07 PSU at -2° C/ 0.9 PSU at 3° C

Average operation pressure: 0.5 - 5 bar


Approved for use in explosive
No
atmospheres:
Max. allowable dosage concentration of
10 mg/L
TRO (Cl2):
Holding time in tank prior to
> 1h
neutralization:
Max. allowable discharge concentration
< 0.1 mg/L
of TRO (Cl2)after neutralizing:
Max. Hydrogen gas generation: ≤ 1.6% vol. (40% LEL)
Max. differential pressure across filter,
0.5 bar
prior to flushing:

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 1
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: Overall information and specifications HN SEE VESSEL TABLE
P.1

Copyright ERMA FIRST ESK ENGINEERING SOLUTIONS SA

All rights reserved.

The data contained in this document is proprietary to ERMA FIRST ESK ENGINEERING SOLUTIONS SA

You are respectfully reminded that none of the following may be directly or indirectly released,
reproduced, modified or used in anyway without the explicit permission of ERMA FIRST S.A., neither
can it be used for the reproduction of the BWT System or any of its components.

All specifications included in this manual are subject to change without notice

ERMA FIRST ESK Engineering Solutions S.A. shall not be responsible or liable for damages resulting from
misapplication or misuse of its products.

Contact Details:

ERMA FIRST ESK Engineering Solutions S.A.

Schisto Industrial Park ( VIPAS ), Block 13,


Keratsiniou–Skaramagas Ave,
188 63, Perama, Greece
Tel: (+30) 2104093000 / Fax: (+30) 2104617423
E-mail: [email protected]
[email protected]
WEB: http://www.ermafirst.com/

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 2
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

INDEX
OVERALL INFORMATION AND SPECIFICATIONS

INDEX

CONTROL PANEL
Power source replacement
FILTER(S)
ELECTROLYTIC CELL(S)
TRANSFORMER/ RECTIFIER(S)
FLOW METER
TRO MONITORS
DOSING PUMP(S)
FLOW SWITCH(ES)
TEMPERATURE SENSOR(S)
PRESSURE TRANSMITTERS
SHUTTER VALVES
SALINITY MEASURING DEVICE
SUCTION PUMP
HYDROGEN SENSOR
DIAPHRAGM AIR PUMP
BUTTERFLY VALVES
PRESSURE & TEMPERATURE SWITCH
LEVEL SENSORS

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 3
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

CONTROL PANEL

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 4
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

Power source replacement


Power source (battery) lifetime: 3-4 years (depending on the use).

Steps for safe replacement

Disconnect the cables in


front and near the power
source

Figure 1: Disconnect the cables

Open the cover and


remove the power source

Check the
polarity of the power
source (battery) before
removing it.

Figure 2: Remove power source

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 5
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

Replace the power source


(replacement time should
not exceed 5 minutes).

Power source tech.


specifications:
- Lithium battery
- 3.6 volt
- Indicative type
(from Schneider)
TSXPLP01

Figure 3: Power source

Replacement time MUST NOT EXCEED 5 minutes

Replace the power source

Be careful of the polarity.

Figure 4: Replace the power source

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 6
1-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

Close the cover and re-


connect the cables.

Figure 5: Replace cables

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 7
1-1920-0801 Equipment Operation & Technical manual –Vol llI Rev. 01
11/6/2019 Chapter: INDEX HN SEE VESSEL TABLE
P.1

FILTER(S)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 8
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 9
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 10
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 11
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 12
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 13
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 14
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 15
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 16
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 17
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 18
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 19
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 20
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 21
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 22
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 23
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 24
Copyright © 2015-2017 Filtersafe®, All rights reserved.
The data contained in this document is proprietary to Filtersafe®. It is disclosed to the receiving party only for
the sole purpose stated herein, and shall not be disclosed by the receiving party to any third party, and shall
not be duplicated, used or disclosed in whole or in part for any purpose other than the purpose specifically
stated.
This publication, or any parts thereof, may not be reproduced in any form without the express written
permission of Filtersafe®.

Filter Control System

Contact Filtersafe®
To communicate with a Filtersafe® representative, use the following contact information:

Israel
HaElla Street, P.O.B 23, Tefen Ind. Zone 2495900
Installation and Operation Manual
Address:
Phone: +972-4-9873620/1
Fax: +972-4-9873617

Software Version 3.xx


Email: [email protected]
Web www.filtersafe.net

P/N DOC-00136 | Rev D Printed 18 July 2017 Germany


Address: Papenreye 55, Unit 11, 22453 Hamburg
Phone: +49-(0)151 5111 9622
Email: [email protected]

Singapore
Address: 56 Toh Tuck Road, #07-02 Signature Park, Singapore 596746
Phone: +65-8321-3739
Email: [email protected]

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Table of Contents
Authorization
1. Preface ..............................................................................................1-6
Signature
2. Safety ................................................................................................2-7
Revision 02 Approval Name Date approved
(HC only) 2.1 Cautions ....................................................................................................................... 2-7
2.2 General Safety Cautions .............................................................................................. 2-7
X System Engineer 01.12.2014 3. Introduction ......................................................................................3-8
X Project Manager 01.12.2014
3.1 System Overview ........................................................................................................ 3-8
X QA Manager 01.12.2014
3.2 System Purpose ........................................................................................................... 3-8
Revision History 4. Operating Principles..........................................................................4-9
4.1 Filter Functions.......................................................................................................... 4-10
Rev. Description of Revisions Changed by: Date/Sign
4.2 Active Components of the Filter ............................................................................... 4-11
A Initial Release 01.12.2014 4.3 Scanner Movement .................................................................................................... 4-13
B Changing Modbus numbers, adding analog inputs 15.5.2015
4.4 Flushing Cycle ........................................................................................................... 4-13
Added new messages, Ver 3.3 info to the Alarm Event table, 26.7.2016
C 4.5 Conditions that Initiate an Auto Flushing Cycle ....................................................... 4-14
Messages and Indicators Logic annex, and Setup Values Form.
D Adding Jazz 20 battery replacement 20.03.2017 4.6 Flushing Cycle Options ............................................................................................. 4-14
4.7 Manual Flushing ........................................................................................................ 4-15
4.8 Remote Flushing ........................................................................................................ 4-16
5. Control Cabinet Overview .............................................................. 5-17
5.1 Control Panel ............................................................................................................. 5-18
5.2 Controller ................................................................................................................... 5-19
5.3 Control Cabinet – Inside View .................................................................................. 5-20
6. Installation ..................................................................................... 6-21
6.1 Mounting ................................................................................................................... 6-21
6.2 Wiring ........................................................................................................................ 6-21
7. Setup .............................................................................................. 7-22
7.1 Introduction ............................................................................................................... 7-23
7.2 Displaying the Setup Menu ....................................................................................... 7-23
7.3 Flushing Parameters .................................................................................................. 7-24
7.4 Optional Flushing Pump Parameters ......................................................................... 7-26
7.5 IP Parameters ............................................................................................................. 7-27
7.6 Controller Name ........................................................................................................ 7-28
7.7 Pressure Transmitter Settings .................................................................................... 7-28
7.8 Analog DPT Settings ................................................................................................. 7-29
7.9 Minimum Flushing Time ........................................................................................... 7-30
7.10 Exiting the Setup Menu ............................................................................................. 7-30
8. Service and Testing ........................................................................ 8-31
8.1 Displaying the Service Menu .................................................................................... 8-31
8.2 Returning to the Main Screen .................................................................................... 8-31
8.3 Service Menu Screens ............................................................................................... 8-32
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8.4 Testing the Scanner Limit Sensors and Motors......................................................... 8-33
8.5 Testing the Pump ....................................................................................................... 8-36 1. Preface
8.6 Testing the Flushing Valve........................................................................................ 8-37
8.7 Testing the MPI Devices ........................................................................................... 8-37 Manual Purpose
9. Operation ....................................................................................... 9-38 The Filter Control System Installation and Operation Manual is designed for the use of authorized operators
and technicians of the Filter Control System. This manual reviews the most common procedures required
9.1 Power Up ................................................................................................................... 9-39 during the operation and maintenance of the Filter Control System.
9.2 Controller Operating Screens .................................................................................... 9-39
This manual is associated with Safe Zone, Ex d and Ex ia model filters. The Filter Control System is used to
9.3 Messages and Indicators ............................................................................................ 9-40 control single filters and multi-filter systems. The images and illustrations are for demonstration only and may
10. Technical Specifications ............................................................... 10-45 not reflect the exact hardware included in your filter model.

10.1 Power Supply .......................................................................................................... 10-45 Controller Model and Software Version
10.2 Control Panel Components ...................................................................................... 10-45 This manual is associated with the Unitronics© JazzTM 20 PLC controller with application version M5-1-00 or,
11. Annex A: Controller Inputs and Outputs ..................................... 11-46 M5-XX-XX-V3.X.

11.1 Inputs ....................................................................................................................... 11-46


11.2 Outputs .................................................................................................................... 11-48
12. Annex B: Modbus Specifications .................................................. 12-49
12.1 Modbus Word Registers .......................................................................................... 12-49 Applicable Documents
12.2 Word Register Bit Map ........................................................................................... 12-52 n BS025-BS200 Operation Manual (P/N 00144)
13. Annex C: PLC Program Upgrade .................................................. 13-53 n BS300/BS400 Automatic Screen Filter Operation Manual (P/N DOC- 00142)
n Compact Model Operation Manual (P/N DOC- 00157)
14. Annex D: Interface Logic ............................................................. 14-54
n Multi-Screen Filter Operation Manual (P/N DOC- 00141)
14.1 Pump Interface Logic .............................................................................................. 14-54
n Safe Zone Data Sheets (P/N DOC 00159)
14.2 Filter Interface Logic ............................................................................................... 14-55 n Ex d Model Operation Manual Appendix (P/N DOC- 00155)
15. Annex: E: Setup Values Form ....................................................... 15-56 n Ex ia-1 Appendix (P/N DOC-0000309)
16. JAZZ 20 BATTERY REPLACEMENT ................................................ 16-57 n Ex ia-0 Appendix (P/N DOC-0000310)
17. User Notes .................................................................................... 17-60

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2. Safety 3. Introduction
This chapter contains an overview of the Filter Control System safety concerns and includes: This manual describes installation and operation of the Filter Control System for Filtersafe automatic single
screen and multi-screen filters.
n Section 2.1: Cautions
n Section 2.2: General Safety Cautions 3.1 System Overview
2.1 Cautions The system includes:
n Control cabinet – controls the filter operation.
n Flushing pump – controls the operation of the optional flushing pump (see Section 4.2.5:
CAUTION Optional Flushing Pump).
CAUTION: Filters may flush automatically, without prior warning. n Customer control system – main control communicates with the filter control via dedicated
inputs and outputs.
n SCADA – enables remote monitoring of the controller. Connected to the controller via Ethernet
The following instructions and guidelines are necessary to ensure safe operation and long filter life. communication (MODBUS TCP). The SCADA system is used by authorized service personnel only.
Before performing any work on the filter, become familiar with the following safety sections: SCADA requires (optional) Ethernet adaptor to communicate with the filter control.

2.2 General Safety Cautions


n Read the installation and the operation instructions prior to installation or before servicing the
filter.
n Before working on the filter, read all safety standards and instructions to avoid injury to the
operator or damage to equipment or property.
n The electrical connections must be connected or serviced by a qualified electrician, using certified
components only, and according to local regulations and standards.
n A main safety power cut-off switch must be installed near the control cabinet.
n Install a main power cut-off switch near the filter if the control cabinet is not visible from the filter.
n The control cabinet and other electrical devices must be installed so that they are not accidentally
exposed to water.
n If the filter is used in hot water applications (i.e. water temperatures up to 55⁰C), additional safety
devices must be installed to avoid injuries.

3.2 System Purpose


The purpose of the Filter Control System is to:
n Control the filter operation
n Enable testing of the filter
n Signal alerts
n Communicate with the customer control system
n Provide communication with a SCADA control system

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4.1 Filter Functions
4. Operating Principles The Filtersafe Automatic Screen Filter performs two primary functions:

This chapter describes operating principles of the filter and control system and includes the following: n Filtering – raw water flows into the filter and comes out clean
n Flushing – the filter screens are cleaned
n Section 4.1: Filter Functions
n Section 4.2: Active Components of the Filter 4.1.1 Filtering
n Section 4.3: Scanner Movement During filtering:
n Section 4.4: Flushing Cycle n Raw water flows through the filter inlet pipe and through the filter screen.
n Section 4.5: Conditions that Initiate an Auto Flushing Cycle n Solids and dirt particles are caught by the screen.
n Section 4.6: Flushing Cycle Options n Clean water exits the system through the filter exit pipe.
n Section 4.7: Manual Flushing 4.1.2 Flushing
n Section 4.8: Remote Flushing
During flushing:
n The Flushing Valve is open.
n The Flushing Pump is operating.
n The Scanner motor is operating.
n The screen is cleaned.
n Dirt is flushed from the system.

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4.2 Active Components of the Filter 4.2.7 DPT
The DPT (Differential Pressure Trigger) indicates the differential pressure between the filter upstream
(incoming) water and the downstream(outgoing) water. Dirt buildup on the screen changes the pressure
differential between the upstream raw water pressure and the downstream clean water pressure.
4.2.1 Scanner The filter includes one of the following DPT options:
n The scanner is a set of nozzles rotated by a Drive Unit that cleans the filter screen during n Differential Pressure Switch – default option
Flushing. n Analog Differential Pressure Transmitter – provides an analog signal
n The scanner moves in a helical motion causing the nozzles to run back and forth across the n Analog Pressure Transmitters – includes two analog transmitters: one for upstream and one
screen. for downstream
n See section 4.3: Scanner Movement.
4.2.8 Optional Alert Switches
4.2.2 Drive Unit
The following optional switches can be connected to the Controller:
n The drive unit powers the Scanner operation.
n Differential Pressure Switch with Alarms –high DP outputs
n The different filter models have different types of drive units (motor + Gear):
n Pressure Switch – located in the upstream; alarm options:
• Safe zone – standard electric motor
• High upstream pressure
• Ex d – Ex d electric motor
• Low upstream pressure (alert on low flushing pressure)
• EX ia – air operation motor
• Contact Filtersafe for additional options
4.2.3 Limit Sensor
n A Scanner includes two limit sensors that control the Scanner Movement (see section 4.3).
n The limit sensors are normally closed (NC).
n The different filter models have different types of limit sensors:
• Safe zone – mechanical limit switches or proximity sensors
• Ex models – mechanical limit switches or proximity sensors
4.2.4 Flushing Valve
n The flushing valve is a normally closed valve and is opened during Flushing.
n The open valve creates a pressure differential between the filter inlet and the atmospheric
pressure at the flushing outlet. This differential creates suction at the scanner nozzles.
4.2.5 Optional Flushing Pump
n The flushing pump is connected to the flushing pipe.
n The flushing pump helps relieve water pressure head in the downstream flow.
n The flushing pump increases the suction pressure at the scanner nozzles.
n The flushing pump is powered and controlled from the Filtersafe control cabinet or the customer
control system.
4.2.6 Optional Flow Switch
n The optional flow switch indicates the water flow at the flushing water outlet.
n The flow switch sends a signal to the control cabinet.
n The flow switch provides pump protection in case of a valve fault.

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4.3 Scanner Movement 4.5 Conditions that Initiate an Auto Flushing Cycle
Scanner movement proceeds as follows (see Figure 4-1): To configure Flushing Cycle settings, see chapter 7: Setup.

1. The Drive Unit starts, causing the Scanner to rotate in a spiral movement. This section describes conditions that initiate an auto Flushing Cycle in filter automatic mode:

2. When the Scanner reaches the end of its travel, a disk on the Scanner shaft activates the Limit Sensor. 4.5.1 DPT Signal

3. The motor changes direction, causing the Scanner to rotate in the opposite direction. The DPT (see section 4.2.7) indicates pressure
differential that requires a Flushing Cycle. The
4. When the Flushing Cycle signal ends, the Scanner moves to the next Limit Sensor and stops. Flushing Cycle starts after a predefined delay time.
5. After Remote Flushing the Scanner continues until it reaches the HOME position and then stops. The Flushing Cycle ends after meeting all of the
following conditions:
n DPT is off
n DPT Off delay timer exceeds its set point
n Minimum flushing time exceeds its set point
n Scanner reaches its stop position.

4.5.2 Timer Operation


At the end of a Flushing Cycle, the timer starts
counting. When the preset time ends, the next
Flushing Cycle starts. This ensures a minimum time
lapse between Flushing Cycles.
4.4 Flushing Cycle The timer resets after any type of Flushing Cycle.
A Flushing Cycle refers to the period of time in which the system operates in Flushing. The following is the
workflow for a full Flushing Cycle from initiation to stopping:
1. A Flushing Cycle initiation condition occurs (see section 4.5: Conditions that Initiate an Auto Flushing Cycle).
2. The Flushing Valve opens.
3. The Flushing Pump starts.
4. The Scanner motor starts rotating and moving.
5. The trigger for stopping the Flushing Cycle is activated.
4.6 Flushing Cycle Options
6. The Scanner reaches the nearest Limit Sensor.
This section describes features that affect Flushing Cycle operation.
7. The Scanner motor and the Flushing Pump stop.
4.6.1 Minimum Flushing Time
8. The Flushing Valve closes.
Minimum Flushing Time maintains the Flushing
Cycle for a preset amount of time regardless of the
DPT . This is to prevent the Flushing Pump motor
from being rapidly turned on and off.
This feature is useful if the pump motor has a limit
on number of activations per hour.
To define the Minimum Flushing Time, see
section 7.9: Minimum Flushing Time.

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4.8 Remote Flushing
4.6.2 DPS Off Delay
Remote flushing is initiated manually using the customer controller. After the controller signal is terminated,
When the DPT turns off, the DPS Off Delay flushing stops when the Scanner reaches the HOME position (see section 4.3: Scanner Movement).
extends the Flushing Cycle for a preset amount of
During the remote flushing procedure:
time. This is to prevent rapid flushes in very dirty
water. It is recommend to set this delay preset to n The flushing switch on the Control Panel must be in Auto position.
half of the scan cycle. n A command signal is sent from the central control system.
To define the DPS Off Delay time, see DPS Off
n The Timer Operation enters rest mode (see section 4.5.2).
Delay screen pg. 7-25.
n The filter enters Flushing (see section 4.1.2) until the flushing trigger is off.
n The Scanner reaches the HOME position.
n Flushing Cycle stops.
4
4.7 Manual Flushing
Manual flushing is initiated and stopped manually.
Manual flushing is used to:
n initiate cleaning.
n During filter testing or service.
To initiate manual flushing:
Turn the flushing switch on the Control Panel to Manual (see section 5.1: Control Panel).
The system enters Flushing (see section 4.1.2).
To stop manual flushing:
1. Turn the flushing switch on the Control Panel to Off or Auto.return the Scanner to the HOME position
place the flushing switch at Auto position and perform one of the following:

• Remote Flushing (see section 4.8).


• Press and hold the 4 button on the Controller.

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5.1 Control Panel
5. Control Cabinet Overview The control panel includes:

This chapter describes the parts of the control cabinet and includes: n Main power switch (1) – turns ON and OFF the filter power.
n Controller (4)– see section 5.2
n Section 5.1: Control Panel
n Power indicator (6) – lights up when the main power switch is ON and power is present in the
n Section 5.2: Controller
system.
n Section 5.3: Control Cabinet – Inside View
n Alarm indicator (5) – indicates alarm events and includes the following states:
• Blinking – alarm (view alarm message on the Controller display screen).
• Constant – attention is required (view alarm message on the Controller display screen).
n Flushing control switch (3) – includes the following settings:
• AUTO – Flushing Cycle activation is controlled by the control system.
• MAN – flushing operates continuously (see section 4.7: Manual Flushing).
• 0 – automatic and manual functions are disabled and alarm is reset.
n Flushing indicator (2) – includes the following states:
• Constant – the system is ready (standby).
• Blinking – the system is in Flushing.
n Pump control switch (8) – controls the Flushing Pump; includes the following states:
• AUTO – pump activation is controlled by the system.
• MAN – pump is activated continuously.
• 0 – pump is OFF.
n Pump indicator (7) – indicates the flushing pump status and includes the following states:
• Constant – pump is ready (standby).
• Blinking – pump is operating.

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5.2 Controller 5.3 Control Cabinet – Inside View
The controller is used to perform Setup (see chapter 7) and Service and Testing (see chapter 8)) and displays The control cabinet inside view includes:
System Information Screens (see section 9.2.2). The controller includes:
n Terminal blocks (1)
n Display screen (3) – displays the current system procedure and alarm messages. n Contactors (2)
n Navigation buttons (1) – used to scroll through the controller menus. n Overload switches (3)
n Number pad (2) – used to enter numeric settings. n Power supply (4)
n Enter button (4) – used to advance the screens and enter values. n Fuses (5)
n Relays (6)

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6. Installation 7. Setup
6.1 Mounting This section describes the tasks associated with using the controller for setting up the filter operation
parameters and includes:
n Install the control cabinet in a dry, secured area.
n Section 7.1: Introduction
n Fasten the control cabinet to a strong stable wall or other stable installation site.
n Section 7.2: Displaying the Setup Menu
6.2 Wiring n Section 7.3: Flushing Parameters
n Section 7.4: Optional Flushing Pump Parameters
CAUTION n Section 7.5: IP Parameters
CAUTION: The control cabinet must be connected by a certified electrician. n Section 7.6: Controller Name
n Section 7.7: Pressure Transmitter Settings
n Section 7.8: Analog DPT Settings
n Section 7.9: Minimum Flushing Time
CAUTION n Section 7.10: Exiting the Setup Menu
CAUTION: The installation must meet or exceed all electrical codes.

n Refer to electrical diagrams.


n Connect a three-phase power source.
n Ground the control cabinet.
n Use 4 x 1.5 mm wires in conduit to connect the filter motor to the control cabinet.

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7.1 Introduction 7.3 Flushing Parameters
7.1.1 Instruction Tables The following table shows cycle times for different filter models.
The following sections contain tables that illustrate how to use the controller menus:
Cycle time (sec) Default cycle
The first column contains a Description of the function of the relevant controller screen. Filter Models Gear
50Hz 60Hz Pneumatics time setup
n
n The second column contains an image of the screen as it appears on the controller and
BS025/050 1:50 ~34 ~28 - 110
Instructions for using the controller buttons for the relevant screen.
BS031/070/061/100 1:60 ~41 ~34 - 110
7.1.2 Entering Numeric Values
BS101/150/151/200/201/603/804/1004/1204/1206/1406 1:80 ~54 ~45 ~60 60
To enter a numeric value for one of the controller menus:
1:120 ~81 ~68 - 110
2. Press the _ button to enter edit mode. BS300/400 1:140 ~95 ~79 ~90 110
3. Use the number pad to enter a value. 1:150 ~102 ~85 - 110

4. Press the button _ to set the value.

7.2 Displaying the Setup Menu Description Instructions


Number of Screens – define the amount of
To display the setup menus on the controller screen: screen units used in the filter.
1. Verify that the Flushing switch and Pump
Note: The number is selectable only in controller Enter a value from 1 – 4 to define the
switch are set to 0/RESET.
application version M5-4A-00. In version M5-1-00 number of filter screens.
only 1 screen is available.
Operation Mode Selection – select how many
2. Press and hold the _ button (1) on the
screen units operate at one time during Flushing.
controller.
In multi-screen filters, Scanners can operate
sequentially. Each Scanner operates until it 1 – 1 Group Flush: all scanners
reaches the Limit Sensor (see section 4.3: operate together
3. Turn the main power switch (2) to ON Scanner Movement), and then the next Scanner in 2 – 2 Group Flush: the filter is divided
the sequence operates. into 2 groups –
(while holding the _ button).
Default setting: Safe Zone - 1 Group Flush n In filters with 2 screens, one
The Set–Up Menu screen is displayed on the
Exd - 1 Group Flush screen unit operates at a time.
controller screen.
Ex ia - 2 Group Flush n In filters with 4 screens, 2
screen units operate at a
Note: This mode is selectable only with a multi time: first scanners 1 and 2,
controller with application version M5-4A-00. In then scanners 3 and 4.
4. Press the _ button (3) on the controller. version M5-1-00 only 1 group is available. 3 – Sequential Flush: one screen unit
operates at a time
The Navigation screen is displayed.
Cycle Time – define the time it takes the Scanner
5. Press the button (4) to go to the next to move from one Limit Sensor to another (see
screen OR press the button to go to the section 4.3: Scanner Movement).
previous screen. This setting is required to measure Limit Sensor _ – press once to edit the value; use
Use the following tables to navigate through the error. An error is a greater than 20% delay of a the press again to set the value
setup screens. stroke.
Default setting: according to the filter model (see
above table).

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Description Instructions 7.4 Optional Flushing Pump Parameters
MPI 0 (Multi-Purpose Input 0) Function
Several optional devices can be connected to the Description Instructions
controller input # 0 (on single filter system) or input Pump Enabling – defines if the Flushing Pump is
#2 (on multi filter). 0 – Not Used: Function not used. used in the system.
This option defines what is connected to this input 1 – Flow Switch: Flow Switch output Default setting: Used (1).
and enables the function of the selected device. contact. 0 – flushing pump is not used
Default setting: Not Used (0). 2 – High PR Alarm: connected to the 1 – flushing pump is used
For more details, refer to the electrical drawings. Pressure Switch. Pump Ready Signal – defines if the Controller
3 – High DP Alarm: connected to the receives a Flushing Pump ready signal input and
Differential Pressure Switch with activates an alarm if this input is not received.
Alarms. Default setting: Enabled (1) 0 – pump ready signal is disabled
4 – Low Inlet Pressure Alarm: 1 – pump ready signal is enabled
connected to the Pressure Switch.
Pump Run Signal – defines if the Controller
Flow Error Delay – when the flow switch is receives a Flushing Pump run signal input and
connected to I2, the function delays activation of activates an alarm this such input is not received.
the flow error alarm. 0 – signal disabled
Default setting: Enabled (1)
See section 4.2.6: Optional Flow Switch. _ – press once to enter a value; press 1 – signal enabled
Default setting: 10 again to set the value
MPI 1 (Multi-Purpose Input 1) Function
Several optional devices can be connected to the
controller input # 1 (on single filter) or input #0 (on
multi filter). 0 – Function not used.
This option defines what is connected to this input 1 – Flushing DPS: DPT output.
and enables the function of the selected device.
2 – High DP Alarm: connected to the
Default setting: Flushing DPS (1).
Differential Pressure Switch with
For more details, refer to the electrical drawings.
Alarms.
3 – High PR Alarm: connected to the
Pressure Switch
DPS Off Delay – defines the time that delays the
DPS output when it switches Off.
See section 4.6.2: DPS Off Delay.
Default setting: 20. _ – press once to enter a value; press
again to set the value
Timer Operation – when activated, a maximum
time between Flushing Cycles can be defined (see
section 4.5.2: Timer Operation and next control).
Default setting: Not Used (0). 0 – Timer Operation is not used
1 – Timer Operation is used
Timer Interval – defines the maximum allowed
time without screen flushing. The Flushing Cycle is
initiated automatically after the interval has
passed. _ – press once to enter a value; press
See section 4.5.2: Timer Operation. again to set the value
Default setting: 45
Timer Cycle Interval – defines the number of
Scanner Movement cycles for each flushing
initiated by a Timer Interval.
Default setting: 1 Enter a value from 1 – 9 .

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7.5 IP Parameters 7.5.2 IP Parameters

7.5.1 Setting IP Parameters The following table describes the different IP parameters.

Define the IP settings by selecting the relevant segment and editing the numbers in the selected segment. Description Instructions
The X represents the segment to be edited. Local IP – defines in four segments the controller
IP address. Each segment is defined on a different
screen.
Sub Net Mask – defines the IP mask in four
segments.
To define an IP setting: Each segment is defined on a different screen.
Gateway IP – defines in four segments the
network gateway address.
1. Press the button to select the relevant Each segment is defined on a different screen.
segment (a).
ModBus Loc Port – defines the Local ModBus
TCP communication port.
(See chapter 12: Annex B: Modbus
Specifications.)
Default setting: 502
The X (b) changes position each time the button
is pressed. The relevant segment number (c) is
displayed.
7.6 Controller Name
Description Instructions
PLC Name – defines the controller name. Only the
last digit can be changed.
2. Press the _ button to edit the segment. Default value: FLSAFE0
Default value ver 3.1 and above: FLSAFE Type a number from 0 – 9 for the last
The Set value (d) is active. digit of the name.

3. Use the controller number pad to define up


to four digits for the selected segment (e). 7.7 Pressure Transmitter Settings
4. Press the button to clear a digit. The following settings associated with the Analog Pressure Transmitters.
5. Press the to return to the last saved Description Instructions
segment (all four digits).
PT0/PT1 Zero Set – type the zero set value found
6. Press the _ button to save the selected on the Analog Pressure Transmitters label at 4ma.
segment. Default setting: 0
1. Define the value for PT0.
2. Advance to the next screen to
define the value for PT1.
PT0/PT1 Span Set – type the span set value
found on the Analog Pressure Transmitters label at
20ma.
Default setting: 0 1. Define the value for PT0.
2. Advance to the next screen to
define the value for PT1.

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7.8 Analog DPT Settings 7.9 Minimum Flushing Time
The following settings are associated with the DPT and optional alert switches with analog output. Description Instructions
All values are in millibar. Minimum Flushing Time – the minimum amount
of time to sustain a Flushing Cycle regardless of
Description Instructions the DPT signal.
Upstream Low Pressure Set Point – defines the See section 4.6.1: Minimum Flushing Time).
set point for the upstream low pressure alarm. Default setting: 0
Default setting: 1600
Upstream High Pressure Set Point – defines the
set point for the upstream high pressure alarm. 7.10 Exiting the Setup Menu
Default setting: 6000
To exit the Setup Menu:
Differential Pressure Flush – defines the DPT set
point for initiating flushing. Turn the main power switch to OFF.
Default setting: 400
Differential Pressure Hysteresis – defines the
defines the set point for stopping the DPT flushing
signal.
Example: if the Differential Pressure Flush is set
to 400 mb and the Hysteresis is set to 150 mb,
the request for flush starts when DP reaches 550
mb and will remain until DP falls below 250 mb.
Default setting: 150
Alarm Set Point – defines the high alarm set point
for the Differential Pressure Switch with Alarms.
Default setting: 1000
Zero 4ma – set the reading for the zero level of the
analog inputs. This setting is performed when all
analog inputs are at zero level only.
Note: Do not perform this function if the readings Press 1 to zero analog readings.
are accurate.
Sel. AN. (Select Analog) – defines analog
sensors used in the system.
Default setting: No analog sensors (0)
Enter on of the following values:
0 – no analog sensors
1 – PT0: upstream, PT1: disabled
2 – PT0: upstream, PT1: downstream
3 – PT0 is disabled, PT1 is connected
to the Analog Differential Pressure
Transmitter
4 – PT0 is upstream, PT1 is connected
to the Analog Differential Pressure
Transmitter
5 (for version 3.1) – Current - the
Flushing Pump motor current.

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8.3 Service Menu Screens
8. Service and Testing
Description Instructions
This section describes the controls for servicing and testing the system. Ethernet Status – displays the connection status
of the Ethernet connection.
Three possible states:
8.1 Displaying the Service Menu Not Attached – no module installed
Attached – module installed and working
To display the service menu: Connected – client connected to PLC
1. Verify that the flushing switch and pump
switch are set to 0. Motor Enabling and Test Selection – enable or
disable a Scanner motor and select a Scanner
motor to be tested.
2. Turn the main power switch (1) to ON. Each motor is enabled on a separate controller 0 – disable relevant motor
screen. Controller screens are displayed according 1 – enable relevant motor
The controller application version screen is to the number of filter screens defined for the
displayed and then the Main Screen is displayed _ – select the displayed motor for
relevant filter model (see Number of Screens on
after a few seconds. pg. 7-24). testing and advance to the Motor
Testing screen
– advance to the next motor
Motor Testing – runs a test of the selected
Scanner motor and its Limit Sensors.
3. Press the _ button (2) on the controller. n MLS – Motor side Limit Sensor
The Service Menu screen is displayed. n FLS – Filter side Limit Sensor – moves the Scanner toward the
motor.
4. Press the _ button again. For full test instructions, see section 8.4: Testing
the Scanner Limit Sensors and Motors. – moves the Scanner toward the
The Navigation screen is displayed. filter.
– advance to the next motor
5. Press the button (3) to go to the next
screen OR press the button to go to the Pump Test Selection – only displayed when the
Flushing Pump is enabled.
previous screen.
See Pump Enabling screen pg. 7-26.
Use the following tables to navigate through the _ – display the Pump Testing screen.
service menu screens.
Pump Testing – tests the Flushing Pump.
For full test instructions, see section 8.5: Testing
8.2 Returning to the Main Screen the Pump.
View the following values: 0 – stop test
To return to the Main Screen from the service menu: FS – flow switch status 1 – start test
1. Scroll one screen past the first or last Rdy – pump ready signal status
service menu screen. Fb – pump operating signal status
The Exit screen is displayed. Valve Test Selection
.
2. Press the _ button (2) on the controller.
The Main Screen is displayed. _ – display the Flushing Valve test
screen.

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Description Instructions 8.4.2 Testing the Limit Sensors

Valve Test Results – tests the Flushing Valve To test the proper functioning of the Scanner Limit Sensors:
For full test instructions, see section 8.6: Testing
1. On the Motor Testing screen, verify that the MLS
the Flushing Valve.
value is 1.
View the following values: 1 – test V1
FS – flow switch status 2 – test V2 n MLS – Motor side Limit Sensor
V1 – flushing valve 1 2. Activate the Limit Sensor on the motor side of the
V2 – flushing valve 2 Scanner.
Multi-Purpose Input A Staus – displays the
status of the optional device or function that is
connected to MPI . The top line of the screen
shows the name of the connected device or
function.
See section 8.7: Testing the MPI Devices
Multi-Purpose Input B Status – displays the
status of the optional device or function that is
connected to MPI . The top line of the screen
shows the name of the connected device or
function. 3. On the Motor Testing Screen, verify that the MLS
See section 8.7: Testing the MPI Devices value is 0.
Analog Readings – view DPS readings for: 4. Release the Limit Sensor.
n Upstream pressure n MLS – Motor side Limit Sensor
n Downstream pressure
Press the button to scroll through the 5. Verify that the FLS value is 1.
n Pressure Differential different readings. n FLS – Filter side Limit Sensor
n Current pump reading (for ver. 3.1)
6. Activate the limit sensor on the filter side of the
8.4 Testing the Scanner Limit Sensors and Motors Scanner.

This section describes the following testing:


n Limit sensors – verifies that the Motor Limit Sensor (MLS) and the Filter Limit Sensor (FLS) are
sending a signal for the correct side. The Limit Sensors are normally closed circuits. When
pressed, the relevant Limit Sensor shows a Controller readout of 0. When not pressed, the
relevant Limit Sensor shows a Controller readout of 1
n Motors – verifies that the scanner motors are rotating and moving the scanner in the correct
direction.
8.4.1 Navigating to the Motor Testing Screen
To display the Motor Testing screen: 7. On the Motor Testing Screen, verify that the FLS
value is 0.
1. Navigate to the Motor Enabling and Test Selection
controller screen (see pg. 8-32). n FLS – Filter side Limit Sensor

2. Verify that the relevant motor is enabled.


3. Press the _ button on the controller.

The Motor Testing Screen is displayed.

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8.4.3 Testing the Scanner Motors 8.5 Testing the Pump
To test the proper functioning of the Scanner motors:

1. When the Motor Testing screen is displayed, press


and hold the button on the controller. To test the proper functioning of the Flushing Pump:

2. Verify that the Scanner limit disk is moving toward 1. Navigate to the Pump Test controller screen (see
the motor and the Motor Testing screen displays: section 8.3: Service Menu Screens).
run to motor.
2. Press the _ button on the controller.
3. Continue to hold the button until the limit disk
activates the Limit Sensor next to the motor and the
Motor Testing screen displays: MLS: 0.
The pump testing screen is displayed.
4. Press and hold the button on the controller. 3. Press the 1 button on the controller.

5. Verify that the Scanner limit disk is moving toward 4. Verify that On value changes to 1. Rdy - Pump Ready signal
the filter and the Motor Testing screen displays: 5. Press the 0 button on the controller. Fb – Pump Running feedback
run to filter. Fs – Flow switch signal
6. Verify that On value changes to 1.
6. Continue to hold the button until the limit disk On – Pump Run output
activates the Limit Sensor next to the filter and the
Motor Testing screen displays: FLS: 0.
8.5.1 Correcting Flushing Pump Operation

8.4.4 Correcting Scanner Motor Operation


If the motor travels in the wrong direction and the wrong Limit Sensor is activated, a Drive Dir. Error is If the flushing pump operates in the wrong order:
displayed. In this case:
1. Turn the Main Power switch to OFF.
1. Turn the Main Power switch to OFF.
2. Change the connection between the two phases.
2. Change the connection between two of the three phases of the motor.
3. Repeat Testing the Flushing Valve.
3. Repeat Testing the Scanner Motors.

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8.6 Testing the Flushing Valve
This section describes testing the proper functioning of the Flushing Valve and the Flow Switch. 0 indicates
9. Operation
the output is OFF and 1 indicates that the output is ON.
This section describes filter startup and operation. For more information, refer to the Startup and First
To test the proper functioning of the Flushing Valve and the Flow Switch:
Operation section in the relevant filter operation manual.
1. Navigate to the Valve Test Selection screen (see n Section 9.1: Power Up
pg. 8-32). n Section 9.2: Controller Operating Screens
2. Press the _ button on the controller. n Section 9.3: Messages and Indicators
For more information, refer to the Startup and First Operation section in the relevant filter operation manual.

The valve testing screen is displayed.


3. Press and hold the 1 button on the controller to
open valve 1.
Fs – Flow switch
4. Verify that V1 value changes to 1. V1 – Flushing valve on group 1
5. Press and hold the 2 button on the controller to V2 – Flushing valve on group 2
open valve 2.
Verify that V2 value changes to 1.

8.7 Testing the MPI Devices


This section describes testing the proper functioning of the devices connected to MPI (see page 7-25) and
MPI (see page 7-25). The readout is 0 when not active and 1 when active.
To test the proper functioning of an MPI device:

1. Navigate to the relevant MPI status screen (see


page 8-33).
2. Verify that the Status value is 0.
3. Activate the device connected to the relevant MPI.
4. Verify that the Status value changes to 1 when
the pressure reaches the flushing initiation set
point.

If the above test is not possible, perform the following:


1. Initiate a shortcut or disconnect the two wires at the junction box.
2. Verify that the Status value changes.

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9.1 Power Up Description Instructions
To power up the filter in automatic mode: Analog Readings – view DPS readings for:
n Upstream pressure
1. Turn the flushing control switch (2)
n Downstream pressure
to 0. Press the button to display this
n Pressure Differential
2. Turn the pump control switch (5) screen.
(optional) to 0. n Current pump reading (for ver. 3.1) Press the button to scroll through the
3. Turn the main power switch (1) different readings.
ON.
The power indicator (4) lights up.
9.3 Messages and Indicators
The controller (3) turns on.
4. Turn the flushing control switch (2) This section explains:
to Auto. n Controller messages – messages that are displayed on the Main Screen (see section 9.2.1)
5. Turn the pump control switch (5) n Indicators – Control Panel lights (see section 5.1) and signals from the control cabinet (see
to Auto. 0. section 5: Control Cabinet Overview).
The filter operates in automatic mode. n Resetting the System After an Alarm Event – clearing alarm event messages and indicators
Flushing Cycles are intiated by the Filter and resuming normal operation (see section 9.3.3).
Control System.

9.3.1 Filter Status Messages and Indicators


9.2 Controller Operating Screens
The following table contains messages that are associated with the filter operating status and are displayed
9.2.1 Main Screen
on the upper line of the controller Main Screen.
Description Instructions
When in operating mode, the controller screen
displays:
n Filter Status (1) – displays the operating
status of the filter (see section 9.3.1: Filter
Status Messages and Indicators). AUTO - - Const Const Const ON OFF - - Control Panel -
READY selectors set to
n Alarm Messages (2) – displays specific Auto.
information about alarm events (see section SYSTEM - - - - - - - - - -
9.3.2: Alarm Event Messages and Indicators). NOT READY
SYSTEM OFF - - - - - - - - - -
9.2.2 System Information Screens
MANUAL - Blink Blink Const - Const - - Manual -
When in operation mode, use the navigation buttons on the controller to view the following screens. FLUSHING Flushing is
active
Description Instructions AUTO DP - Blink Blink Const - Const - - Flushing Cycle -
FLUSHING triggered by
Flushing Cycle History – displays how long ago DPT Signal
the last flushing cycle occurred and how many REMOTE - Blink Blink Const - Const - - Remote -
flushing cycle have occurred since the filter was FLUSHING Flushing cycle
installed. Press the button to display this is operating

screen. TIMER - Blink Blink Const - Const - - Timer Operation -


FLUSHING flushing
The display returns to the main screen (preset),
after a few seconds. regardless of
the DPT signal

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9.3.2 Alarm Event Messages and Indicators
The following table contains messages that are associated with alarm events and are displayed on the lower
line of the controller Main Screen.

FLOW Const Blink OFF ON OFF N/R N/R Warning Pump is on Check flow,
ERROR alarm, and Flow Flushing
pump Switch mode valve, pump,
shutdown. is “ON” Flow Switch
(Setup (if no flow
High DP Const N/R N/R ON Off N/R ON Warning Differential Menu). After switch is
(Ver. Pressure preset used, make
3.2- Switch with seconds sure it is
OFF) Alarms is (Setup “OFF” in the
signaling Menu), the setup menu).
that the flow signal
pressure remains
differential OFF.
has reached PUMP IS Const N/R Off Off Off Off N/R Warning Remote Start Not
a critical OFF alarm, Auto Pump Possible.
point. operation selected check Pump,
High PR Const N/R N/R ON Off N/R N/R Warning Pressure not (Setup connection or
Switch is possible. Menu) and change
signaling pump switch selections
that the on the (pump switch
pressure in Control must be on
one side of Cabinet is Auto)
the filter has not on “0”
reached a MOTOR Const N/R N/R On Off N/R N/R Warning Filter Motor Check
critical point. OVERLOAD overload Motors and
HEAVY DIRT Const N/R N/R ON OFF N/R ON Warning Filter runs in Caution, the protection drive
LOAD (after 10 AUTO and system is device goes mechanism/
cycles) differential working hard. OFF. Wiring. Reset
(Ver. 3.3 pressure It resets Mechanical and start the
after 5 signal automatically overload, system
cycles) remains once DPS is Defective
“ON” after released Motor,
10 cleaning Defective
cycles (Ver. Wiring
3.3 after 5 M1/M2/M3/ Const N/R N/R ON/ Off. N/R N/R Alarm + Relevant Check Limit
cleaning M4 Failed relevant motor works, Sensors and
OFF
cycles). (Dir) Filter stops Limit Disk wiring.
when
CHECK Blink N/R N/R ON ON, N/R Off. Alarm Filter runs in Check proper all moves away If necessary,
DPS/VALVE OFF- (after 20 AUTO and operation of motor from Limit switch
after 20 cycles) differential the system: Sensor but connection
fail
cycles (Ver. 3.3 pressure pressure, the LS between 2
(Ver. after 10 signal DPS, valves, signal does phases, to
3.3 cycles) remains Scanner not change. change the
after 10 “ON” after rotation. Also used to relevant
cycles) 20 cleaning Cause could check the motor’s
cycles (Ver. be the result relevant direction.
3.3 after 10 of a heavy motor
cleaning load of dirt in connection/d
cycles). the water. It irection on
resets startup.
automatically M1/M2/M3/M Const N/R N/R ON/ Off. N/R N/R Alarm + Relevant Check Limit
once DPS is 4 Failed (LS) relevant motor’s Limit Sensors and
OFF
released Filter stops Sensors wiring. Reset
when
broke, or & Start
all
have wiring
motor
problems.
fail

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M1/M2/M3/M Const N/R N/R ON/ Off. N/R N/R Alarm + It takes the Check Limit High Const N/R N/R On Off. N/R N/R Warning Pressure in
4 Failed OFF relevant Limit Disk Sensors and Pressure!!! the filter is
(RunT) Filter stops more than Drive system. greater than
when
all 15% longer Reset & Start maximum
motor to reach a plate stated
Limit working
fail
Sensor, than pressure.
the selected
No DPT Const Off N/R Off Off. N/R N/R Fatal Error No
Run Time
selected! Filter differential
(Setup
operation pressure
Menu)
trigger
Not
Low PLC Blink N/R N/R On Off. N/R N/R Warning Controller Change the (DPT)device
possible
Battery backup backup selected at
battery is battery setup.
running low
Leakage Const N/R N/R On Off. N/R N/R Warning Flow Switch
Pump Not Blink N/R On On Off. On N/R Warning Ready Check pump Detected detected
Ready Signal not functionality flow while
received and wiring flushing
from pump valve
controller. closed.
Pump Not Const Const Off. Off. Off. N/R N/R Warning Run Signal Check pump Replace
Run not received functionality Flushing
from pump and wiring Valve or
controller. faulty Flow
Switch.
PT0/PT1 Out Blink N/R N/R Off. Off. N/R N/R Warning Relevant Check wiring
of Range analog or replace Err. Power Blink Off Off Off Off Off Off Fatal Error All Setup Check PLC
pressure device. Down Filter parameters battery;
transmitter Run Setup operation have been replace if
(see Analog first lost. PLC faulty and run
Not
Pressure battery low Setup.
possible
Transmitters OR no setup
) done during
malfunctioni installation.
ng – output Pump N/R N/R Blink N/R N/R N/R N/R Indication Pump run
is less than Run Ext from
4ma or Cab external
greater than pump
20ma. cabinet.
US.PR. Too Const Blink N/R On Off. On On Warning Upstream
Low! pressure is Man. Const Off. Off. Off. Off. Off. N/R Warning Power Up Reset -
lower than Power while filter In Change
optimal Up Manual Flushing
flushing Restart Mode. Selector to 0.
pressure.
US.PR.Too Const N/R N/R On Off. N/R N/R Warning Upstream
High!! pressure is
greater than
maximum 9.3.3 Resetting the System After an Alarm Event
plate stated
working After investigating the cause of the alarm and performing any necessary actions the reset the system to clear
pressure. the alarm message and resume normal operation.
DP. Too Const N/R N/R On Off. N/R On Warning Differential
High!!! (ver. pressure is To reset the system after an alarm event:
3.1 Off) too high. Turn the Flushing switch to Manual or Auto and
The filter
may become
then to 0.
damaged.

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10. Technical Specifications 11. Annex A: Controller Inputs and Outputs
10.1 Power Supply 11.1 Inputs
10.1.1 Line voltage 11.1.1 Analog Inputs
n Type A – 190 ÷ 220 V 50/60Hz (3~) Input Name Normal State Notes
n Type B – 380 ÷ 480 V 50/60Hz (3~) Upstream Analog Pressure
A0 OPTIONAL K
10.1.2 Control voltage Transmitters
24 VDC A1 Downstream Analog Pressure OPTIONAL K
Transmitters/ Analog Differential
10.2 Control Panel Components Pressure Transmitter / pump current
transmitter
n Motor Overloads – Q11-Q14
n Contactors – K11.X - K14.X operate the Filter Motor and K17 operates the Pump Motor
n Switching Modulation Power Supply (U5) – Power Supply for 24VDC control voltage 11.1.2 Single Filter
n 2 x 6 Amp (Q5) – -protect the power supply input Input Name Normal State Notes
n 1.0 Amp Fuses (F16-17-18) – -protect the control circuits. 0 MPI Function (see page 7-25) NO/NC
n Analog circuits protection – F7-F8, 32 mA
1 MPI Function (see page 7-25) NO/NC
n Controller type – JZ20-T40/JZ20-R31
2 Limit Sensor #1 (Motor Side) NC
3 Limit Sensor #2 (Filter Side) NC
4 Screen Motor Auto Mode NO
5 Screen Motor MAN Mode NO
6 Screen’s Motor O.L / Pump Motor NO Control Panel wiring diagram:
O.L
7 Pump Auto Mode NO OPTIONAL D / J
8 Pump MAN Mode NO OPTIONAL D / J
9 Old pump Motor O.L / Reserved NO
10 Run Flushing Remote NO
11 Pump Ready (external) NO OPTIONAL D / J
12 Pump Run (external) NO OPTIONAL D / J

11.1.3 Multi-Filter

Input Name Normal State Notes


0 MPI Function (see page 7-25) NO/NC
1 External Pump Run NO OPTIONAL J
2 MPI Function (see page 7-25) NO/NC
3 External Pump Ready NO OPTIONAL J
4 Filter Flushing MAN Mode. NO
5 Filter Flushing Auto Mode NO
6 Filter’s Motor O.L NO
7 Pump Motor MAN Mode NO OPTIONAL J
8 Pump Motor Auto Mode NO OPTIONAL J
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Input Name Normal State Notes 11.2 Outputs
9 Run Flushing Remote NO
11.2.1 Single Filter
10 Screen 1 Limit Sensor (Motor Side) NC
11 Screen 1 Limit Sensor (Filter Side) NC Output Name Notes
12 Screen 2 Limit Sensor (Motor Side) NC 0 Screen Motor A (to filter) (K11.1)
13 Screen 2 Limit Sensor (Filter Side) NC 1 Screen Motor B (to motor) (K11.2)
14 Screen 3 Limit Sensor (Motor Side) NC 2 Filter Status Lamp (L12)
15 Screen 3 Limit Sensor (Filter Side) NC 3 Solenoid Valve (SV1)
16 Screen 4 Limit Sensor (Motor Side) NC 4 Pump Motor (K17) OPTIONAL D / J
17 Screen 4 Limit Sensor (Filter Side) NC 5 Pump Status Lamp (L13) OPTIONAL D / J
6 Alarm Lamp (L14)
7 System Filter Status Relay (K15)
8 Fault Relay (K16)
9 System Flushing (K18)
10 Continuous Flushing/ Very High DP (K19)

11.2.2 Multi-Filter

Output Name Notes


0 Free
1 Free
2 Filters Status Lamp (L12)
3 Pump 1 - Status Lamp (L13) OPTIONAL J
4 Screen 1 Motor (K11.1)
5 Screen 1 Motor (K11.2)
6 Screen 2 Motor (K12.1)
7 Screen 2 Motor (K12.2)
8 Screen 3 Motor (K13.1)
9 Screen 3 Motor (K13.2)
10 Screen 4 Motor (K14.1)
11 Screen 4 Motor (K14.2)
12 System Status (K15)
13 System Fault Relay (K16)
14 Run Pump 1 (K17) OPTIONAL J
15 Alarm Lamp (L14)
16 Solenoid Valve Group 1 (SV1)
17 Solenoid Valve Group 2 (SV2)
18 System Flushing (K18)
19 Continuous Flushing/Very High DP (K19)

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Register Access Name Limits Units Data Function
12. Annex B: Modbus Specifications number Type Code
209 Read/Write Start Remote 1 = Flush None Bit 06
Flushing
12.1 Modbus Word Registers
Motor Alarm Bits
Register Access Name Limits Units Data Function
210 Read Only Motor 1 bit high = in alarm None Bit 01
number Type Code
Limit Switch Error
40210 Read Only Motor Alarms bit high = in alarm Bit Mask signed 03 211 Read Only Motor 1 bit high = in alarm None Bit 01
16-bit Direction Error
integer
212 Read Only Motor 1 bit high = in alarm None Bit 01
40211 Read Only System Alarms bit high = in alarm Bit Mask signed 03 Run Time Error
16-bit 213 Read Only Motor 2 bit high = in alarm None Bit 01
integer Limit Switch Error
40212 Read Only System Status bit high = active Bit Mask signed 03 214 Read Only Motor 2 bit high = in alarm None Bit 01
16-bit Direction Error
integer
215 Read Only Motor 2 bit high = in alarm None Bit 01
Run Time Error
40213 Read Only Cycles Totalizer 0-32000 signed 03 216 Read Only Motor 3 bit high = in alarm None Bit 01
16-bit Limit Switch Error
integer
217 Read Only Motor 3 bit high = in alarm None Bit 01
40214 Read Only Last Cycle (MM 0-60 Minutes signed 03 Direction Error
Ago) 16-bit
218 Read Only Motor 3 bit high = in alarm None Bit 01
integer
Run Time Error
40215 Read Only Last Cycle (HHH 0-999 Hours signed 03
219 Read Only Motor 4 bit high = in alarm None Bit 01
Ago) 16-bit
Limit Switch Error
integer
220 Read Only Motor 4 bit high = in alarm None Bit 01
40216 Read Only PT0 Analog 0-16000 millibar signed 03
Direction Error
Rearding (mbar) 16-bit
integer 221 Read Only Motor 4 bit high = in alarm None Bit 01
Run Time Error
40217 Read Only PT1 Analog 0-16000 millibar signed 03
Rearding (mbar) 16-bit 222 Read Only Reserved bit high = in alarm None Bit 01
integer 223 Read Only Reserved bit high = in alarm None Bit 01
40218 Read Only DP Rearding (mbar) 0-1000 millibar signed 03 224 Read Only Motor OverLoad bit high = in alarm None Bit 01
16-bit
integer 225 Read Only 1 Second Blink Bit Not applicable None Bit 01

40219 Read Only Pump Current 0-20000 miliAmper signed 03 System Alarms Bits
16-bit 226 Read Only Pump Switch Is Off bit high = in alarm None Bit 01
integer
227 Read Only No Run Signal From bit high = in alarm None Bit 01
40220 Read Only Reserved signed 03 Pump
16-bit
228 Read Only No Ready Signal bit high = in alarm None Bit 01
integer
From Pump
40221 Read Only Reserved signed 03
229 Read Only Flow Error bit high = in alarm None Bit 01
16-bit
integer 230 Read Only Leakege bit high = in alarm None Bit 01
Detected
40222 Read Only Const Value 32767 None signed 03
16-bit 231 Read Only Heavy Dirt bit high = in alarm None Bit 01
integer Load Warning
Function Bits 232 Read Only Check bit high = in alarm None Bit 01
DPS Or Valves
208 Read/Write Reset Alarms 1 = reset None Bit 06
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Register Access Name Limits Units Data Function
number Type Code 12.2 Word Register Bit Map
233 Read Only PT0 Out Off Range bit high = in alarm None Bit 01 Register Number

234 Read Only PT 1 Out Off Range bit high = in alarm None Bit 01
235 Read Only Upstream Pressure bit high = in alarm None Bit 01
Too Low
40210
236 Read Only Upstream Pressure bit high = in alarm None Bit 01
Too High
237 Read Only High Pressure Alarm bit high = in alarm None Bit 01
238 Read Only Differential Pressure bit high = in alarm None Bit 01
To High
239 Read Only PLC Battery LOW bit high = in alarm None Bit 01
40211
240 Read Only Reserved bit high = in alarm None Bit 01
241 Read Only 1 Second Blink Bit Not applicable None Bit 01
System Status Bits
242 Read Only Pump Status bit high = ON None Bit 01
243 Read Only System Ready bit high = Ready None Bit 01
244 Read Only System Alram bit high = Alarm None Bit 01 40212
245 Read Only Flushing Relay bit high = Flushing None Bit 01
246 Read Only High DP Relay bit high = OK None Bit 01
247 Read Only Valve 1 bit high = Open None Bit 01
248 Read Only Valve 2 bit high = Open None Bit 01
249 Read Only Home Return bit high = None Bit 01
Returning
250 Read Only Remote Flushing bit high = Flushing None Bit 01
251 Read Only DP Flushing bit high = Flushing None Bit 01
252 Read Only Timer Flushing bit high = Flushing None Bit 01
253 Read Only Run To Home bit high = Flushing None Bit 01
254 Read Only Scanner Home bit high = Home None Bit 01
255 Read Only 1 Second Blink Bit Not applicable None Bit 01

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13. Annex C: PLC Program Upgrade 14. Annex D: Interface Logic
1. Open the side cover of the controller and push in the PLC programmer (CLONER) until it snaps into place. 14.1 Pump Interface Logic

2. Press and hold the i button for 5 seconds.

The PROGRAM CLONER (PLC programmer) screen is displayed.


3. Press the _ button.
The CLONER (PLC programmer) TO PLC screen is displayed.
4. Press the _ button.
The IMPORT screen is displayed.
5. Press the _ button.
The PLC WILL STOP! CONTINUE screen is displayed.
6. Press the _ button.
The upgrading process takes about one minute.
When the process is finished The PLC WILL RESET & RUN CONTINUE screen is displayed.
7. Press the _ button to restart the controller.
The controller is back in operating state.
8. Remove the PLC programmer (CLONER) and close the side cover of the controller.
9. Restart the control cabinet and verify that the PLC displays the updated version on the Start Up screen.

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14.2 Filter Interface Logic
15. Annex: E: Setup Values Form
The following form is used by the client to define setup values for the controller.

No Parameter Name Controller Display Setup Value Comments


1 Numbers of screens Num.Of Screens
2 Flushing Operation Mode OP Mode Sel(1-3)
3 Cycle Time Cycle Time
4 MPI0 Function MPI Function(0-4)
5 Flow Error Delay Flow Error Delay
6 MPI2 Function MPI Function(0-3)
7 Differential Pressure Switch Off DPS. Off Delay
Delay
8 Timer Operation (Enabling) Timer Operation:
9 Timer Interval Timer Interval:
10 Cycles Per Interval (Timer Mode) Timer Cyc/inter
11 Pump (Enabling) Pump: Used Sel
12 Pump Ready Signal Pump Ready Sig.
13 Pump Running Signal Pump Run Sig.
14 IP Address Loc. IP X.X.X.X
15 Subnet Mask SubN.M. X.X.X.X
16 Gateway G.Way IP X.X.X.X
17 Modbus Port Modbus Loc Port
18 PLC Name PLC Name:FSM54A_
19 Analog Transmitter "'0" Zero (4ma) PT0 Zero Set
20 Analog Transmitter "'0" Zero (4ma) PT0 Span Set
21 Analog Transmitter "'1" Zero (4ma) PT1 Zero Set
22 Analog Transmitter "'1" Zero (4ma) PT1 Span Set
23 Upstream Low Pressure Alarm SP U.S. Low PR SP
24 Upstream High Pressure Alarm SP U.S. High PR SP
25 Differential Pressure Flushing SP DP. Flush SP
26 Differential Pressure Hysteresis DP. Hysteresis
27 High Differential Pressure Alarm SP HDP. Alarm SP
28 Analog Sensor Selection Sel.AN. OP (0-4)
29 Minimal Flushing Duration Min. Flush Time

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16. JAZZ 20 BATTERY REPLACEMENT

n Once the battery is disconnected, all setup values will be lost. It is highly important to copy (or
photo) all setup values, for setup process see Chapter 7.
n Disconnect all plugs from the OPLC.
n Make sure to replace the battery with battery model CR2032.
n Before opening the controller, touch a grounded object to discharge any electronic charge.
n Avoid touching the PCB board directly by holding the PCB board by its connectors.

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17. User Notes

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2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

ELECTROLYTIC CELL(S)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 9
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

Contents

User Operations and Maintenance Manual 1. Identification ........................................................................................................................................................................................... 3


1.1 Marking plate ................................................................................................................................................................................. 3
1.2 Type Identification ......................................................................................................................................................................... 3
1.3 Protection ...................................................................................................................................................................................... 3

PermaChlor® BWT 2.
2.1
Product Certification ............................................................................................................................................................................... 4
List of applicable standards ........................................................................................................................................................... 4
Ballast Water Treatment Cell: 6ppm, 3PSU (0.9PSU) 3. Product Description ................................................................................................................................................................................. 5
BWT 100, BWT 250, BWT 500, BWT 750, BWT 1000 3.1 General .......................................................................................................................................................................................... 5
3.2 Design ............................................................................................................................................................................................ 5
3.3 Flow rate range vs. salinity ............................................................................................................................................................ 6
3.4 Technical data ................................................................................................................................................................................ 6
4. Installation ............................................................................................................................................................................................... 7
4.1 Installation of cell into piping......................................................................................................................................................... 7
4.2 Cable connection ........................................................................................................................................................................... 8
5. Safety ..................................................................................................................................................................................................... 12
5.1 System safety ............................................................................................................................................................................... 12
5.2 Process safety .............................................................................................................................................................................. 12
5.3 Monitoring ................................................................................................................................................................................... 13
5.4 Training of service personnel ....................................................................................................................................................... 13
5.5 Functional tests............................................................................................................................................................................ 14
5.6 Special conditions of use ............................................................................................................................................................. 15
6. Operation .............................................................................................................................................................................................. 16
6.1 Start up ........................................................................................................................................................................................ 16
6.2 Shut down .................................................................................................................................................................................... 16
7. Maintenance ......................................................................................................................................................................................... 17
7.1 Daily – Self-monitoring ................................................................................................................................................................ 17
7.2 Monthly - Self-monitoring ........................................................................................................................................................... 17
7.3 Yearly ........................................................................................................................................................................................... 17
7.4 Every five year.............................................................................................................................................................................. 17
7.5 Acid cleaning ................................................................................................................................................................................ 18
8. Troubleshooting .................................................................................................................................................................................... 19
9. Declaration of Conformity ..................................................................................................................................................................... 20
Operation by authorized personnel only Appendix I
Read this manual carefully before use

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

1. Identification
2. Product Certification
1.1 Marking plate
2.1 List of applicable standards

The PermaChlor® BWT cells are developed and manufacture according to and in compliance with the
following standards:

EN 13121-1 ,2, 3:2008 (under European Commission Mandate 83/139/EEC)


ISO 2878-1 (Standard for machining)
SS-ISO 965-2 (Thread tolerance)
ISO 17637:2003 (“Non-destructive testing of welds – Visual testing of fusionwelded joints”)
ISO EN 13920:1996 (“Welding – General tolerances for welded construction..")
ISO 5817:2014 (“Welding – Fusion-welded joints in steel, nickel, titanium and their alloys..")
ISO 14731:2006 (“Welding coordination – Tasks and responsibilities”)
IEC 50186
Furthermore, the PermaChlor® BWT cells are in conformity with listed EU Directive(s):
EMC Directive 2004/108/EC
EN 61000-6-4:2007, Electromagnetic compatibility – Emission standard for industrial
environments
EN 61000-6-2:2005, Electromagnetic compatibility – Immunity for industrial environments

The manufacturer of PermaChlor® BWT cells, Permascand AB, is certified in accordance with following
management standards:

1.2 Type Identification ISO 9001:2008


ISO 14001:2004
OHSAS 18001:2007
Product name: PermaChlor® BWT
Model range: 100 (for water flow up to 150m3/h at 3PSU)
250 (for water flow up to 300m3/h at 3PSU) (Accredited unit: DNV GL Business Assurance Sweden AB)
500 (for water flow up to 600m3/h at 3PSU)
750 (for water flow up to 800m3/h at 3PSU)
1000 (for water flow up to 1200m3/h at 3PSU)

1.3 Protection
All PermaChlor® BWT equipment comply with protection class IP66 according to EN 60529. However, in
particularly exposed applications, protection in the form of shielding is recommended.

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

3. Product Description 3.3 Flow rate range vs. salinity


The PermaChlor® BWT produces sodium hypochlorite from DC current and chloride dissolved in the
treated fresh, brackish or full salinity seawater. The capacity is maximum 6 ppm Total Residual Oxidants
3.1 General (TRO) for the specific maximum flow (m3/h) rating of the system. Maximum flow rate is related to the
An electrochemical cell like the PermaChlor® BWT produces sodium hypochlorite from seawater and DC selected operation mode of the system: min. 3PSU (“standard”) or min. 0.9PSU (“low salinity”) operation.
current; the capacity is maximum 6 ppm for the specific flow (m3/h) rating of the system depending on the In Appendix I, the respective tables for each model gives operational flow rate range for “standard” and
minimum salinity requirement (3PSU or 0.9PSU). Electrolysis is the most energy, cost and environment “low salinity” operational modes.
effective way to produce sodium hypochlorite. When producing sodium hypochlorite on-site with
available recourses like water, DC current and an electrochemical cell, there is no need for transportation,
handling or storing of sodium hypochlorite. The PermaChlor® BWT is intended as disinfection unit
incorporated in a complete Ballast Water Treatment System (BWTS) and thus for use after proper
mechanical pre-treatment (e.g. filtration, hydrocyclone) and under the control of the overall BWTS. This BWTS control settings of flow rate range and relating input current must be carefully adjusted to
Operations and Maintenance Manual describes the PermaChlor® BWT model series developed as the correct mode of operation and implemented in overall control system!
“Generation 2” following the first series of cells having the same model range by flowrate but different
operational salinity and hypochlorite concentration ranges.

3.2 Design 3.4 Technical data


The PermaChlor® BWT cell is a bipolar electrochemical cell which consists of an electrode assembly
package mounted in a cell house. To reduce weight and optimize strength, the cell house is made of PermaChlor® BWT cells 100-1000m3/h are designed with parameters according to installation
Glassfiber Reinforced Plastic (GRP). Both cathodes and anodes are made of titanium plates and the specific requirements and specific water quality regarding salinity. See Appendix I for full technical specification of
anode areas with a specially developed coating are capable to produce sodium hypochlorite to a each model.
concentration of up to 6ppm directly into the water. The PermaChlor® BWT electrochemical cell is
designed for most energy and cost efficient production of sodium hypochlorite.

Installation of the electrochemical cells into the piping is done by to the flange connections. The two
cabling boxes for contacting anode- and cathode side are mounted from factory.

1. 4.

5.
2.
3.
Fig. 1: Design of PermaChlor® BWT electrochemical cell

1. Cell house
2. Cell inlet flange connection
3. Cabling (connection) boxes w. terminal connection plints
4. Electrode assembly
5. Cell outlet flange connection
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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

4. Installation
In relation to installment of cell into ballast water piping, check torque on main assembly bolts between
the two cellhouse halves – if required (due to loosening after manufacturing) re-apply torque in
The PermaChlor® BWT cells are delivered pre-assembled and ready for installment in the ballast water
accordance with values given by Table 3 to each bolt.
piping and main power connected by cables to the connection boxes.

Model Torque (Nm)


The installation must be performed as intended in order to have a safe system. In case of 135
PermaChlor® BWT 100
doubt or uncertainties, contact Permascand AB! 190
PermaChlor® BWT 250
PermaChlor® BWT 500 220
PermaChlor® BWT 750 240
All national safety regulations must be fulfilled in connection with installation, start-up
PermaChlor® BWT 1000 330
and operation of the PermaChlor® BWT. Furthermore, the requirements of the Declaration
of Conformity, Class rules for installation etc. applies as well. Work in connection with the
electrical actuations of this manual must be performed only by professionals and qualified Table 3. Tightening torque of center flanges
persons.

4.2 Cable connection


The PermaChlor® BWT cells have the widest possible flexibility in terms of cabling connection options.
4.1 Installation of cell into piping General cable dimensioning is based on international standard IEC 60092-352. Cables used should be
The PermaChlor® BWT is connected in-line the ballast water piping with the flange type of choice. Due to suitable for temperatures up to minimum 70°C. The cable type is recommended to follow requirements
efficient evacuation of produced gases, cell outlet must always be located at higher vertical position than given by standards according to Table 4:
inlet! Table 2 shows applicable torque values for installment of the cell into piping via inlet- and outlet
flanges:
Property Standard
Current rating IEC 60092-352 (Table B4)
Model DIN PN6 DIN PN10 ANSI 150 ANSI 300 JIS 10K JIS 15K Design guideline IEC 60092-353
PermaChlor® BWT 100 60 60 60 60 60 60 Insulation IEC 60092-351
PermaChlor® BWT 250 90 90 90 90 90 90 Sheath IEC 60092-359
PermaChlor® BWT 500 85 85 85 85 85 85 Flame retardant IEC 60332-3-22, Cat. A
PermaChlor® BWT 750 85 85 85 85 85 85 Fire resistant IEC 60331
PermaChlor® BWT 1000 120 120 120 120 120 120 Halogen free IEC 60754-1
Low smoke IEC 61034-2
Table 2. Tightening torque of connection flanges (Nm*)

* Manufacturer's rating of torque specifications are maximum safe limits Table 4. Cable properties for contacting PermaChlor® BWT cells

The PermaChlor® BWT is obliged to be installed with a cable specified to the surrounding conditions and
to the given diameter of the cable gland. The different capacities of models in the PermaChlor® BWT
Cell outlet must always be located at a vertically higher position than inlet. Either whole cell product range requires different amount of DC current (A) and thus a required cable size (mm2 per cable
installed in vertical position with inlet from below, or horizontally with the inlet water going into or cable core) is given for each model. Furthermore, PermaChlor® BWT connection boxes and terminal
the lower cell connection. connection plints may also, under some conditions, be chosen by customer to fit preferred cable size and
if one-core or three-core cable option shall be used. Table 5 below gives the cabling options for each
PermaChlor® BWT model.
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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

For contacting, the cables are first installed into the gland(s). Thereafter, the very important attachment
of the cable lugs can be done to the cable end. The cable shall be connected to the lug using crimping,
Model Cable size [mm2] No. of core Required no. cables preferably hexagonal, with a minimum pressure of 13tons for 70/95/120mm2 cables and 20tons for
1 2 185mm2 cable. The maximum dimensions of crimped lugs must be controlled to secure adequate
70
PermaChlor® BWT 100 3 1 contacting. The connection shall fulfill electrical properties as required by standard IEC/EN 62138-1. Figure
95 1 1 4 and Table 5 shows proper crimping geometry, together with maximum dimensions of crimped lug for
1 4 each size:
70
3 2
PermaChlor® BWT 250
1 2
95
3 1
70 1 6
PermaChlor® BWT 500 1 4
95
3 2
1 6
95
3 3
PermaChlor® BWT 750
1 4
120
3 2
95 3 4
PermaChlor® BWT 1000 Fig.4: Geometry of crimped lug and measuring points for contacting control
185 1 6

Table 5. Cabling options contacting PermaChlor® BWT cells Crimping of Cable Lug
Conductor size (mm2) Max dimension N (mm)
Contacting is done via cable lugs connected to the terminal plints located in the connection boxes for 70 13.5
anode and cathode side. Number of lugs to each plint equal to number of cores in the cable times the 95 16.3
number of cables. Cables are secured via cable glands in the wall of the respective connection box. 120 16.5
185 20.6
Fig. 2-3 shows the parts included in the delivery and used for mounting of cable to the terminal plints via
the connection boxes.
Table 5. Maximum dimensions for crimped cable lug

The crimping shall be done by authorized staff and with recommended tools only!
Cables used should be suitable for temperatures up to minimum 70°C

Fig.2: Cable lug Fig.3: Cable gland

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

Cable lugs are thereafter connected to the terminal connection plints. All contact surfaces, shall be applied 5. Safety
with suitable contact paste, such as e.g. PENETROXTM oxide inhibiting compound, for preventing of
oxidation. The cable lugs are then contacted onto the plint using suitable bolts and washers. Table 6 shows
correct bolt size and correct applied torque for the connection, and Figure 5 shows the correct positioning
of cables at the plint:
5.1 System safety
For own safety and to allow a proper use of the electrochemical cell; it is important that you read through
this manual, including tips and warnings before start/using the PermaChlor® BWT for the first time. In
Cross section (mm2) Bolt Torque (Nm) order to avoid unnecessary mistakes and accidents; it is important that anyone who manages the
70 M10 50 electrochemical cell have good knowledge of its area of use and its safety features. Save this manual and
95 M10 50 ensure that it accompanies the electrochemical cell if it is moved so that all users have accurate safety
120 M12 90 information and information on how to manage it.

185 M12 90
• It is dangerous to alter the specifications or attempt to modify this product in any way.

Table 6. Bolt size and correct torque for connecting the cable lugs to the terminal plint • The voltage across the terminals of the cell is max 30 V (DC). In case of bad contact due to non-
compliant installment, the connection terminals might become very hot. External short-cuts are
avoided by the shielding from connection boxes,
• The electrochemical cell is not intended for use by persons with reduced physical or sensory ability,
lack of sensory ability, or lack of experience and knowledge if they are not instructed and
supervised by a person responsible for their safety.
• The installation must be professionally done by suitably trained personnel. When disassembling
the system for replacement, it must first be emptied of water.
• Repairs carried out by inexperienced staff can result in injury or serious malfunctioning. Always
contact your dealer or Permascand AB service department. Always insist on genuine Permascand
spare parts.

5.2 Process safety


Sodium hypochlorite produced by electrolysis is the most effective and safe from a working environment
perspective.
• Handling and transport of chlorine. The risks are avoided because the only thing handled and
transported is seawater.
Fig.5: Detail of terminal plint, with correctly connected cable lugs (cables not visible in figure)
• Storage of sodium hypochlorite. There is no storage of sodium hypochlorite since it is made
directly in the seawater flow, inside the electrolysis cell.
• Free chlorine gas. There is no free chlorine gas because the electrolysis process takes place directly
Cables coming from connection boxes must be secured externally at a maximum in the seawater flow where the chlorine gas immediately reacts with the water and becomes
distance of 30cm from exit via the glands, in order to unload the cable weight from dissolved sodium hypochlorite.
the boxes and cell! • Fire and explosion. A small amount of hydrogen is formed as by-product in the electrolysis of salt
and water, the same principle as when the batteries in an electric truck are being charged.
Hydrogen gas is fire and explosion hazardous at concentrations above the Lower Explosion Limit
(LEL) of 4%. With the PermaChlor® BWT cell on-site generation the produced hydrogen will follow
the treated water from the cell and never pose any explosion hazard in the cell.

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

5.5 Functional tests


5.3 Monitoring After contacting of cables to terminal plints, a test of proper connections shall be done before operation.
This test is carried out as a resistance test described in the scheme given in Figure 9. All connections, on
All operating parameters shall be recorded by the control/PLC unit of the BWTS. As a minimum,
terminal plints of both anode- and cathode side, must be checked against common reference points given
parameters to be recorded are current (A), voltage (V), temperature log (°C) and total time in operation
(h). in the figure (“G3”). Criteria for adequate connection is, that resistance (µΩ) against reference point
must not exceed 5% deviation from mean value of all ohmic resistances after complete test schedule.
Chlorination kinetics effect the chlorine consumption at temperatures above 35°C. This can be compensated
Table 7 shows a simple template which could be used for registry of measured values, for evaluation.
by increased current feed to the electrolytic cell. For electrolytic cell dry running/ water stagnation avoidance,
set power cut-off alarm at maximum temperature of 40°C.

5.4 Training of service personnel


Personnel handling the electrochemical cell must have good knowledge of this product and its
management. It is the product owner’s responsibility to make sure that the involved personnel has
sufficient expertise and adequate training in accordance with requirements. For increased general
knowledge of PermaChlor® BWT products, courses can be ordered from Permascand AB or product
supplier, including any of following areas:

a) Review of equipment
b) Review of the manuals
c) Operation and supervision
d) Troubleshooting, including cleaning of electrodes
e) Personnel safety and machinery safety in the use of the electrochemical cell

Fig.9: Control resistance test of cabling connections

Resistance control of connection after cable contacting

Ref. Point Resistance [µΩ] Deviation [%] OK/Not


G3 3.1
G3 3.2
G3 3.3
G3 3.4
G3 3.5
G3 3.6
G3 3.7
G3 3.8
G3 3.9
Mean:

Table 7: Resistance control schedule for test and evaluation of cable contacting

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

The above resistance control test must be repeated also between the reference point and respective cable 6. Operation
ends, in order to include the important connection of cables into the cable lugs. The same criteria for
acceptance applies: resistance between reference point and respective cable ends must not deviate more
than 5% (higher) from mean value of all measurements. Correct start-up and shut down process are handled by main control system of the BWTS. Functional
system and control are not part of delivery. Below indications are for reference only. The PermaChlor®
BWT could be controlled by several of principles, e.g. via TRO concentration, flowrate etc.
5.6 Special conditions of use
The PermaChlor® BWT cells are intended for use as disinfection component in Ballast
Water Treatment Systems (BWTS) by the manufacturer(s) of such equipment. It is the 6.1 Start up
responsibility of the BWTS manufacturer to ensure and properly follow the requirements a) Ensure that there is a flow of water in the pipe system where the electrochemical cell is mounted.
as set by Permascand AB regarding the use in respect of correct installation parameters, (i.e. proper integration of control logic of BWTS towards operation of cell)
control, operation and maintenance. b) Switch on main power at the power supply.
The used DC power supply (the rectifier) must be limited to maximum output current (A) c) Check that current and voltage have the correct values within limits given by the respective table
in accordance with maximum design current for the specific capacity – see Appendix I in Appendix I.
Technical data. d) The electrochemical cell PermaChlor® BWT cell delivers requested amount/concentration of
Demounting of a PermaChlor® BWT should be done in a non-explosive area (safe area) sodium hypochlorite to the water system and shall be controlled by the regulation system from
Functional test of safety control function(s) must be performed before use (see 5.6) the PLC unit of the BWTS system.

6.2 Shut down


a) Turn off the main power at the control cabinet.
b) If the pipe system where the electrochemical cell is mounted will be shut down; rinse the cell with
water.

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

7. Maintenance 7.5 Acid cleaning


During electrolysis operation over time, positively charged cations dissolved in water (Ca 2+, Mg2+ etc.) will
move towards the negatively charged cathode and be precipitated on the surface as a deposit hard to
The PermaChlor® BWT is a primarily maintenance free installation. Following sections functions as dissolve due to the very high local pH. This cathodic “scaling” can be of various properties depending on
maintenance schedule based on normal operation as disinfection unit in the BWTS onboard of a vessel water quality, how the electrolysis has run etc.
(assuming ballasting operations of approx.. 500h/year)
The scaling does not affect the production of hypochlorite (which takes place at the anode), but may need
to be removed due to physical impact to proper flow, increased voltage/energy consumption etc. Efficient
7.1 Daily – Self-monitoring cleaning of cathodes shall be done with a weak acid solution, 5-9% hydrochloric acid solution is
recommended. As alternative, citric acid (7-15%) can also be used and as alternative to solution this can
a) All operating parameters shall be recorded on the PLC unit of the BWTS system.
be bought as crystals (=no storage of liquids) and dissolved to desired concentration on-board.
b) Check leaks and if any fix them immediately.
c) Visual check for any physical damage. The entire cell may be filled with the weak acid solution, using nearby valves or blind flanges to separate
the cell from the pipings. For stand-still cleaning, 20-30min should be sufficient and if a re-circulation loop
d) Keep equipment clean externally.
could be implemented even shorter time is normally required. Regarding corrosivity: the cell housing and
7.2 Monthly - Self-monitoring internal components are resistant to these chemicals but be aware of composition of surrounding
pipeworks (sensitive Zn galvanizing etc.). If possible, the acid should be confined by the cell only during
a) Check the bolts at the cable connection on the cell and in the control cabinet.
cleaning and rapid dilution at discharge is advised.
7.3 Yearly
a) Measure both the voltage and the current during operation with volt- and ampere meter. Make
sure it is consistent with the values in the display of the power supply or PLC unit for the BWTS
system. IMPORTANT: Make sure proper drainage of cleaning solution before re-start of operation, and
b) Clean electrodes with weak (5%) hydrochloric acid: fill cell and/or recirculate for 5-24h (see ch. 7.5 check local regulations regarding discharge of acids! (Storage capacity for used cleaning solution
below) may be required).
c) Check torque on main assembly bolts of cellhouse two parts – re-apply torque given by Table 3 at
each bolt if required.

7.4 Every five year


NOTE: If use of citric acid: It is extra important that this acid is flushed out thoroughly before re-
a) Replace the electrochemical cell if necessary.
start of the electrochemical cell!

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

9. Declaration of Conformity
8. Troubleshooting (In accordance with standard EN ISO 17050-1:2004)

Folketshusvägen 50, 840 10


Problem Probable cause(s) Solution We, Permascand AB Ljungaverk
For efficient hypochlorite production, make sure hereby declare that:
salinity of treated water is >3PSU OR make sure PermaChlor® BWT
Too low salinity
operational settings are adjusted to “low salinity” with capacities: 100 (for water flow up to 150 m3/h)
(see Appendix I) for operation down to 0.9PSU 250 (for water flow up to 300 m3/h)
High/max
voltage, low Clean electrodes with weak (5%) hydrochloric acid: 500 (for water flow 600 m3/h)
current Cathodic scaling fill cell and/or recirculate for 5-24h- See further ch. 750 (for water flow up to 800 m3/h)
7.5 1000 (for water flow up to 1200 m3/h)

Electrodes worn out Exchange the PermaChlor® BWT are developed and manufactured in conformity with and complies with all the applicable
Essential Requirements of the following standards:
Low
hypochlorite see previous see previous ISO 2878-1 (Standard for machining)
production SS-ISO 965-2 (Thread tolerance)
ISO 17637:2003 (“Non-destructive testing of welds – Visual testing of fusionwelded joints”)
ISO EN 13920:1996 (“Welding – General tolerances for welded construction..")
Voltage over ISO 5817:2014 (“Welding – Fusion-welded joints in steel, nickel, titanium and their alloys..")
accepted Connecting cables/cableshoes to the Unscrew cableshoes, clean contact surfaces from ISO 14731:2006 (“Welding coordination – Tasks and responsibilities”)
value, cell and/or to the terminals at the oxides and re-apply antioxidant contact paste. Re- IEC 50186

heated control cabinet have loose, bad or connect cableshoes to terminal plints via bimetal EN 13121-1 ,2, 3:2008 (under European Commission Mandate 83/139/EEC)

junction oxidized connections or damages. spacers. Check contacting similarly at rectifier.


Further, Permascand AB is certified in accordance with management standards:
boxes
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007

Accredited unit: DNV GL Business Assurance Sweden AB

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

Appendix I
PermaChlor® BWT 100
Salinity, min. "Normal" (>3PSU) "Low" (0.9-3PSU)
3
Fl ow ra te (Min-Max) 75-150 20-40 m /h
Chl ori ne concentra ti on
≤6 ≤6 ppm
(TRO)
Opera ti ng tempe ra ture
5 - 35 5 - 35 ˚C
(Mi n-Max)
Ambi ent tempera ture
0 - 60 0 - 60 ˚C
(Mi n-Max)
Stora ge tempera ture
-30 - 60 -30 - 60 ˚C
(Mi n-Max)

Vol ta ge 15 - 30 25 - 30 V

Ampe ra ge (ma x) 250 200 A

Powe r s uppl y (V*A) 7.5 7.5 kW

Li feti me > 5000 > 5000 h

Des i gn opera ti ng
0-6 0-6 Ba r(g)
pres s ure

Opera ti ng pres s ure 1-2 1-2 Ba r(g)

Pres s ure tes ted 9 9 Ba r(g)

Nomi na l worki ng
0.6 0.6 Ba r(g)
pres s ure (DP)

Wei ght Empty 76 76 Kg

No. Rev. Date Sign. Comments Wei ght duri ng ope ra ti on ~135 ~135 Kg
1 0 2016-04-28 JET First edition
Cel l hous e di a meter DN250 DN250 --

Inl et/Outl et DN150 DN150 --

Length 1970 1970 mm

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

PermaChlor® BWT 250 PermaChlor® BWT 500


Salinity, min. "Normal" (>3PSU) "Low" (0.9-3PSU) Salinity, min. "Normal" (>3PSU) "Low" (0.9-3PSU)
3
3 Flow rate (Mi n-Ma x) 300-600 75-150 m /h
Flow ra te (Mi n-Max) 150-300 40-75 m /h
Chlori ne concentra tion
Chlorine concentra tion ≤6 ≤6 ppm
≤6 ≤6 ppm (TRO)
(TRO)
Opera ti ng tempera ture
Operating temperature 5 - 35 5 - 35 ˚C
5 - 35 5 - 35 ˚C (Min-Max)
(Min-Ma x)
Ambient tempera ture
Ambient tempera ture 0 - 60 0 - 60 ˚C
0 - 60 0 - 60 ˚C (Min-Max)
(Min-Ma x)
Storage temperature
Stora ge tempera ture -30 - 60 -30 - 60 ˚C
-30 - 60 -30 - 60 ˚C (Min-Max)
(Min-Ma x)
Voltage 15 - 30 25 - 30 V
Volta ge 15 - 30 25 - 30 V

Ampera ge (ma x) 1000 750 A


Amperage (max) 500 400 A

Power s upply (V*A) 30 30 kW


Power s upply (V*A) 15 15 kW

Lifetime > 5000 > 5000 h


Lifetime > 5000 > 5000 h

Des i gn operating Des ign opera ting


0-6 0-6 Ba r(g) 0-6 0-6 Ba r(g)
pres s ure pres s ure

Operating pres s ure 1-2 1-2 Ba r(g) Opera ti ng pres s ure 1-2 1-2 Ba r(g)

Pres s ure tes ted 9 9 Ba r(g) Pres s ure tes ted 9 9 Ba r(g)

Nominal working Nomina l working


0.6 0.6 Ba r(g) 0.6 0.6 Ba r(g)
pres s ure (DP) pres s ure (DP)

Weight Empty 114 114 Kg Wei ght Empty 190 190 Kg

Weight during opera tion ~220 ~220 Kg Wei ght duri ng operation ~400 ~400 Kg

Cell hous e dia meter DN350 DN350 -- Cell hous e dia meter DN450 DN450 --

Inl et/Outlet DN200 DN200 -- Inlet/Outlet DN250 DN250 --

Length 1970 1970 mm Length 2450 2450 mm

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BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual

PermaChlor® BWT 1000


PermaChlor® BWT 750 Salinity, min. "Normal" (>3PSU) "Low" (0.9-3PSU)
3
Salinity, min. "Normal" (>3PSU) "Low" (0.9-3PSU) Flow ra te (Min-Ma x) 800-1200 200-300 m /h

Flow ra te (Min-Max) 500-800 125-200 3 Chlorine concentra ti on


m /h ≤6 ≤6 ppm
(TRO)
Chlori ne concentration Operating tempera ture
≤6 ≤6 ppm 5 - 35 5 - 35 ˚C
(TRO) (Min-Ma x)
Opera ting tempera ture Ambient tempera ture
5 - 35 5 - 35 ˚C 0 - 60 0 - 60 ˚C
(Mi n-Ma x) (Min-Ma x)
Ambi ent tempera ture Stora ge tempera ture
0 - 60 0 - 60 ˚C -30 - 60 -30 - 60 ˚C
(Mi n-Ma x) (Min-Ma x)
Storage tempera ture
-30 - 60 -30 - 60 ˚C Volta ge 15 - 30 25 - 30 V
(Mi n-Ma x)

Volta ge 15 - 30 25 - 30 V Amperage (max) 2000 1600 A

Ampera ge (ma x) 1250 1000 A Power s upply (V*A) 60 60 kW

Power s uppl y (V*A) 37.5 37.5 kW Lifetime > 5000 > 5000 h

Lifetime > 5000 > 5000 h Des ign operating


0-6 0-6 Ba r(g)
pres s ure
Des ign opera ting
0-6 0-6 Ba r(g) Operating pres s ure 1-2 1-2 Ba r(g)
pres s ure

Opera ting pres s ure 1-2 1-2 Ba r(g) Pres s ure tes ted 9 9 Ba r(g)

Nominal working
Pres s ure tes ted 9 9 Ba r(g) 0.6 0.6 Ba r(g)
pres s ure (DP)
Nomi na l working
0.6 0.6 Ba r(g) Weight Empty 320 320 Kg
pres s ure (DP)

Weight Empty 280 280 Kg Weight during opera tion ~650 ~650 Kg

Weight during operation ~590 ~590 Kg Cell hous e dia meter DN600 DN600 --

Cell hous e dia meter DN500 DN500 -- Inl et/Outlet DN400 DN400 --

Inlet/Outlet DN250 DN250 -- Length 2910 2910 mm

Length 2450 2450 mm

Permascand AB ǀ Folkets Husvägen 50 ǀ SE-840 10 Ljungaverk ǀ www.permascand.com Permascand AB ǀ Folkets Husvägen 50 ǀ SE-840 10 Ljungaverk ǀ www.permascand.com
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

TRANSFORMER/ RECTIFIER(S)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 10
User Guide Page 1(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
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USCG

1 Safety instructions

SAFETY INSTRUCTION

There are hazardous voltages inside this product. If


touched, they may cause electric shock, burns or death.

This product is only intended for use as a constant DC-power supply for industrial
processes, the product may only be used for other purposes after approval from
User Guide KraftPowercon. The product must not be used for charging batteries or welding.

Read the instruction manual before installing, using or working on the product.
FlexKraft Marine USCG

77-107.0296 GB Rev. B WARNING! Only authorised personnel may install this product. It
must be installed in accordance with the installation
instructions and local regulations.

WARNING! Only authorised personnel may carry out servicing or


maintenance.

WARNING! Always safely disconnect the electric power supply


before starting servicing or maintenance work. The
work must be done in accordance with the service
instructions in the Technical Description.

CAUTION! Water along with electricity needs special attention.


Pay attention to errors in the cooling system and check that
no water has leaked into the electronics.

The product is intended only for professional use. It must not be used in homes
and offices.

KraftPowercon Sweden AB. P.O.Box 2102. SE-445 02 SURTE. Sweden Tel: +46 31 97 97 00. www.kraftpowercon.com
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Table of Contents
1.1 Description of safety symbols used on FlexKraft Marine:

1 SAFETY INSTRUCTIONS .................................................................................1 Warning, risk of electric shock!


1.1 Description of safety symbols used on FlexKraft Marine: .......................................3
1.2 Standards ......................................................................................................................4 Before operating the unit:
2 GENERAL..........................................................................................................5 - Carefully read the manual.
3 BASIC CONTROL..............................................................................................6
3.1 Normal operation ..........................................................................................................7
3.1.1 Keypad.............................................................................................................7
3.1.2 LED indication..................................................................................................8 Danger, risk of electric shock!
3.1.3 Audio signals ...................................................................................................8
3.1.4 LCD display .....................................................................................................8
3.1.5 Special functions .............................................................................................8 Before opening the unit:
3.1.6 Alarms / Warnings / Fault messages ..............................................................9 - Isolate from the electrical supply.
3.1.7 Operating modes ...........................................................................................12
3.1.8 Brief overview of functions.............................................................................15
3.1.9 Starting the rectifier .......................................................................................16
3.1.10 Stopping the rectifier......................................................................................17
3.1.11 Blocking the rectifier RUN/BLOCK ................................................................17
3.1.12 Blocking rectifier START/STOP ....................................................................18
3.1.13 Setting polarity (optional function) .................................................................18 Connection point for the protective earth.
3.1.14 Setting the time limit ......................................................................................19
3.1.15 Setting the Ah limit.........................................................................................20
3.1.16 Setting the start ramp ....................................................................................22
3.1.17 Setting the auto-dosing function (optional) ....................................................23 Warning, risk of electric shock!
3.1.18 Running program ...........................................................................................25
3.1.19 Setting the remote control .............................................................................26
3.1.20 Locking keypad to enter parameters in SLAVE mode...................................27
Before opening the unit:
3.1.21 Setting the under voltage / short circuit detection..........................................27 - Isolate from the electrical supply.
3.2 Calibration/Configuration...........................................................................................28 - WAIT UNTIL REMAINING VOLTAGE
3.3 Password .....................................................................................................................28 HAS
4 WARRANTY.....................................................................................................28 DISCHARGED
5 APPENDICES, SEE FOLLOWING PAGES.....................................................28
5.1 List of figures ..............................................................................................................28 DO NOT FREEZE!
5.2 List of tables ................................................................................................................28
THERE IS A MAJOR RISK OF
MALFUNCTION AND REPAIR NEED IF
5.3 Description of order-specific equipment, where applicable...................................28
THE RECTIFIER FREEZE WITH WATER
This description applies to software versions: INSIDE THE COOLING SYSTEM.
FLX-10 VER. 2.18 and later. In case of any freezing risk must unit be
PMC-01 VER. 1.09 and later. emptied of water, see Technical
Description 77-107.0295 section 8.3.1.
Slight differences can exist between the program versions.
Warning, risk of crushing hands or feet!
To upgrade the software from earlier versions, contact KraftPowercon service. During installation or under ship inclination:
Be aware of the risk of crushing under
The manufacturer reserves the right to change specifications. rectifier and in the wire isolators.

Internal CUST-3051
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USCG USCG

1.2 Standards
The following European standards or technical specifications apply: 2 General
Document no. Edition Year Title FlexKraft Marine is a modular designed rectifier for use in industrial processes. The
rectifier consists of one control module and one to ten identical power modules. If more
2014/30/EU - 2014 Electromagnetic compatibility directive current or power is needed from an existing rectifier, power modules can be added, up
EN 61000-6-2 2.0 2005 EMC Immunity standard for industrial environments to a maximum of 50.
EN 61000-6-4 2.0 2007 EMC Emission standard for industrial environments FlexKraft Marine has built in EMC filter according to the EMC directive.
IEC 62477-1 1.0 2012 Safety requirements for power electronic converter systems
and equipment - Part 1: General
1 Top
IEC 60092-101 4.0 1994 Electrical installations in ships - Part 101: Definitions and 2 Control module
general requirements 3 Power module
4 Base
IEC 60092-304 3.0 1980 Electrical installations in ships - Part 304: Equipment - 5 Display with keys
Semiconductor convertors 6 Connection to mains supply
7 Connections for control
signals
Signs with connection
Society Document no. Year Title information.
8 Protective cover (metal) for
DNVGL DNVGL-CP-0338 2015 DNV GL type approval scheme DC busbars
DNVGL DNVGL-CG-0339 2015 Environmental test specification for electrical, 9 Water connections
electronic and programmable equipment and systems 10 Vibration dampers

DNVGL DNVGL-CP-0395 2015 Semiconductor converters Side A is on the left when


viewed from in front
DNVGL DNVGL-RU-SHIP- 2016 Part 4 Systems and components Chapter 8 Electrical
Pt4Ch8 installations
USCG 46 CFR 162.060-30 2015 Testing requirements for ballast water management
system (BWMS) components
IMO MEPC 174(58) 2008 Guidelines for approval of ballast water management
Figure 1. Overview of components.
systems (G8)
IACS E10 (Revision 6) 2014 Test Specification for Type Approval
Table 1. Standards
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3.1 Normal operation


The rectifier is operated using the display unit on the front of the control module.

Figure 4. FlexKraft Marine display unit


For more functions and detailed information see the Technical description 77-107.0295,
chapter Operating instructions
Figure 2. FlexKraft Marine with six power modules.

3.1.1 Keypad
The display unit membrane keypad has the following keys:

ON Starts the rectifier; (the contactor closes if fitted)


OFF Stops the rectifier; (the contactor opens if fitted)
Current έ Increase current
Current ί Decrease current
Voltage έ Increase voltage
Voltage ί Decrease voltage
Menu keys A – D Menu options
OK! Used to confirm a change (disabled in some submenus)
ESC Used to undo a change or back out of a menu
(disabled in some submenus)

The longer a key is held, the faster the set value changes. The value stops at
zero.

Figure 3. Five parallel rectifiers, Master rectifier to the left In REMOTE mode, some or all control functions cannot be operated from the display
Master rectifier must always be at one end. unit and are instead controlled by serial communication or by external analogue control
signals. If the rectifier is not in REMOTE mode it can only be operated from the display
unit.
3 Basic Control
This chapter deals with control from the local display. The rectifier will, in most cases, When SLAVE MODE is active, the keypad is disabled and no operating parameters can
probably be remotely controlled from an external control system. The local display unit be changed.
is useful for service and troubleshooting. The OFF key is also disabled, even if the rectifier is set in LOCAL mode.
The keypad is activated using a password-protected menu.

Pressing the OK key saves changes and pressing the ESC key discard changes!
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3.1.2 LED indication 3.1.6 Alarms / Warnings / Fault messages


The panel has LED indication for the following functions: An alarm signal from the rectifier is indicated by a red LED on the display unit. The
reason for the alarm is shown on the display.
ON Green LED Indicates rectifier on (contactor closed)
ALARM Red LED Indicates end of process or rectifier fault If the rectifier is fitted with the optional CONTACTOR, the contactor opens at the alarm.
The LED flashes to indicate a WARNING and glows steadily If the sound indication is set to “ON” in the CFG/USR menu, see the Technical
to indicate ALARM Description 77-107.0295, chapter Operating instructions, the buzzer goes on at the
REMOTE Yellow LED Indicates the rectifier is controlled by a remote control alarm. The buzzer is turned off by pressing any button.

To reset from fault mode: switch the rectifier off using the keypad or serial
3.1.3 Audio signals communication. Alternatively, send the ALARM RESET command using the DIG IN
The panel is equipped with a piezo buzzer that sounds to confirm keypad use, end of digital input.
process (EOP) and a rectifier fault. The buzzer sound indication can be turned off in the
CFG/USR menu. See in the Technical Description 77-107.0295, chapter Operating ALARM = The rectifier stops.
instructions WARNING = The rectifier continues to operate but possibly with reduced output.

The ALARM signal is activated in the event of either an ALARM or WARNING.


3.1.4 LCD display The POWER GOOD signal is deactivated when there is an ALARM or WARNING.
The LCD display is a high contrast graphic type with integrated background lighting.
The display contrast may need to be adjusted depending on the ambient temperature Message Explanation
and age. Adjustment is made from the configuration menu. “HIGH TEMP.” Excess temperature in a power module. Too high temperature
on the output causes over temperature in the power module.
Background lighting comes on when a key is pressed and remains on for 60 seconds (the output from the affected power module is stopped as long
after the last key is pressed. as the temperature remains too high. The ‘Power Good’ LED is
off on the power module that has sent the high temperature
signal). The rectifier remains running with the remaining power
3.1.5 Special functions modules, the output current is decreased accordingly.
The rectifier control system is configured on delivery, however, if for some reason you
wish to reset the settings to their default values this can be done by holding down the
ESC key for more than 8 seconds. CAUTION! The cooling water can be hot if the system has shut down
NOTE - The SET parameters, Ah counter and process timer are reset to zero. due to over temperature.
- The CFG settings are not changed (the buzzer is switched on if it has
been switched off)
-The loaded software is not changed.
The buzzer sounds when the system has been reset.
“HIGH TEMP C-M” Excess temperature in the control module. The rectifier runs.
The system is reset if the OFF key is held down for 5 seconds. The buzzer sounds The output current is unaffected.
to indicate that reset has occurred.
“RGL ERROR” Regulator control error in the rectifier. The rectifier runs, but the
output is not according to set values (in earlier system also
called ‘Phase missing’).
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Message Explanation Message Explanation


“WARNING!” One of the following warnings is active on at least one power “EXT ALARM 1” User configurable.
module:
· Regulation error EXT ALARM A/B Alarm from PRU (pole reverse unit) in case the unit is equipped
· RS485 communication lost with this optional function.
· Overcurrent Can also be used as be used as interlock from process.
· Overvoltage

Regulation error: In the case of an ALARM rectifier stops, See Technical Description 77-107.0295
One or both sides in one or more power modules are not able User menu.
to regulate properly. Check that mains supply is within range The reason for the ALARM should be determined. See Technical Description 77-
and has not lost a phase. 107.0295, chapter Service and Maintenance

RS485 communication lost:


One or more power modules lost RS485 communication. The display can also show four fault messages.

Overcurrent: Message Explanation


Overcurrent in one or both sides in one or more power “CHK USRCFG” Only applies with pole reversal option. Fault in
modules. Power cycle of the power module is needed to reset configuration of DIG IN or DIG OUT signals.
this warning.

Overvoltage: “MAX POWER!” The output of the rectifier does not correspond to the
High voltage on the busbar output in one or both sides in one or (ALARM LED flashes) set values of current and voltage due to power
more power modules. Power cycle of the power module is limitation. The set values for current and voltage are
needed to reset this warning. within the triangle 30-50V/125-100A@ mains 420-
480VAC. If the mains power is lower than needed to
Common for all warnings: give the set output, a Regulation error is generated
· The rectifier continues to run although the output instead of “MAX POWER”
current might decrease (due to that the affected power
module in the system is shut down). 1
Effektgräns
Power limit
· ‘Power Good’ LED is blinking when the warning is U
active
· When the warning has ceased to be active, ‘Power 50V

Good’ LED on affected power module is turned off to 30V 1 Power Limit
indicate that there has been a warning. 2 Voltage
3 Current
“MODULE FAILED!” Reverse current in a power module. (The rectifier stops. The
‘Power Good’ LED is off on the power module that has sent the
alarm signal).
I
100A 125A
“SHORT CKT!” The output voltage has been below the under voltage set value 3 Ström/Current

for a longer period of time than set time value.

“CAN FAIL” CAN communication lost (rectifier shuts down).


When an EOP for elapsed time limit or ampere hour limit is reached the “ALARM” LED
flashes, see 3.1.14 Setting the time limit and 3.1.15 Setting the Ah limit for information.
“CANWARNING” CAN communication is not working properly.
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3.1.7 Operating modes Example, mains voltage 420-480VAC (-0/+10%)


The rectifier has two operating modes (three with option pole reverse): SINGLE 2 submodules in
100V/100A series
Single Sub-modules can be connected in series for higher
voltage, and these sub-module groups can be connected
in parallel for higher current (ether side A to side B,
horizontal connections, or vertically adjacent sub-modules,
vertical connections). M=Master, S=Slave
Output voltage and current in this mode is 0- SINGLE 3 submodules in
30(50)V@125(100) A/module at 420-480V (-0/+10%) 150V/200A series
primary voltage.
See Technical manual 77-107.0295 for more information. 2 groups in
parallel over sides
Single See Technical manual 77-107.0297 for more information.
Pole reverse
(optional)

Dual Power module sub-modules are independent (side A and


B). Sub-modules can be connected in series for higher
voltage, and these sub-module groups can be connected in
parallel for higher current (within the side).
Sides A and B can be switched on and off independently
and behave like two rectifiers.
The set values for current and voltage can be different for DUAL 2x50V/200A 2 submodules in
each side. The time limits are the same for both sides. parallel
The Ah limit can be set independently for each side.
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DUAL 4 submodules in
2x200V/200A series. 3.1.8 Brief overview of functions

2 groups in Please note that some functions require that options are installed.
parallel on the
same side Heading Sub-function 1 Sub-function 2 Sub-function 3

Operating modes SINGLE (sides connected in series/parallel or both)


(SINGLE Pole Reverse , needs option pole reverse )
DUAL (groups connected in series in the group, in parallel, or both)

Remote control Serial communication RS485 PROFIBUS DP


MODBUS RTU

Analogue current 0-20mA


4-20mA

voltage 0-10VDC
0-6 VDC
0-5 VDC
6-0 VDC
10-0 VDC
contacts Increase/decrease current
Increase/decrease voltage
ON/OFF
START/STOP
RUN/BLOCK

Program No. 1-4 STEP


Several rectifiers can be connected in parallel to obtain higher output current, but U-RAMP
they must be equipped with the parallel configuration option. I-RAMP
PULSE
REPEAT

For examples with pole reverse, see Technical Description 77-107.0297.


Limits Ah limit Side A Stop rectifier
Side B Signal
HOLD function U/I

Time limit Side A+B Stop rectifier


Signal
HOLD function U/I

Under voltage Limits Side A Voltage


Limits Side B Time
Time limit Side A
Time limit Side B

Dosing function Side A Dosing pulse time


Side B
Total A+B

Monitoring Temperature
Regulation
Configuration
External emergency stop

See Technical Description 77-107.0295 for more information.


See Technical Description 77-107.0297 for option Pole Reverse.
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3.1.9 Starting the rectifier 3.1.10 Stopping the rectifier


When first switched on the display is dimmed and shows the following start displays. Switch the rectifier from “RUN” mode to “STANDBY” mode with the “OFF” key.
Side
A B Shut down the rectifier by pressing the “OFF” key again to switch from “STANDBY”
mode to “OFF” mode.
STATUS: - OFF - - OFF - - OFF -
Also see 3.1.19 Setting the remote control

PRESS ON TO START PRESS ON TO START


Flex Kraft The rectifier can also be stopped by set limits or alarms

SINGLE DUAL
www.kraftpowercon.com DUTY SET BLOCK CFG DUTY SET BLOCK CFG Rectifier stops after
set time. STATUS: TLIMIT! T-LIMIT! T-LIMIT!
Welcome screen Example of start screen
Displayed for some seconds The rectifier can be configured to go to OFF,
REMOTE, CONTINUE or RUN 00.00 V 000.0 A 00.00 V 00.00 V
when mains power is connected. 000000 Ah 00000 S 000.0 A 000.0 A
SINGLE DUAL DUTY SET BLOCK CFG DUTY SET BLOCK CFG
Switch on the rectifier DUTY SET
with the “ON” key. STATUS: STANDBY STANDBY STANDBY CFG

The backlight comes Rectifier stops after STATUS: AHLIMIT! AH-LIMIT! AH-LIMIT!
on and the display 00.00 V 000.0 A 00.00 V 00.00 V set number of Ah
changes. 000000 Ah 00000 S 000.0 A 000.0 A
00.00 V 000.0 A 00.00 V 00.00 V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET
CFG DUTY SET BLOCK CFG DUTY SET BLOCK CFG
DUTY SET
CFG
Start the rectifier by STATUS: RUN DC RUN DC RUN DC
pressing the ON key Rectifier stops due to STATUS: HIGH TEMP HIGH TEMP HIGH TEMP
once more - output excess temperature
current and voltage is 00.00 V 000.0 A 00.00 V 00.00 V
delivered. 000000 Ah 00000 S 000.0 A 000.0 A 00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG
CFG DUTY SET DUTY SET BLOCK CFG DUTY SET BLOCK CFG
CFG DUTY SET
In order to control the rectifier locally, set the Remote control option to “NO” CFG
See Technical description 77-107.0295, chapter “Set menu” for further information.
3.1.11 Blocking the rectifier RUN/BLOCK
The rectifier can be blocked and stopped without entering “STANDBY”.
The blocking function turns the rectifier output off and it restarts with the set
values. In DUAL mode output A and B are blocked independently.
This can be done using the “BLOCK” key, from the SET menu, or by remote
control. In DUAL mode the rectifiers can only be operated independently from the
SET menu, or by remote control.
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3.1.14 Setting the time limit


3.1.12 Blocking rectifier START/STOP The rectifier can be set, once a specific time has elapsed, to:
The rectifier can be blocked and stopped without going to “OFF”. -Stop and give a signal
The ‘BLOCK’ function turns the rectifier output off immediately and then again the -Continue with operations and give a signal
‘RUN’ function restarts the rectifier with a start ramp to the set values. -Change the output data to a HOLD level and give a signal.
In DUAL mode outputs A and B can be operated independently. Set in CFG/USR menu using EOP MODE

SINGLE DUAL The time is set in the SET menu using TIMERLIMIT.

STATUS: STANDBY STANDBY STANDBY SINGLE DUAL


REMOTE CONTROL : NO REMOTE CONTROL : NO
00.00 V 000.0 A 00.00 V 00.00 V SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A RUN/BLOCK : RUN SETCURRENT A: 000.0 A
START/STOP : STOP SETCURRENT B: 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
DUTY SET
CFG
← → ↓ ↑ ← → ↓ ↑

STATUS: STANDBY STANDBY STANDBY Press ↓ to get TIMERLIMIT

Setting whether the rectifier should stop, use HOLD level or only light the ALARM LED
00.00 V 000.0 A 00.00 V 00.00 V when the set limit has been reached (option: contact to remote system) is set using the
000000 Ah 00000 S 000.0 A 000.0 A CFG/USER menu with the EOP MODE parameter.
NOTE that the settings also apply for the Ah limit. The CFG menu is password
DUTY SET RUN CFG DUTY SET RUN CFG protected.
DUTY SET
CFG
The set menu The set menu SINGLE DUAL

REMOTE CONTROL : NO REMOTE CONTROL : NO STATUS: STANDBY STANDBY STANDBY


SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
RUN/BLOCK : RUN SETCURRENT A: 000.0 A 00.00 V 000.0 A 00.00 V 00.00 V
START/STOP : STOP SETCURRENT B: 000.0 A
TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG
← → ↓ ↑ ← → ↓ ↑ DUTY SET
CFG
SELECT SUB-MENU OR SELECT SUB-MENU OR
3.1.13 Setting polarity (optional function) PRESS ESC TO EXIT! PRESS ESC TO EXIT!
This function require that option Pole Reverse is fitted.
See Technical Description 77-107.0297
FIRMWARE FIRMWARE
FLX-01 VER xx.xx FLX-01 VER xx.xx

PROG USER CAL KRAFT PROG USER CAL KRAFT


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SINGLE DUAL
SINGLE DUAL
LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 %
PASSWORD :000001 PASSWORD :000001
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP STATUS: STANDBY STANDBY STANDBY
BYTESWAP : YES BYTESWAP : YES
ADDRESS : 00002 ADDRESS : 00002
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT 00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
← → ↓ ↑ ← → ↓ ↑
DUTY SET BLOCK CFG DUTY SET BLOCK CFG
Press ↓ to get to EOP MODE Press ↓ to get to EOP MODE DUTY SET
CFG
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS REMOTE CONTROL : NO REMOTE CONTROL : NO
SLAVEMODE: NO SLAVEMODE: NO SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
POWERONMODE: OFF POWERONMODE: OFF SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
OUTPUTMODE : SERIES OUTPUTMODE : SERIES RUN/BLOCK : RUN SETCURRENT A: 000.0 A
EOP MODE : STOP EOP MODE : STOP START/STOP : STOP SETCURRENT B: 000.0 A
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0% TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑

Press ↓ to get to AH-LIMIT Press ↓ to get to AH-LIMIT A / B


Press “OK” to activate change.
SETCURRENT : 000.0 A POLARITY A : FWD
RUN/BLOCK : RUN POLARITY B : FWD
When the set limit is reached, switch off the buzzer by pressing ESC. START/STOP : STOP TIMERLIMIT : -OFF- S
POLARITY : FWD AH-LIMIT A : -OFF-AH
Pausing the process: TIMERLIMIT : -OFF- S AH-LIMIT B : -OFF-AH
The process can be paused before the set limit is reached by pressing the “OFF” key AH-LIMIT : -OFF-AH START RAMP : 0000.5 S
and then restarted by pressing “ON” key. A restart is also made if the “OFF” key has
been pressed twice so that the rectifier is in “OFF” mode. ← → ↓ ↑ ← → ↓ ↑

Interrupting the process:


Setting whether the rectifier should stop, use HOLD level or only light the ALARM LED
Pause the process using the “OFF” key. Reset the counter in the DUTY menu with
when the set limit has been reached (option: contact to remote system) is set using the
CLEAR. Restart the process from zero with the “ON” key.
CFG/USER menu with the EOP MODE parameter.
Restart the process: NOTE that the settings also apply for the time limit. The CFG menu is password
When the process has completed and an EOP has been obtained, the rectifier is protected.
stopped/set in STANDBY mode using the “OFF” key. Restart the process from zero SINGLE DUAL
with the “ON” key.
See the Technical description for further setting options and programming functions. STANDBY STANDBY
STATUS: STANDBY

3.1.15 Setting the Ah limit 00.00 V 000.0 A 00.00 V 00.00 V


The rectifier can be set, once a specific number of ampere hours have elapsed, to: 000000 Ah 00000 S 000.0 A 000.0 A
-Stop and give a signal
-Continue with operations and give a signal DUTY SET BLOCK CFG DUTY SET BLOCK CFG
-Change the output data to a HOLD level and give a signal. DUTY SET
Set in CFG/USR menu using EOP MODE CFG

The number of ampere hours is set in the SET menu using AH-LIMIT A and AH-
LIMIT B.
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SINGLE DUAL SINGLE DUAL


SELECT SUB-MENU OR SELECT SUB-MENU OR
PRESS ESC TO EXIT! PRESS ESC TO EXIT! STATUS: STANDBY STANDBY STANDBY

FIRMWARE FIRMWARE 00.00 V 000.0 A 00.00 V 00.00 V


FLX-01 VER xx.xx FLX-01 VER xx.xx 000000 Ah 00000 S 000.0 A 000.0 A
PROG USER CAL KRAFT PROG USER CAL KRAFT DUTY SET BLOCK CFG DUTY SET BLOCK CFG
DUTY SET
CFG
LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 % REMOTE CONTROL : NO REMOTE CONTROL : NO
PASSWORD :000001 PASSWORD :000001 SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
BYTESWAP : YES BYTESWAP : YES RUN/BLOCK : RUN SETCURRENT A: 000.0 A
ADDRESS : 00002 ADDRESS : 00002 START/STOP : STOP SETCURRENT B: 000.0 A
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑

Press ↓ to get to EOP MODE Press ↓ to get to EOP MODE Press ↓ to get to START RAMP Press ↓ to get to START RAMP
RUN/BLOCK : RUN POLARITY A : FWD
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS START/STOP : STOP POLARITY B : FWD
SLAVEMODE: NO SLAVEMODE: NO POLARITY : FWD TIMERLIMIT : -OFF- S
POWERONMODE: OFF POWERONMODE: OFF TIMERLIMIT : -OFF- S AH-LIMIT A : -OFF-AH
OUTPUTMODE : SERIES OUTPUTMODE : DUAL AH-LIMIT : -OFF-AH AH-LIMIT B : -OFF-AH
EOP MODE : STOP EOP MODE : STOP START RAMP : 0000.5 S START RAMP : 0000.5 S
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0%
← → ↓ ↑ ← → ↓ ↑
← → ↓ ↑ ← → ↓ ↑
Press “OK” to activate change.
Press “OK” to activate change.

When the set limit is reached, switch off the buzzer by pressing ESC. 3.1.17 Setting the auto-dosing function (optional)
The rectifier can be equipped with an auto-dosing function. This function requires that
See the Technical description 77-107.0295, chapter Operating Instructions for further the digital I/O or analogue I/O option is fitted to the rectifier.
setting options and programming functions.
The rectifier can be set to close a potential free contact when a preset number of Ah
3.1.16 Setting the start ramp hours have elapsed. The number of Ah hours between the start of each pulse is set
The rectifier can be set to ramp up voltage and current from zero to set value during a using parameter AUTODOS, and the closed time for the contacts is set by the
preset time. The time is set using the SET menu and the parameter START RAMP for parameter PULSLENG. in the CFG/USER menu. The menu is password protected.
both side A and side B.
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There are three adjustable Ah counters and three adjustable times. SINGLE DUAL

Side Parameter AH Parameter pulse time AUTODOS. : -OFF-AH AUTODOS. : -OFF-AH


PULSELENG. : 000.5 S PULSELENG. : 000.5 S
SINGLE AUTODOS. A : -OFF-AH AUTODOS. A : -OFF-AH
AUTODOS. PULSELENG. PULSELENG.A: 000.5 S PULSELENG.A: 000.5 S
AUTODOS. B : -OFF-AH AUTODOS. B : -OFF-AH
DUAL PULSELENG.B: 000.5 S PULSELENG.B: 000.5 S
A AUTODOS.A PULSELENG.A
B AUTODOS.B PULSELENG.B ← → ↓ ↑ ← → ↓ ↑

Press “OK” to activate change.


AUTODOS has a range of 0-30,000 Ah, and sets the number of ampere hours between
See the Technical description 77-107.0295, chapter Operating Instructions and Dosing
dosing.
function for further setting options and programming information.
PULSELENG has a range of 0-999.9 s, and sets the length of time that the contacts
remains closed. 3.1.18 Running program
The DIG OUT 1 to DIG OUT 4 parameter determines which contacts are used.
Parameters are set in the CFG/USER menu. The rectifier can be programmed with 4 different programs.
The program and operating mode are selected using the PROGRAMMODE and PROGRAM
SINGLE DUAL NO parameters in the SET menu.

SINGLE DUAL
STATUS: STANDBY STANDBY STANDBY

STATUS: STANDBY STANDBY STANDBY


00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
00.00 V 000.0 A 00.00 V 00.00 V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET
CFG DUTY SET BLOCK CFG DUTY SET BLOCK CFG
SINGLE DUAL DUTY SET
CFG
SELECT SUB-MENU OR SELECT SUB-MENU OR REMOTE CONTROL : NO REMOTE CONTROL : NO
PRESS ESC TO EXIT! PRESS ESC TO EXIT! SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
RUN/BLOCK : RUN SETCURRENT A: 000.0 A
FIRMWARE FIRMWARE START/STOP : STOP SETCURRENT B: 000.0 A
FLX-10 VER xx.xx FLX-10 VER xx.xx TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN

PROG USER CAL KRAFT PROG USER CAL KRAFT ← → ↓ ↑ ← → ↓ ↑

Press ↓ to get to PROGRAMMODE Press ↓ to get to PROGRAMMODE


LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 %
PASSWORD :000001 PASSWORD :000001 POLARITY : FWD AH-LIMIT B : -OFF-AH
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP TIMERLIMIT : -OFF- START RAMP :0000.5 S
BYTESWAP : YES BYTESWAP : YES AH-LIMIT : -OFF-AH PROGRAMMODE A : NO
ADDRESS : 00002 ADDRESS : 00002 START RAMP :0000.5 S PROGRAMMODE B : NO
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT PROGRAMMODE : NO PROGRAM A NO : 01
PROGRAM NO : 01 PROGRAM B NO : 01

← → ↓ ↑ ← → ↓ ↑
← → ↓ ↑ ← → ↓ ↑
Press ↓ to get PULSELENG.A Press ↓ to get PULSELENG.A / B
(Note; when running SINGLE mode, PULSELENG.B is not used) Press “OK” to activate change.
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Programs are entered using the CFG/PROG menu. The menu is password protected.
REMOTE CONTROL : NO REMOTE CONTROL : NO
SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
Basic functions: SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
Number of programs: 4 RUN/BLOCK : RUN SETCURRENT A: 000.0 A
Program steps per program: 8 START/STOP : STOP SETCURRENT B: 000.0 A
Program repeat Yes, possible TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN

← → ↓ ↑ ← → ↓ ↑

The parameters for remote control must to be set to give correct remote control
Basic functionality.
functions:
The protocol and parameters must be set for serial communication.
RAMP STEP PULSE For analogue remote control, the inputs must be activated and configured.
Individual adjustment of voltage and current for each program step. Use the CFG/USER menu (the menu is password protected).

3.1.19 Setting the remote control If the rectifier is delivered with remote digital or analogue control box, the parameters
The rectifier can be remotely controlled by serial communication or analogue signals. are factory set.
When the rectifier is remotely controlled, the local control is disabled. When controlled
remotely, parameters that are controlled by the analogue interface have precedence NOTE If the rectifier is set for analogue remote control of set values these values
over parameters sent by serial communication. take, in REMOTE mode, priority over set values via serial communication.
Special case: When using analogue remote control, some set values and functions can
be remotely controlled and others locally controlled from the keypad, REMOTE=ON See the Technical description 77-107.0295, chapter Programming for further
PROTOCOL=NONE. However, it is possible to read out actual values. The rectifier information.
cannot be switched OFF with the OFF key. LOCAL mode must first be selected in the
SET menu by setting REMOTE=NO.
If the rectifier loses contact with the master during PROFIBUS control, the keypad will 3.1.20 Locking keypad to enter parameters in SLAVE mode
be re-activated. When the rectifier is in SLAVEMODE the keys are disabled and no operating
parameters can be changed. The operating parameters can be displayed.
Remote control via serial communication is selected with the parameter REMOTE in The keypad is unlocked by deactivating SLAVEMODE using the password-
the SET menu. protected CFG/USER menu.

SINGLE DUAL
3.1.21 Setting the under voltage / short circuit detection
STATUS: STANDBY STANDBY STANDBY Due to voltage drop in DC-cabling a S.C: Level of 2-4V is appropriate.
A time delay of 30 -120 sec before shutdown effectively prohibits false alarms due to
normal variation of current.
00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A Default settings:
S.C. LEVEL 2,00V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG S.C. DELAY 0sec = -OFF-
DUTY SET
CFG For SINGLE rectifiers the “A-side” parameters shall be used.

NB! The output voltage set value must be higher than the under voltage/short circuit
detection voltage. Otherwise the under voltage/short circuit detection is disabled.
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3.2 Calibration/Configuration
The rectifier is calibrated and configured at the factory before delivery.

The rectifier can be calibrated from the CFG/CAL menu. The calibration menu is
password protected.

See Technical description 77-107.0295, chapter Operating Instructions for further


information

3.3 Password
Some menus and settings are password protected. KraftPowercon service can set a
new password should the old one be lost.
See the Technical description 77-107.0295, chapter Operating Instructions for further
information.

4 Warranty
KraftPowercon Sweden AB provides warranty terms according to the order
acknowledgement or contract. The warranty covers defects in design, materials and
manufacturing. Defects that can be shown to have arisen as a consequence of
incorrect use and/or maintenance are not covered. If a fault develops during the
warranty period, KraftPowercon Sweden AB or local representative must be contacted
before any work is undertaken on the rectifier.

KraftPowercon Sweden AB
P.O. Box 2102 Phone: +46 31 - 979700
SE-445 02 SURTE E-mail: [email protected]
Sweden Website: www.kraftpowercon.com

5 Appendices, see following pages


Description of order-specific equipment, where applicable

5.1 List of figures


Figure 1. Overview of components. 5
Figure 2. FlexKraft Marine with six power modules. 6
Figure 3. Five parallel rectifiers, Master rectifier to the left Master rectifier must always be at one end. 6
Figure 4. FlexKraft Marine display unit 7

5.2 List of tables


Table 1. Standards 4

5.3 Description of order-specific equipment, where applicable


2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

FLOW METER

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 11
Operating Instruction Electromagnetic Flowmeter Blinder Text
OI/FEX300/FEX500-EN
ProcessMaster, HygienicMaster
FEX300, FEX500 Electromagnetic Flowmeter
ProcessMaster, HygienicMaster
FEX300, FEX500

Operating Instruction
OI/FEX300/FEX500-EN
Valid as of software version
• 01/01/00 with HART
• 01/00/00 with PROFIBUS PA or 02.2018
FOUNDATION fieldbus Rev. I

Translation of the original instruction

Manufacturer:
ABB Automation Products GmbH ABB Inc. ABB Engineering (Shanghai) Ltd.
Measurement & Analytics Measurement & Analytics Measurement & Analytics
Dransfelder Straße 2 125 E. County Line Road No. 4528, Kangxin Highway,
D-37079 Göttingen Warminster, PA 18974 Pudong New District,
Germany USA Shanghai, 201319, P.R. China
Tel.: +49 551 905-0 Tel.: +1 215 674 6000 Tel.: +86(0) 21 6105 6666
Fax: +49 551 905-777 Fax: +1 215 674 7183 Fax: +86(0) 21 6105 6677
Mail: [email protected]
Customer service center
Phone: +49 180 5 222 580
Fax: +49 621 381 931-29031
[email protected]

© Copyright 2018 by ABB Automation Products GmbH


Subject to changes without notice
This document is protected by copyright. It assists the user in safe and efficient operation of the device. The contents of this
document, whether whole or in part, may not be copied or reproduced without prior approval by the copyright holder.
Co nte nt s

2 FEX300, FEX500 OI/FEX300/FEX500-EN


Contents Contents
1 Safety ............................................................................................................................................................. 8 4.4.9 Installation of the high temperature design ........................................................................................... 33
1.1 General information and notes for the reader ................................................................................................8 4.4.10 Devices with extended diagnostic functions ......................................................................................... 33
1.2 Intended use ...................................................................................................................................................9 4.4.11 Minimum distance ................................................................................................................................. 33
1.3 Improper use ..................................................................................................................................................9 4.4.12 Installation in pipelines with larger nominal diameters ..........................................................................33
1.4 Target groups and qualifications .................................................................................................................... 9 4.5 Rotating the LCD display / Rotating the housing ......................................................................................... 34
1.5 Warranty provisions ........................................................................................................................................9 4.5.1 Rotating the LCD display ......................................................................................................................35
1.6 Plates and symbols ......................................................................................................................................10 4.5.2 Rotating the housing ............................................................................................................................. 35
1.6.1 Safety- / warning symbols, note symbols..............................................................................................10 4.6 Ground..........................................................................................................................................................35
1.6.2 Name plate ............................................................................................................................................ 11 4.6.1 General information on ground connections ......................................................................................... 35
1.7 Transport safety information......................................................................................................................... 14 4.6.2 Metal pipe with fixed flanges .................................................................................................................36
1.8 Installation safety information ....................................................................................................................... 14 4.6.3 Metal pipe with loose flanges ................................................................................................................37
1.9 Safety instructions for electrical installation .................................................................................................14 4.6.4 Plastic pipes, non-metallic pipes or pipes with insulating liner ............................................................. 38
1.10 Safety instructions for operation ................................................................................................................... 15 4.6.5 Sensor type HygienicMaster .................................................................................................................39
1.11 Technical limit values ...................................................................................................................................15 4.6.6 Ground for devices with protective plates ............................................................................................. 39
1.12 Allowed measuring media ............................................................................................................................ 15 4.6.7 Ground with conductive PTFE grounding plate ....................................................................................39
1.13 Maintenance and inspection safety information ........................................................................................... 16 4.6.8 Devices with extended diagnostic functions ......................................................................................... 39
1.14 Returning devices .........................................................................................................................................16 4.6.9 Installation and grounding in pipelines with cathodic corrosion protection (CCP) ................................ 40
1.15 Integrated management system ...................................................................................................................17 5 Electrical connections ............................................................................................................................... 42
1.16 Disposal ........................................................................................................................................................17 5.1 Routing the signal and magnet coil cable ....................................................................................................42
1.16.1 Information on WEEE Directive 2012/19/EU (Waste Electrical and Electronic Equipment) .................17 5.2 Preparing the signal and magnet coil cable in the case of transmitters with dual-compartment housing ... 43
2 Design and function ................................................................................................................................... 18 5.2.1 Cable with part number D173D027U01 ................................................................................................ 43
2.1 Measuring principle ......................................................................................................................................18 5.2.2 Cable with part number D173D031U01 ................................................................................................ 44
2.2 Device designs .............................................................................................................................................19 5.3 Preparing the signal and magnet coil cable in the case of transmitters with single-compartment housing . 45
2.2.1 Design ...................................................................................................................................................20 5.3.1 Cable with part number D173D027U01 ................................................................................................ 46
2.2.2 Integral mount design............................................................................................................................20 5.3.2 Cable with part number D173D031U01 ................................................................................................ 46
2.2.3 Remote mount design ...........................................................................................................................21 5.4 Connecting the flowmeter sensor .................................................................................................................47
3 Transport and storage ............................................................................................................................... 22 5.4.1 Metal terminal box for ProcessMaster and HygienicMaster .................................................................47
3.1 Inspection .....................................................................................................................................................22 5.4.2 Connection via cable conduit ................................................................................................................48
3.2 Transport of flanged units smaller than DN 450........................................................................................... 22 5.4.3 IP rating IP 68 ....................................................................................................................................... 49
3.3 Transport of flanged units larger than DN 400 .............................................................................................23 5.5 Connecting the transmitter ........................................................................................................................... 51
3.4 Storage conditions ........................................................................................................................................23 5.5.1 Connecting the power supply ................................................................................................................51
4 Mounting .....................................................................................................................................................24 5.5.2 Transmitter with dual-compartment housing ......................................................................................... 52
4.1 General information on installation ............................................................................................................... 24 5.5.3 Transmitter with single-compartment housing ...................................................................................... 52
4.1.1 Supports for meter sizes larger than DN 400 ....................................................................................... 24 5.5.4 Connecting the signal and magnet coil cables ..................................................................................... 53
4.1.2 Selecting gaskets .................................................................................................................................. 25 5.6 Terminal connection diagrams ..................................................................................................................... 54
4.1.3 Devices with a wafer-type design .........................................................................................................25 5.6.1 HART, PROFIBUS PA and FOUNDATION fieldbus protocol ...............................................................54
4.1.4 Installing the meter tube ........................................................................................................................ 26 5.7 Electrical data ...............................................................................................................................................55
4.2 Torque information .......................................................................................................................................27 5.7.1 Current / HART output ..........................................................................................................................55
4.3 Information on 3A conformity ....................................................................................................................... 31 5.7.2 Digital output DO1 ................................................................................................................................. 55
4.4 Installation Requirements ............................................................................................................................. 32 5.7.3 Digital output DO2 ................................................................................................................................. 55
4.4.1 Flow direction ........................................................................................................................................ 32 5.7.4 Digital input DI ....................................................................................................................................... 55
4.4.2 Electrode axis ........................................................................................................................................ 32 5.7.5 Digital communication ...........................................................................................................................56
4.4.3 In- and outlet pipe sections ...................................................................................................................32 5.8 Connection examples ................................................................................................................................... 56
4.4.4 Vertical connections .............................................................................................................................. 32 5.8.1 Digital output DO2 ................................................................................................................................. 56
4.4.5 Horizontal connections ..........................................................................................................................32 5.8.2 Digital outputs DO1 and DO2 ...............................................................................................................56
4.4.6 Free inlet or outlet ................................................................................................................................. 32 5.8.3 PROFIBUS PA - Connection via M12 plug ........................................................................................... 56
4.4.7 Strongly contaminated measuring media.............................................................................................. 32 6 Digital communication ............................................................................................................................... 57
4.4.8 Installation in the vicinity of pumps .......................................................................................................33 6.1 HART protocol ..............................................................................................................................................57

OI/FEX300/FEX500-EN FEX300, FEX500 3 4 FEX300, FEX500 OI/FEX300/FEX500-EN


Contents Contents
6.1.1 System integration ................................................................................................................................ 57 8.5 Alarm Simulation ........................................................................................................................................133
6.2 PROFIBUS PA .............................................................................................................................................57 8.6 FEP500 and FEH500 during fill operation ..................................................................................................134
6.2.1 Bus topology ......................................................................................................................................... 57 8.6.1 Configuration ....................................................................................................................................... 134
6.2.2 Voltage / current consumption ..............................................................................................................57 8.7 Software – history .......................................................................................................................................137
6.2.3 System integration ................................................................................................................................ 57 8.7.1 Devices with HART protocol ...............................................................................................................137
6.3 FOUNDATION fieldbus (FF) ........................................................................................................................58 8.7.2 Devices with PROFIBUS PA or FOUNDATION fieldbus ....................................................................137
6.3.1 Bus topology ......................................................................................................................................... 58 9 Extended diagnostic functions ...............................................................................................................138
6.3.2 Voltage / current consumption ..............................................................................................................58 9.1 General remarks .........................................................................................................................................138
6.3.3 Bus address .......................................................................................................................................... 58 9.1.1 Detection of partial filling ..................................................................................................................... 138
6.3.4 System integration ................................................................................................................................ 58 9.1.2 Detection of gas bubbles ....................................................................................................................138
7 Commissioning .......................................................................................................................................... 59 9.1.3 Electrode coating detection .................................................................................................................139
7.1 Preliminary checks prior to start-up .............................................................................................................. 59 9.1.4 Conductivity monitoring .......................................................................................................................139
7.2 Configuring the current output ...................................................................................................................... 59 9.1.5 Electrode impedance monitoring ........................................................................................................ 139
7.2.1 Transmitter with dual-compartment housing ......................................................................................... 60 9.1.6 Sensor measurements ........................................................................................................................140
7.2.2 Transmitter with single-compartment housing ...................................................................................... 61 9.1.7 Trend ...................................................................................................................................................140
7.3 Start-up of PROFIBUS PA units ...................................................................................................................62 9.1.8 Fingerprint ...........................................................................................................................................140
7.3.1 Local address setting in the case of transmitters with dual-compartment housing .............................. 63 9.1.9 Checking the grounding ......................................................................................................................140
7.3.2 Configuration in the case of transmitters with single-compartment housing ........................................64 9.2 Performing the earthing check ...................................................................................................................141
7.3.3 Voltage / current consumption ..............................................................................................................65 9.3 Recommended settings for diagnostic limit values .................................................................................... 142
7.3.4 System integration ................................................................................................................................ 65 9.3.1 Limit values for the coil resistance ......................................................................................................142
7.4 Start-up of FOUNDATION FIELDBUS devices ............................................................................................ 66 9.3.2 Limit values for the electrode deposits................................................................................................143
7.4.1 Configuration of transmitters with dual-compartment housing ............................................................. 67 9.3.3 Limit values for the electrode impedance ........................................................................................... 143
7.4.2 Configuration of transmitters with single-compartment housing ...........................................................68 9.3.4 Recommended settings for the Trend Logger ....................................................................................143
7.4.3 Bus address settings ............................................................................................................................. 69 10 Error messages ........................................................................................................................................144
7.5 Commissioning the unit ................................................................................................................................ 70 10.1 Invoking the error description ..................................................................................................................... 144
7.5.1 Downloading the system data ...............................................................................................................70 10.2 Error states and alarms .............................................................................................................................. 145
7.5.2 Parameterization via the "Commissioning" menu function ................................................................... 72 10.2.1 Errors ..................................................................................................................................................145
7.6 Flowmeter sizes, flow range ......................................................................................................................... 78 10.2.2 Function check .................................................................................................................................... 146
8 Parameterization ........................................................................................................................................79 10.2.3 Operation outside of specifications (Off Spec) ................................................................................... 148
8.1 Operation ......................................................................................................................................................79 10.2.4 Maintenance ........................................................................................................................................ 149
8.1.1 Menu navigation .................................................................................................................................... 79 10.3 Overview of error states and alarms ..........................................................................................................150
8.2 Menu levels ..................................................................................................................................................80 10.3.1 Error messages during commissioning ............................................................................................... 154
8.2.1 Process display ..................................................................................................................................... 81 11 Maintenance ..............................................................................................................................................156
8.2.2 Switching to the information level (operator menu) .............................................................................. 82 11.1 Flowmeter sensor .......................................................................................................................................156
8.2.3 Switching to the configuration level (parameterization) ........................................................................85 11.2 Gaskets ......................................................................................................................................................156
8.2.4 Hardware write protection .....................................................................................................................86 11.3 Replacing the transmitter or the sensor .....................................................................................................157
8.2.5 Selecting and changing parameters ..................................................................................................... 87 11.3.1 Transmitter .......................................................................................................................................... 157
8.3 Overview of parameters on the configuration level ...................................................................................... 89 11.3.2 Sensor .................................................................................................................................................158
8.4 Description of parameters ............................................................................................................................ 97 11.3.3 Downloading the system data .............................................................................................................159
8.4.1 Menu: Easy Setup ................................................................................................................................. 97 12 Spare parts list .........................................................................................................................................160
8.4.2 Menu: Device Info ...............................................................................................................................100 12.1 Fuses for transmitter electronics ................................................................................................................ 160
8.4.3 Menu: Device Setup ............................................................................................................................104 12.2 Spare parts for devices with integral mount design ................................................................................... 160
8.4.4 Menu: Display ..................................................................................................................................... 108 12.3 Spare parts for devices with remote mount design .................................................................................... 161
8.4.5 Menu: Input/Output .............................................................................................................................110 12.3.1 field-mount housing .............................................................................................................................161
8.4.6 Menu: Process Alarm ..........................................................................................................................116 12.3.2 Round field-mount housing .................................................................................................................161
8.4.7 Menu: Communication ........................................................................................................................117 12.3.3 Flowmeter sensor (Zone 2 / Div. 2) .....................................................................................................162
8.4.8 Menu: Diagnostics...............................................................................................................................122 12.3.4 Flowmeter sensor (Zone 1 / Div. 1) .....................................................................................................162
8.4.9 Menu: Totalizer ................................................................................................................................... 131 13 Performance specifications ....................................................................................................................163

OI/FEX300/FEX500-EN FEX300, FEX500 5 6 FEX300, FEX500 OI/FEX300/FEX500-EN


Contents Safety
13.1 General .......................................................................................................................................................163
13.1.1 Reference conditions ..........................................................................................................................163
1 Safety
13.1.2 Maximum measuring error ..................................................................................................................163
1.1 General information and notes for the reader
13.1.3 Reproducibility, response time ............................................................................................................163
13.1.4 Power supply....................................................................................................................................... 163 You must read these instructions carefully prior to installing and commissioning the device.
13.2 Mechanical properties ................................................................................................................................ 164 These instructions are an important part of the product and must be kept for future reference.
13.3 IP rating ......................................................................................................................................................164 These instructions are intended as an overview and do not contain detailed information on all
designs for this product or every possible aspect of installation, operation and maintenance.
13.4 Vibration .....................................................................................................................................................164
For additional information or if specific problems occur that are not discussed in these
13.5 Temperature data .......................................................................................................................................164
instructions, contact the manufacturer.
14 Functional and technical properties - ProcessMaster .........................................................................165
The content of these instructions is neither part of any previous or existing agreement, promise
14.1 IP rating ......................................................................................................................................................165 or legal relationship nor is it intended to change the same.
14.2 Pipeline vibration ........................................................................................................................................165 This product is built based on state-of-the-art technology and is operationally safe. It has been
14.3 Installation length .......................................................................................................................................165 tested and left the factory in perfect working order from a safety perspective. The information in
14.4 Signal cable ................................................................................................................................................165 the manual must be observed and followed in order to maintain this state throughout the period
of operation.
14.5 Temperature data .......................................................................................................................................165
Modifications and repairs to the product may only be performed if expressly permitted by these
14.5.1 Storage temperature ...........................................................................................................................165
instructions.
14.5.2 Minimum permissible pressure as a function of measuring medium temperature ............................. 165
Only by observing all of the safety instructions and all safety/warning symbols in these
14.5.3 Maximum permissible cleaning temperature ......................................................................................165 instructions can optimum protection of both personnel and the environment, as well as safe and
14.5.4 Maximum ambient temperature depending on measuring medium temperature ............................... 166 fault-free operation of the device, be ensured.
14.5.5 ProcessMaster with remote mount design (standard sensor design) .................................................167 Information and symbols directly on the product must be observed. They may not be removed
14.5.6 Overview sensor design level "C" .......................................................................................................168 and must be fully legible at all times.
14.6 Material load ...............................................................................................................................................168
14.6.1 Flowmeter sensor design level “B” ......................................................................................................168 IMPORTANT (NOTE)
14.6.2 Flowmeter sensor design level “C” ..................................................................................................... 169 • An additional document with Ex safety instructions is available for measuring systems that
14.7 Materials for flowmeter sensors .................................................................................................................170 are used in explosion hazardous areas.
14.7.1 Wetted parts ........................................................................................................................................ 170 • Ex safety information is an integral part of this manual. As a result, it is crucial that the
installation guidelines and connection values it lists are also observed.
14.7.2 Non-wetted parts (process connection) .............................................................................................. 170
14.7.3 Flowmeter sensor housing ..................................................................................................................170
The icon on the name plate indicates the following:
15 Functional and technical properties - HygienicMaster ........................................................................171
15.1 Flowmeter sensor .......................................................................................................................................171
15.1.1 IP rating according to EN 60529 .........................................................................................................171
15.1.2 Pipeline vibration according to EN 60068-2-6 .................................................................................... 171
15.1.3 Installation length ................................................................................................................................ 171
15.1.4 Signal cable (for external transmitters only) ....................................................................................... 171
15.1.5 Temperature range .............................................................................................................................171
15.1.6 Material load ........................................................................................................................................ 173
15.1.7 Mechanical properties .........................................................................................................................174
16 Appendix ...................................................................................................................................................175
16.1 Return form ................................................................................................................................................175
16.2 Overview of parameter settings (factory settings) ......................................................................................176
16.2.1 For Profibus PA version ......................................................................................................................176
16.3 Declaration of conformity ............................................................................................................................177

OI/FEX300/FEX500-EN FEX300, FEX500 7 8 FEX300, FEX500 OI/FEX300/FEX500-EN


Safety Safety
1.2 Intended use 1.6 Plates and symbols

This device is intended for the following uses: 1.6.1 Safety- / warning symbols, note symbols
• To transmit fluid, pulpy or pasty measurement media with electrical conductivity.
• To measure the flowrate of the operating volume or mass flow units (at constant pressure / DANGER – <Serious damage to health / risk to life>
temperature), if a mass engeineering unit is selected. This symbol in conjunction with the signal word "Danger" indicates an imminent danger.
Failure to observe this safety information will result in death or severe injury.

The following items are included in the intended use: DANGER – <Serious damage to health / risk to life>
• Read and follow the instructions in this manual. This symbol in conjunction with the signal word "Danger" indicates an imminent electrical
• Observe the technical ratings; refer to the section 1.11 „Technical limit values“. hazard. Failure to observe this safety information will result in death or severe injury.
• Use only allowed measurement media; refer to the section 1.12 „Allowed measuring media“.
WARNING – <Bodily injury>
1.3 Improper use This symbol in conjunction with the signal word “Warning“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in death or severe injury.
The following are considered to be instances of improper use of the device:
WARNING – <Bodily injury>
• Operation as a flexible adapter in piping, e.g., to compensate for pipe offsets, pipe vibrations,
This symbol in conjunction with the signal word "Warning" indicates a potential electrical
pipe expansions, etc.
hazard. Failure to observe this safety information may result in death or severe injury.
• As a climbing aid, e. g., for mounting purposes
• As a support for external loads, e. g., as a support for piping, etc.
• Adding material, e. g., by painting over the name plate or welding/soldering on parts CAUTION – <Minor injury>
• Removing material, e. g., by spot drilling the housing This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury.
This may also be used for property damage warnings.
1.4 Target groups and qualifications
NOTICE – <Property damage>!
Installation, commissioning, and maintenance of the product may only be performed by trained The symbol indicates a potentially damaging situation.
specialist personnel who have been authorized by the plant operator to do so. The specialist
Failure to observe this safety information may result in damage to or destruction of the product
personnel must have read and understood the manual and comply with its instructions.
and/or other system components.
Prior to using corrosive and abrasive measurement media, the operator must check the level of
resistance of all parts coming into contact with the wetted parts. ABB Automation Products
GmbH will gladly support you in selecting the materials, but cannot accept any liability in doing IMPORTANT (NOTE)
so. This symbol indicates operator tips, particularly useful information, or important information
The operators must strictly observe the applicable national regulations with regards to about the product or its further uses. It does not indicate a dangerous or damaging situation.
installation, function tests, repairs, and maintenance of electrical products.

1.5 Warranty provisions

Using the device in a manner that does not fall within the scope of its intended use, disregarding
this instruction, using underqualified personnel, or making unauthorized alterations releases the
manufacturer from liability for any resulting damage. This renders the manufacturer's warranty
null and void.

OI/FEX300/FEX500-EN FEX300, FEX500 9 10 FEX300, FEX500 OI/FEX300/FEX500-EN


Safety Safety
1.6.2 Name plate 1.6.2.2 Name plate for the remote mount design

IMPORTANT (NOTE)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.

1.6.2.1 Name plate for integral mount design

Fig. 2: Remote mount design


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

IMPORTANT (NOTE)
Meters with 3A approval are labeled with an additional plate.

OI/FEX300/FEX500-EN FEX300, FEX500 11 12 FEX300, FEX500 OI/FEX300/FEX500-EN


Safety Safety
1.6.2.3 Name plate for remote transmitter 1.7 Transport safety information

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

1.8 Installation safety information

Observe the following instructions:


• The flow direction must correspond to the direction indicated on the device, if labeled.
• Comply with the maximum torque for all flange bolts.
• Install the devices without mechanical tension (torsion, bending).
• Install flange and wafer type units with coplanar counter flanges.
• Only install devices for the intended operating conditions and with suitable seals.
• Secure the flange bolts and nuts against pipeline vibrations.

1.9 Safety instructions for electrical installation


Fig. 3: Remote transmitter (e.g., transmitter with dual-compartment housing)
1 Model number (for more detailed information about 5 Protection type according to EN 60529 Electrical connections may only be established by authorized specialist personnel in
the technical design, refer to the data sheet or the 6 Supply voltage accordance with the electrical circuit diagrams.
order confirmation) 7 Communications protocol of transmitter The electrical connection information in the manual must be observed; otherwise, the type of
2 Project number 8 Software version electrical protection may be adversely affected.
3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx) Ground the flowmeter and the sensor housing.
4 Tamb = maximum permissible ambient temperature
The line for the supply power must be installed according to the relevant national and
international standards. A separate fuse must be connected upstream and in close proximity to
each unit. The fuses must be identified accordingly. The rated current of the circuit breaker must
not exceed 16 A.
The unit has a protection class of I and overvoltage class II (IEC664).
The power supply and the electrical circuit for the coils of the flowmeter sensor are dangerous
and pose a contact risk.
The coil and signal circuit may be connected with the corresponding ABB flowmeter sensors
only. Use the supplied cable.
Only electrical circuits that do not pose a contact risk can be connected to the remaining signal
inputs and outputs.

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Safety Safety
1.10 Safety instructions for operation 1.13 Maintenance and inspection safety information

During operation with hot fluids, contact with the surface may result in burns. WARNING – Risk to persons!
Aggressive fluids may result in corrosion or abrasion of the parts that come into contact with the When the housing cover is open, EMC and protection against contact are suspended. There
medium. As a result, pressurized fluids may escape prematurely. are electric circuits within the housing which pose a contact risk.
Wear to the flange gasket or process connection gaskets (e.g., aseptic threaded pipe The auxiliary power must be switched off before opening the housing cover.
connections, Tri-Clamp, etc.) may enable a pressurized medium to escape.
When using internal flat gaskets, these can become embrittled through CIP/SIP processes. WARNING – Risk to persons!
If pressure shocks exceeding the device's permissible nominal pressure occur continuously The inspection screw (for draining condensate fluid) for devices ≥ DN 450 can be under
during operation, this can have a detrimental effect on the device's service life. pressure. The fluid which spurts out can cause severe injuries.
Depressurize pipes before opening the inspection screw.

1.11 Technical limit values Corrective maintenance work may only be performed by trained personnel.
The device is designed for use exclusively within the stated values on the name plate and within • Depressurize the device and adjoining lines or containers before removing the device.
the technical limit values specified in the data sheets. • Check whether hazardous materials are used as materials to be measured before opening
The following technical limit values must be observed: the device. Residual amounts of hazardous material may still be present in the device and
could escape when the device is opened.
• The permissible operating pressure (PS) in the permissible temperature (TS) may not
exceed the pressure-temperature ratings. • As far as provided in the scope of the operational responsibility, check the following items
through a regular inspection:
• The maximum operating temperature may not be exceeded.
- the pressure-carrying walls / lining of the pressure device
• The permitted operating temperature may not be exceeded.
- the measurement-related function
• The housing protection system must be observed.
- the leak tightness
• The flowmeter sensor may not be operated in the vicinity of powerful electromagnetic fields,
e.g., motors, pumps, transformers, etc. A minimum spacing of approx. 1 m (3.28 ft) should - the wear (corrosion)
be maintained. For installation on or to steel parts (e.g., steel brackets), a minimum spacing
of approx. 100 mm (3.94 inch) should be maintained (based on IEC801-2 and IECTC77B).
1.14 Returning devices

1.12 Allowed measuring media Use the original packaging or suitably secure shipping containers if you need to return the
device for repair or recalibration purposes. Fill out the return form (see the Appendix) and
When using measuring media, the following points must be observed: include this with the device.
• Measuring media (fluids) may only be used if it can be ensured that the chemical and According to EC guidelines for hazardous materials, the owner of hazardous waste is
physical properties—which are required for operational security—of the components coming responsible for its disposal or must observe the following regulations for shipping purposes:
into contact with the media are not affected during the operating life. This can be achieved All devices delivered to ABB Automation Products GmbH must be free from any hazardous
through the use of state-of-the-art technology or the operating experience of the operator. materials (acids, alkalis, solvents, etc.).
Components coming into contact with the media include measuring electrodes, lining, and, if
applicable, earth electrodes, mating parts, protective washers or protective flanges Rinse out and neutralize hazardous materials from all hollow spaces such as between meter
tube and housing. For flowmeters larger than DN 400, the service screw (for draining
• Measuring media with unknown properties or abrasive measuring media may only be used if condensate fluid) at the lower point of the housing must be opened to dispose of hazardous
the operator is able to perform regular and suitable tests to ensure the safe condition of the substances and to neutralize the coil and electrode chamber. These activities must be
device confirmed in writing using the return form.
• The information on the name plate must be observed
Plea se

Please contact Customer Center Service acc. to page 2 for nearest service location.

OI/FEX300/FEX500-EN FEX300, FEX500 15 16 FEX300, FEX500 OI/FEX300/FEX500-EN


Safety Design and function
1.15 Integrated management system 2 Design and function
ABB Automation Products GmbH operates an integrated management system, consisting of:
2.1 Measuring principle
• Quality management system to ISO 9001
• Environmental management system to ISO 14001 Measurements performed by the electromagnetic flowmeter are based on Faraday’s law of
induction. A voltage is generated in a conductor when it moves through a magnetic field.
• Occupational health and safety management system to BS OHSAS 18001 and
This principle is applied to a conductive fluid in the measuring tube through which a magnetic
• Data and information protection management system
field is generated perpendicular to the flow direction (see schematic).
The voltage induced in the fluid is measured by two electrodes located diametrically opposite
Environmental awareness is an important part of our company policy. each other. This signal voltage UE is proportional to the magnetic induction B, the electrode
Our products and solutions are intended to have a minimal impact on the environment and on spacing D and the average flow velocity v.
people during manufacturing, storage, transport, use, and disposal. Considering that the magnetic induction B and the electrode spacing D are constant values, a
This includes the environmentally-friendly use of natural resources. We conducts an open proportionality exists between the signal voltage UE and the average flow velocity v. From the
dialog with the public through our publications. equation for calculating the volume flowrate, it follows that the signal voltage is linearly
proportional to the volume flowrate: U E ~ qv.
The induced voltage is converted by the transmitter to standardized, analog and digital signals.
1.16 Disposal

This product is manufactured from materials that can be reused by specialist recycling
companies.

1.16.1 Information on WEEE Directive 2012/19/EU (Waste Electrical and Electronic Equipment)

This product is not subject to WEEE Directive 2012/19/EU or relevant national laws
(e.g., ElektroG in Germany).
The product must be disposed of at a specialist recycling facility. Do not use municipal garbage
collection points. According to the WEEE Directive 2012/19/EU, only products used in private
applications may be disposed of at municipal garbage facilities. Proper disposal prevents
negative effects on people and the environment, and supports the reuse of valuable raw
materials.
If it is not possible to dispose of old equipment properly, ABB Service can accept and dispose of
returns for a fee.

Fig. 4: Electromagnetic flowmeter schematic


1 Magnet coil
2 Measuring tube in electrode plane
3 Signal electrode
UE Signal voltage
UE ~ BΧ DΧv
B Magnetic induction
D Electrode spacing D2
Χv
v Average flow velocity
qv = 4
qv Volume flow
UE ~ q v

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Design and function Design and function
2.2 Device designs 2.2.1 Design

IMPORTANT (NOTE) An electromagnetic flowmeter system consists of a sensor and a transmitter. The sensor is
An additional document with Ex safety instructions is available for measuring systems that are installed in the specified pipeline while the transmitter is mounted locally or at a central location.
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed. 2.2.2 Integral mount design

For devices with an integral mount design, the transmitter and the sensor form a single
ProcessMaster / HygienicMaster is available in two series. mechanical unit.
ProcessMaster / HygienicMaster 300 with basic functionality and ProcessMaster / The transmitter is available in two housing designs:
HygienicMaster 500 with extended functions and options. The following table gives an overview. • Single-compartment housing:
On the single-compartment housing, the electronics area and the connection area in the
transmitter are not separated from each other.
ProcessMaster HygienicMaster
• Dual-compartment housing:
FEP300 FEP500 FEH300 FEH500 On the dual-compartment housing, the electronics area and the connection area in the
Measuring accuracy X - X - transmitter are separated from each other.
0.4 % (optional 0.2 %) of rate
Measuring accuracy - X - X ProcessMaster
0,3 % (optional 0.2 %) of rate The ProcessMaster sensor is available in two designs, which are distinguished by the design
Batch functions - X - X level.
Presetting counter, overrun correction, FEP311 (without explosion protection) FEP315 Zone 2, Div. 2 FEP315
external start/stop, batch end contact Zone 1, Div. 1
Other software functions X X X X
Mass units, editable totalizers,
Two measuring ranges - X - X
Graphic display X X X X
Line recorder function
Diagnostic functions - X - X
Fig. 5: ProcessMaster versions (example)
Detection of gas bubbles or deposits on
1) Single-compartment housing.
electrodes, conductivity monitoring, 2) Dual-compartment housing.
temperature monitoring, finger print, trend 3) Design level "B" sensor.
Partially filled X X - - 4) Design level "B" sensor, versions made from stainless steel
5) Design level "C" sensor, nominal diameter: DN 25 ... 600
Recognition through partial filling
electrode (TFE)
Hardware options - X - - HygienicMaster
• Ceramic carbide lining FEH311 (without explosion FEH315 Zone 2, Div. 2 FEH315 Zone 1, Div. 1
protection)
• Wolfram carbide electrodes
• Double layer electrodes
Hardware options - - - X
DN 1 ... 2
Startup functions - X - X
Grounding check
Fieldbus X X X X
Fig. 6: HygienicMaster versions (example)
PROFIBUS PA, FOUNDATION fieldbus
1) Single-compartment housing.
Verifications / Diagnostic tool X X X X 2) Dual-compartment housing.
ScanMaster

OI/FEX300/FEX500-EN FEX300, FEX500 19 20 FEX300, FEX500 OI/FEX300/FEX500-EN


Design and function Transport and storage
2.2.3 Remote mount design
3 Transport and storage
For devices with a remote mount design, the transmitter and sensor are mounted in separate locations. The
electrical connection between the transmitter and the sensor is provided by a signal cable. 3.1 Inspection
When the minimum conductivity of the measuring medium is 5 µS/cm, a maximum signal cable length of 50 m
(164 ft) is possible without fitting an additional preamplifier to the sensor. With a pre-amplifier, the maximum Check the devices for possible damage that may have occurred during transport. Damages in
permissible signal cable length is 200 m (656 ft). transit must be recorded on the transport documents. All claims for damages must be claimed
without delay against the shipper and before the installation.
The transmitter is available in two housing designs:
• Single-compartment housing:
On the single-compartment housing, the electronics area and the connection area in the transmitter are not 3.2 Transport of flanged units smaller than DN 450
separated from each other.
• Dual-compartment housing:
On the dual-compartment housing, the electronics area and the connection area in the transmitter are separated WARNING – Danger of injuries due to slipping meter.
from each other. The center of gravity for the complete device may be higher than the lifting straps.
Make sure the device has not rotated or slipped unintentionally during transport. Support the
meter laterally.
ProcessMaster
The ProcessMaster sensor is available in two designs, which are distinguished by the design level. For transport of flanged units smaller than DN 450 use a lifting strap. Wrap the straps around
Sensor both process connections when lifting the device. Avoid chains since these may damage the
FEP321 / FEP521 FEP325 / FEP525 FEP325 / FEP525 housing.
(without explosion Zone 2, Div. 2 Zone 1, Div. 1
protection)

Transmitter
FET321 / FET521 FET325 / FET525 FET321 / FET521 FET325 / FET525 FET325 / FET525 FET321 / FET521
(without explosion (Zone 2, Div. 2) (without explosion (Zone 1, Div. 1) (Zone 2, Div. 2) (without explosion
protection) protection) protection)

Fig. 7: Transport of flanged units smaller than DN 450

HygienicMaster
Sensor
FEH321 / FEH521 (without FEH325 / FEH525 (Zone 2, Div. 2)
explosion protection)

Transmitter
FET321 / FET521 (without FET325 / FET525 (Zone 2, Div. 2) FET321 / FET521 (without explosion
explosion protection) protection)

1) Design level "B" sensor.


2) Design level "C" sensor, DN 25 … 600.
3) Single-compartment housing.
4) Dual-compartment housing.

OI/FEX300/FEX500-EN FEX300, FEX500 21 22 FEX300, FEX500 OI/FEX300/FEX500-EN


Transport and storage Mounting
3.3 Transport of flanged units larger than DN 400 4 Mounting
NOTICE - Potential damage to device! IMPORTANT (NOTE)
Use of a forklift to transport the device can bend the housing and damage the internal magnet An additional document with Ex safety instructions is available for measuring systems that are
coils. used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
Flanged units may not be lifted at the middle of the housing when transporting via forklift. lists are also observed.

Flanged units may not be lifted by the terminal box or at the middle of the housing. Use only the 4.1 General information on installation
eye bolts on the device to lift and install it in the pipeline.
The following points must be observed during installation:
• The flow direction must correspond to the marking, if present
• The maximum torque for all flange screws must be complied with
• The devices must be installed without mechanical tension (torsion, bending)
• Install flange devices / wafer-type devices with plane parallel counterflanges and use
appropriate gaskets only
• Only gaskets made from a material that is compatible with the measuring medium and
measuring medium temperature may be used
• Gaskets must not extend into the flow area, since possible turbulence could influence the
accuracy of the device
• The piping may not exert any inadmissible forces or torques on the device
Fig. 8: Transport of flanged units larger than DN 400 • Do not remove the sealing plugs in the cable glands until you are ready to install the
electrical cable
• Make sure the gaskets for the housing cover are seated correctly. Carefully gasket the
3.4 Storage conditions cover. Tighten the cover fittings
When storing the unit, please note the following points. • The transmitter with a remote mount design must be installed at a largely vibration-free
location
• Store the unit in its original packaging in a dry and dust-free location.
• Do not expose the transmitter and sensor to direct sunlight. Provide appropriate sun
• Avoid storing the unit in direct sunlight.
protection as necessary
• When installing the transmitter in a control cabinet, make sure adequate cooling is provided
• For devices with a remote mount design and a measuring accuracy of 0.2 % of the
measured value, make sure that the sensor and the transmitter have been correctly
assigned. Compatible devices have the same end numbers on the name plate, e.g. X001
and Y001 or X002 and Y002

4.1.1 Supports for meter sizes larger than DN 400

NOTICE - Potential damage to device!


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

Fig. 9: Support for meter sizes larger than DN 400

OI/FEX300/FEX500-EN FEX300, FEX500 23 24 FEX300, FEX500 OI/FEX300/FEX500-EN


Mounting Mounting
4.1.2 Selecting gaskets 4.1.4 Installing the meter tube

The following points must be observed when installing gaskets: Notice – potential damage to device!
Devices with a hard rubber, soft rubber or ceramic carbide liner The use of graphite with the flange or process connection gaskets is prohibited. This is
• Devices with a hard / soft rubber liner always require additional gaskets because, in some instances, an electrically conductive coating may form on the inside of the
meter tube. Vacuum shocks in the piping should be avoided to prevent damage to the liners
• ABB recommends using gaskets made from rubber or rubber-like sealing materials
(PTFE). Vacuum shocks can destroy the device.
• When selecting the gaskets, ensure that the tightening torques specified in chapter „Torque
information“ on page 27 are not exceeded
The meter tube can be installed at any location in the piping while taking the installation
conditions into account.
Devices with a PTFE, PFA or ETFE liner
1. Remove protective plates, if present, to the right and left of the meter tube. To prevent
• In principle, devices with a PTFE, PFA or ETFE liner do not require additional gaskets
possible leakage, make sure that the liner on the flange is not cut or damaged.
2. Position the meter tube coplanar and centered between the piping.
4.1.3 Devices with a wafer-type design 3. Install gaskets between the surfaces; see chapter „Torque information“ on page 27.
For devices with a wafer-type design, ABB offers an installation set as an accessory that
comprises threaded rods, nuts, washers and centering sleeves for installation. IMPORTANT (NOTE)
For achieve the best results, ensure the gaskets fit concentrically with the meter tube

4. Use the appropriate screws for the holes in accordance with chapter „Torque information“ on
page 27.
5. Slightly grease the threaded nuts.
6. Tighten the nuts in a crosswise manner as shown in the figure. Observe the tightening
torques in accordance with chapter „Selecting gaskets“ on page 25!
First tighten the nuts to approx. 50 % of the maximum torque, then to 80 %, and finally a
third time to the maximum torque. Do not exceed the max. torque.

Fig. 10: Installation set for wafer-type installation


1 Threaded rod 3 Centering sleeves
2 Nut with washer

Fig. 11

OI/FEX300/FEX500-EN FEX300, FEX500 25 26 FEX300, FEX500 OI/FEX300/FEX500-EN


Mounting Mounting
4.2 Torque information Nominal diameter Nominal pressure Maximum tightening torque [Nm]
[mm (inch)] rating Hard / soft rubber PTFE, PFA, ETFE Ceramic carbide
IMPORTANT (NOTE) 2) 3) 2) 3) 2) 3)
The specified torques are valid only for greased threads and piping that is not subject to tensile stress. PN16 14,94 8 37,02 39,1 37,02 39,1
PN40 30,88 21,11 43,03 44,62 43,03 44,62
ProcessMaster in flange design and HygienicMaster in flange or wafer-type design PN63 57,89 51,5 81,66 75,72 81,66 75,72
DN 65 (2 1/2“) CL150 30,96 30,96 89,93 89,93 89,93 89,93
Nominal diameter Nominal pressure Maximum tightening torque [Nm] CL300 38,38 27,04 61,21 61,21 61,21 61,21
[mm (inch)] rating Hard / soft rubber PTFE, PFA, ETFE Ceramic carbide CL600 53,91 53,91 – – – –
2) 3) 2) 3) 2) 3) JIS 10K 14,94 8 37,02 39,1 37,02 39,1
PN40 – – 12,43 12,43 – – PN40 38,3 26,04 51,9 53,59 51,9 53,59
PN63/100 – – 12,43 12,43 – – PN63 63,15 55,22 64,47 80,57 64,47 80,57
DN 3 ... 101)
CL150 – – 12,98 12,98 – – CL150 19,46 19,46 104,6 104,6 104,6 104,6
(1/10 ... 3/8“1)) DN 80 (3“)
CL300 – – 4,94 17,38 – – CL300 75,54 26,91 75,54 75,54 75,54 75,54
JIS 10K – – 12,43 12,43 – – CL600 84,63 84,63 – – – –
PN40 6,74 4,29 14,68 14,68 – – JIS 10K 16,26 9,65 45,07 47,16 45,07 47,16
PN63/100 13,19 11,2 22,75 22,75 – – PN16 20,7 12,22 49,68 78,19 49,68 78,19
CL150 3,65 3,65 12,98 12,98 – – PN40 67,77 47,12 78,24 78,19 78,24 78,19
DN 15 (1/2“)
CL300 4,94 3,86 4,94 17,38 – – PN63 107,4 95,79 148,5 119,2 148,5 119,2
CL600 9,73 9,73 – – – – DN 100 (4“) CL150 17,41 7,82 76,2 76,2 76,2 76,2
JIS 10K 2,84 1,37 14,68 14,68 – – CL300 74,9 102,6 102,6 102,6 102,6 102,6
PN40 9,78 7,27 20,75 20,75 – – CL600 147,1 147,1 – – – –
PN63/100 24,57 20,42 42,15 42,15 – – JIS 10K 20,7 12,22 49,68 78,19 49,68 78,19
CL150 5,29 5,29 18,49 18,49 – – PN16 29,12 18,39 61,4 64,14 61,4 64,14
DN 20 (3/4“)
CL300 9,77 9,77 33,28 33,28 – – PN40 108,5 75,81 123,7 109,6 123,7 109,6
CL600 15,99 15,99 – – – – PN63 180,3 164,7 242,6 178,2 242,6 178,2
DN 125 (5“)
JIS 10K 4,1 1,88 20,75 20,75 – – CL150 24,96 11,05 98,05 98,05 98,05 98,05
PN40 13,32 8,6 13,32 8,6 13,32 8,6 CL300 81,64 139,4 139,4 139,4 139,4 139,4
PN63/100 32,09 31,42 53,85 53,85 53,85 53,85 CL600 244,1 244,1 – – – –
CL150 5,04 2,84 23,98 23,98 23,98 23,98 PN16 46,99 23,7 81,23 85,08 81,23 85,08
DN 25 (1“)
CL300 17,31 16,42 65,98 38,91 65,98 38,91 PN40 143,5 100,5 162,5 133,5 162,5 133,5
CL600 22,11 22,11 – – – – PN63 288,7 269,3 371,3 243,4 371,3 243,4
DN 150 (6“)
JIS 10K 8,46 5,56 26,94 26,94 26,94 26,94 CL150 30,67 13,65 111,4 111,4 111,4 111,4
PN40 27,5 15,01 45,08 45,08 45,08 45,08 CL300 101,4 58,4 123,6 123,6 123,6 123,6
PN63/100 42,85 41,45 74,19 70,07 74,19 70,07 CL600 218,4 218,4 – – – –
CL150 4,59 1,98 29,44 29,44 29,44 29,44 PN10 45,57 27,4 113 116,9 113 116,9
DN 32 (1 1/4“)
CL300 25,61 14,22 45,52 45,52 45,52 45,52 PN16 49,38 33,82 70,42 73 70,42 73
CL600 34,09 34,09 – – – – PN25 100,6 69,17 109,9 112,5 109,9 112,5
JIS 10K 9,62 4,9 45,08 45,08 45,08 45,08 PN40 196,6 144,4 208,6 136,8 208,6 136,8
DN 200 (8“)
PN40 30,44 23,71 56,06 56,06 56,06 56,06 PN63 350,4 331,8 425,5 282,5 425,5 282,5
PN63/100 62,04 51,45 97,08 97,08 97,08 97,08 CL150 49,84 23,98 158,1 158,1 158,1 158,1
CL150 5,82 2,88 36,12 36,12 36,12 36,12 CL300 133,9 78,35 224,3 224,3 224,3 224,3
DN 40 (1 1/2“)
CL300 33,3 18,41 73,99 73,99 73,99 73,99 CL600 391,8 391,8 – – – –
CL600 23,08 23,08 – – – – PN10 23,54 27,31 86,06 89,17 86,06 89,17
JIS 10K 12,49 6,85 56,06 56,06 56,06 56,06 PN16 88,48 61,71 99,42 103,1 99,42 103,1
PN40 41,26 27,24 71,45 71,45 71,45 71,45 PN25 137,4 117,6 166,5 133,9 166,5 133,9
DN 250 (10“)
PN63 71,62 60,09 109,9 112,6 109,9 112,6 PN40 359,6 275,9 279,9 241 279,9 241
CL150 22,33 22,33 66,22 66,22 66,22 66,22 CL150 55,18 27,31 146,1 148,3 146,1 148,3
DN 50 (1 1/2“)
CL300 17,4 22,33 38,46 38,46 38,46 38,46 CL300 202,7 113,2 246,4 246,4 246,4 246,4
CL600 35,03 35,03 – – – –
JIS 10K 17,27 10,47 71,45 71,45 71,45 71,45 Continued on next page
Continued on next page
2) Flange material: steel.
3) Flange material: stainless steel.
1) Connection flange DIN / EN1092-1 = DN 10 (3/8"), connection flange ASME = DN 15 (1/2").
2) Flange material: steel.
3) Flange material: stainless steel.

OI/FEX300/FEX500-EN FEX300, FEX500 27 28 FEX300, FEX500 OI/FEX300/FEX500-EN


Mounting Mounting

Nominal diameter Nominal pressure Maximum tightening torque [Nm] Nominal diameter Nominal pressure Maximum tightening torque [Nm]
[mm (inch)] rating Hard / soft rubber PTFE, PFA, ETFE Ceramic carbide [mm (inch)] rating Hard / soft rubber PTFE, PFA, ETFE Ceramic carbide
2) 3) 2) 3) 2) 3) 2) 3) 2) 3) 2) 3)
PN10 58,79 38,45 91,29 94,65 91,29 94,65 PN10 541,3 419,2 On request On request 541,3 419,2
PN16 122,4 85,64 113,9 114,8 113,9 114,8 PN16 955,5 756,1 On request On request 955,5 756,1
PN25 180,6 130,2 151,1 106,9 151,1 106,9 DN 1000 (40“) PN25 2006 1612 On request On request 2006 1612
DN 300 (12“)
PN40 233,4 237,4 254,6 252,7 254,6 252,7 CL150 654,2 598,8 650,6 385,1 654,2 598,8
CL150 90,13 50,37 203,5 198 203,5 198 CL300 2181 On request On request On request 2181 On request
CL300 333,3 216,4 421,7 259,1 421,7 259,1 CL150 749,1 682,6 741,3 345,9 – –
DN 1100 (44“)
PN10 69,62 47,56 72,49 75,22 72,49 75,22 CL300 2607 On request On request On request – –
PN16 133,6 93,61 124,9 104,4 124,9 104,4 PN 6 363,5 On request – – – –
DN 350 (14“) PN25 282,3 204,3 226,9 167,9 226,9 167,9 PN10 705,9 On request – – – –
CL150 144,8 83,9 270,5 263 270,5 263 DN 1200 (48“) PN16 1464 On request – – – –
CL300 424,1 252,7 463,9 259,4 463,9 259,4 CL150 815,3 731,6 – – – –
PN10 108,2 75,61 120,1 113,9 120,1 113,9 CL300 3300 On request – – – –
PN16 189 137,2 191,4 153,8 191,4 153,8 CL150 1036 983,7 – – – –
DN 1350 (54“)
DN 400 (16“) PN25 399,4 366 404 246,7 404 246,7 CL300 5624 On request – – – –
CL150 177,6 100 229,3 222,8 229,3 222,8 PN 6 515 On request – – – –
CL300 539,5 318,8 635,8 328,1 635,8 328,1 DN 1400 (56“) PN10 956,3 On request – – – –
CL150 218,6 120,5 267,3 192,3 267,3 192,3 PN16 1558 On request – – – –
DN 450 (18“)
CL300 553,8 327,2 660,9 300 660,9 300 CL150 1284 1166 – – – –
DN 1500 (60“)
PN10 141,6 101,4 153,9 103,5 153,9 103,5 CL300 6139 On request – – – –
PN16 319,7 245,4 312,1 224,8 312,1 224,8 PN 6 570,7 On request – – – –
DN 500 (20“) PN25 481,9 350,5 477,1 286 477,1 286 DN 1600 (64“) PN10 1215 On request – – – –
CL150 212,5 116 237,3 230,4 237,3 230,4 PN16 2171 On request – – – –
CL300 686,3 411,8 786,8 363,1 786,8 363,1 PN 6 708,2 On request – – – –
PN10 224,7 164,8 238,7 149,1 238,7 149,1 DN 1800 (72“) PN10 1492 On request – – – –
PN16 515,1 399,9 496,7 365,3 496,7 365,3 PN16 2398 On request – – – –
DN 600 (24“) PN25 826,2 600,3 750,7 539,2 750,7 539,2 PN 6 857,9 On request – – – –
CL150 356,6 202,8 451,6 305,8 451,6 305,8 DN 2000 (80“) PN10 1840 On request – – – –
CL300 1188 719 1376 587,4 1376 587,4 PN16 2860 On request – – – –
PN10 267,7 204,9 On request On request 267,7 204,9
PN16 455,7 353,2 On request On request 455,7 353,2 Continued on next page
DN 700 (28“) PN25 905,9 709,2 On request On request 905,9 709,2
2) Flange material: steel.
CL150 364,1 326,2 449,2 432,8 364,1 326,2
3) Flange material: stainless steel.
CL300 1241 On request On request On request 1241 On request
CL150 423,8 380,9 493,3 442 423,8 380,9 Variable process connections HygienicMaster
DN 750 (30“)
CL300 1886 On request On request On request 1886 On request
PN10 391,7 304,2 On request On request 391,7 304,2 Nominal diameter Max. tightening torque
PN16 646,4 511,8 On request On request 646,4 511,8 [mm] [inch] [Nm]
DN 800 (32“) PN25 1358 1087 On request On request 1358 1087 DN 1 ... 2 1/25 ... 3/32“ PVC / POM: 0.2 brass / 1.4571: 3
CL150 410,8 380,9 493,3 380,9 410,8 380,9 DN 3 ... 10 3/8“ 8
CL300 2187 On request On request On request 2187 On request DN 15 1/2“ 10
PN10 387,7 296,3 On request On request 387,7 296,3 DN 20 3/4“ 21
PN16 680,8 537,3 On request On request 680,8 537,3 DN 25 1 31
DN 900 (36“) PN25 1399 1119 On request On request 1399 1119 DN 32 1 1/4“ 60
CL150 336,2 394,6 511 458,5 336,2 394,6 DN 40 1 1/2“ 80
CL300 1972 On request On request On request 1972 On request DN 50 2 5
DN 65 2 1/2“ 5
Continued on next page DN 80 3 15
DN 100 4 14
2) Flange material: steel.
3) Flange material: stainless steel.

OI/FEX300/FEX500-EN FEX300, FEX500 29 30 FEX300, FEX500 OI/FEX300/FEX500-EN


Mounting Mounting
Ch ang e f ro m o ne to t wo co lum ns

4.3 Information on 3A conformity 4.4 Installation Requirements 4.4.4 Vertical connections


Vertical installation for measuring abrasive fluids, preferably with flow
4.4.1 Flow direction in upward direction.
IMPORTANT (NOTE)
The device measures the flowrate in both directions. Forward flow is
If concentric reducers are installed on the device, it must be mounted in a vertical position. the factory setting, as shown in Fig. 13.

Fig. 13 Fig. 16

4.4.2 Electrode axis 4.4.5 Horizontal connections


Electrode axis (1) should be horizontal if at all possible or no more • Meter tube must always be completely full.
that 45° from horizontal. • Provide for a slight incline of the connection for degassing.
Fig. 12
1 Bracket 2 Leakage hole

Please observe the following points:


• Do not install the device vertically with the terminal box or transmitter housing pointing Fig. 17
downward. Fig. 14
• The "angle bracket" option no longer applies. 4.4.6 Free inlet or outlet
• Please ensure that the leakage hole of the process connection is located at the deepest • Do not install the flowmeter at the highest point or in the draining-
point of the installed device. 4.4.3 In- and outlet pipe sections off side of the pipeline, flowmeter runs empty, air bubbles can
form (1).
• Only devices with a transmitter with dual-compartment housing are 3A-compliant. The metering principle is independent of the flow profile as long as • Provide for a siphon fluid intake for free inlets or outlets so that
standing eddies do not extend into the metering section, such as may the pipeline is always full (2).
occur after double elbows (1), in the event of tangential inflow, or
where half-open gate valves are located upstream of the flowmeter
sensor.
In such cases, measures must be put in place to normalize the flow
profile.
• Do not install fittings, manifolds, valves, etc., directly in front of the
flowmeter sensor (1).
• Butterfly valves must be installed so that the valve plate does not
extend into the flowmeter sensor.
Fig. 18
• Valves or other turn-off components should be installed in the
outlet pipe section (2).
4.4.7 Strongly contaminated measuring media
Experience has shown that, in most installations, straight inlet
For strongly contaminated measuring media, a bypass connection
sections 3 x DN long and straight outlet sections 2 x DN long are
according to the figure is recommended so that operation of the
sufficient (DN = nominal diameter of the sensor Fig. 15 ).
system can continue to run without interruption the during the
For test stands, the reference conditions of 10 x DN straight inlet and
mechanical cleaning.
5 x DN straight outlet must be provided, in accordance with EN 29104
/ ISO 9104.

Fig. 15
Fig. 19

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Mounting Mounting

4.4.8 Installation in the vicinity of pumps 4.4.12 Installation in pipelines with larger nominal 4.5 Rotating the LCD display / Rotating the housing
diameters
For flowmeter primaries which are to be installed in the vicinity of Depending on the mounting position, the LCD display or transmitter housing can be rotated to
pumps or other vibration generating equipment, the utilization of Determine the resulting pressure loss when using reduction
mechanical snubbers is advantageous. enable horizontal readings.
pieces (1):
1. Calculate the diameter ratio d/D.
2. Determine the flow velocity based on the flow range nomograph
(Fig. 24). Transmitter with dual-compartment housing
3. Read the pressure drop on the Y-axis in Fig. 24.

Fig. 20

4.4.9 Installation of the high temperature design


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

Nomograph for pressure drop calculations


For flange transition piece with a/2 = 8°

Fig. 21
1 Insulation

4.4.10 Devices with extended diagnostic functions


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

4.4.11 Minimum distance


In order to prevent the devices from interfering with each other, a
minimum distance of 0.7 m (2.3 ft) must be maintained between the Transmitter with single-compartment housing
devices.
Fig. 25

Fig. 24
Fig. 22
Ch ang e f ro m o ne to t wo co lum ns

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Mounting Mounting
4.5.1 Rotating the LCD display
4.6.2 Metal pipe with fixed flanges
WARNING – Electrical dangers!
Use a copper wire (at least 2.5 mm² (14 AWG)) to establish the ground connection between the
When the housing is open, EMC protection is impaired and there is no longer any protection sensor (1), the pipeline flanges and an appropriate grounding point.
against accidental contact.
Switch off the power supply before opening the housing.

1. Switch off the power supply.


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

NOTICE - Potentially adverse effect on housing ingress protection


If the gasket (o-ring) is seated incorrectly or damaged, this may have an adverse effect on the
housing ingress protection.
Before closing the housing cover, check the gasket (o-ring) for any damage and replace if
necessary. Check that the gasket is properly seated when closing the housing cover.
Flange design Wafer-type design
Fig. 26: Metal pipe, without liner (example)
4.5.2 Rotating the housing

1. Loosen screws (3) and rotate housing 90° to the left or right. IMPORTANT (NOTE)
2. Retighten screws (3). • Earthing is illustrated using the example of the dual-compartment transmitter housing; in
the case of transmitters with single-compartment housing, earthing is to be performed as
shown
4.6 Ground

IMPORTANT (NOTE)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.

4.6.1 General information on ground connections

Observe the following items when grounding the device:


• For plastic pipes or pipes with insulating lining, the ground is provided by the grounding plate
or grounding electrodes.
• When stray potentials are present, install a grounding plate upstream and downstream of the
flowmeter sensor.
• For measurement-related reasons, the potentials in the station ground and in the pipeline
should be identical.
• An additional ground on the terminals is not required.

IMPORTANT (NOTE)
If the flowmeter sensor is installed in plastic or earthenware pipelines, or in pipelines with an
insulating lining, transient current may flow through the grounding electrode in special cases.
In the long term, this may destroy the sensor, since the ground electrode will in turn degrade
electrochemically. In these special cases, the connection to the ground must be performed
using grounding plates. Install a grounding plate upstream and downstream of the device in
this case.

OI/FEX300/FEX500-EN FEX300, FEX500 35 36 FEX300, FEX500 OI/FEX300/FEX500-EN


Mounting Mounting
4.6.3 Metal pipe with loose flanges 4.6.4 Plastic pipes, non-metallic pipes or pipes with insulating liner

1. Solder the threaded nuts M6 (1) to the pipeline and connect the ground as shown in the For plastic pipes or pipes with insulating lining, the earthing for the measuring medium is
illustration. provided by the grounding plate as shown in the figure below or via grounding electrodes that
2. Use a copper wire (at least 2.5 mm² (14 AWG)) to establish the ground connection between must be installed in the device (option). If grounding electrodes are used, the grounding plate is
the sensor (2) and an appropriate grounding point. not necessary.
1. Install the flowmeter sensor with grounding plate (3) in the pipeline.
2. Connect the terminal lug (2) for the grounding plate (3) and ground connection (1) on the
flowmeter sensor with the grounding strap.
3. Use a copper wire (min. 2.5 mm² (14 AWG)) to link the earthing terminal (1) to a suitable
earthing point.

Flange design Wafer-type design


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

IMPORTANT (NOTE)
• Earthing is illustrated using the example of the dual-compartment transmitter housing; in
the case of transmitters with single-compartment housing, earthing is to be performed as
shown
Flange design Wafer-type design
Fig. 28: Plastic pipes, non-metallic pipes or pipes with insulating liner

IMPORTANT (NOTE)
• Earthing is illustrated using the example of the dual-compartment transmitter housing; in
the case of transmitters with single-compartment housing, earthing is to be performed as
shown

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Mounting Mounting
4.6.5 Sensor type HygienicMaster 4.6.9 Installation and grounding in pipelines with cathodic corrosion protection (CCP)

Ground the stainless steel model as shown in the figure. The measuring fluid is grounded via The installation of electromagnetic flowmeters in systems with cathodic corrosion protection
the adapter (1) and an additional ground is not required. must be made in compliance with the corresponding system conditions. The following factors
are especially important:
a) Pipelines inside electrically conductive or insulating.
b) Pipelines completely or for the most part with cathodic corrosion protection (CCP) or mixed
systems with CCP areas and PE areas.
• When installing an EMF in pipes with insulating inner lining and free from foreign matter, it
should be insulated with grounding plates on the upstream and downstream side. The CCP
potential is diverted. The grounding plates upstream and downstream of the EMF are
connected to functional ground (Fig. 30 / Fig. 31).
• If the occurrence of external stray currents is to be expected in pipelines with internal
insulation (e.g. in the case of long pipe sections in the vicinity of power supply units), an
uninsulated pipe of approx. 1/4 DN of length should be provided upstream and downstream
of the flowmeter sensor in order to deviate these currents away from the measuring system
(Fig. 32).

Fig. 29 4.6.9.1 Internally insulated pipelines with cathodic corrosion protection potential

4.6.6 Ground for devices with protective plates


The protective plates are used to protect the edges of the liner in the measuring tube, e.g., for
abrasive fluids. In addition, they function as a grounding plate.
• For plastic or pipes with insulating lining, electrically connect the protective plate in the same
manner as a grounding plate.

4.6.7 Ground with conductive PTFE grounding plate

For devices with a meter size between DN 10 … 250, grounding plates made of conductive
PTFE are available. These are installed in a similar way to conventional grounding plates.
Fig. 30: Bolt screw view
4.6.8 Devices with extended diagnostic functions 1 Pipe flange 6 Insulating plate
2 Insulating plate 7 Flange
For devices with extended diagnostic functions different grounding conditions may be valid.
3 Gasket / insulating ring 8 Lining
For further information read and observe chapter 9 “Extended diagnostic functions”. 4 Grounding plate 9 Insulation
5 Insulating pipe 10 Flowmeter sensor

Install grounding plates on each side of the flowmeter sensor. Insulate the grounding plates
from the pipe flanges and connect them to the flowmeter sensor and to functional ground.
Insulate the screw bolts for the flange connections when mounting. The insulation plates and
the insulation pipe are not included in the delivery. They must be provided onsite by the
customer.

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Mounting Electrical connections

The CCP potential must be diverted through a connecting line "A" away from the insulated
5 Electrical connections
flowmeter sensor.
5.1 Routing the signal and magnet coil cable

Observe the following points when routing cables:


• A magnet coil cable (red and brown) is run parallel to the signal lines (violet and blue). As a
result, only one cable is required between the flowmeter sensor and the transmitter. Do not
run the cable over junction boxes or terminal strips.
• The signal cable carries a voltage signal of only a few millivolts and must, therefore, be
routed over the shortest possible distance. The max. allowable signal cable length is 50 m
(164 ft) without pre-amplifier and 200 m (656 ft) with pre-amplifier.
• Avoid routing the cable in the vicinity of electrical equipment or switching elements that can
create stray fields, switching pulses, and induction. If this is not possible, run the signal /
magnet coil cable through a metal pipe and connect this to the station ground.
• All leads must be shielded and connected to the station ground potential.
• To shield against magnetic interspersion, the cable contains outer shielding. This is attached
to the SE clamp.
• The supplied stranded steel wire is also connected to the SE clamp
• Do not damage the sheathing of the cable during installation.
Fig. 31: Flowmeter sensor with grounding plate and functional ground
• Make sure during installation that the cable
1 Insulated pipe A Connecting line for CCP potential is provided with a water trap (1). For vertical
2 Functional ground ≥ 4 mm2 Cu, not included in the delivery, installation, align the cable glands pointing
3 Grounding plate to be provided onsite downward.
B Insulated screw bolts without grounding
plates

4.6.9.2 Mixed system pipeline with CCP and functional ground potentials
This mixed system has an insulated pipeline with CCP potential and an uninsulated bar metal
pipe (L = 1/4 x flowmeter sensor size) with functional ground potential upstream and
downstream of the flowmeter sensor.
Fig. 33
The Fig. 32 shows the preferred installation for cathodic corrosion protection systems.

Fig. 32: Flowmeter sensor with functional ground


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

OI/FEX300/FEX500-EN FEX300, FEX500 41 42 FEX300, FEX500 OI/FEX300/FEX500-EN


Electrical connections Electrical connections
5.2 Preparing the signal and magnet coil cable in the case of transmitters with dual-compartment 5.2.2 Cable with part number D173D031U01
housing
Prepare both cable ends as shown.
5.2.1 Cable with part number D173D027U01
IMPORTANT (NOTE)
Prepare both cable ends as shown. Use wire end sleeves.
• Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
IMPORTANT (NOTE)
• Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
Use wire end sleeves.
The shields may not touch (signal short circuit).
• Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
• Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
Flowmeter sensor side
The shields may not touch (signal short circuit).

Fig. 34: Flowmeter sensor side, dimensions in mm (inch)

Transmitter side
Fig. 36: Flowmeter sensor side, dimensions in mm (inch)
1 Measurement potential 3, green L2 = 70 (2.76) 8 Magnet coil, M2, red L2 = 90 (3.54)
Fig. 35: Transmitter side, dimensions in mm (inch) 2 Signal line E1, violet L2 = 60 (2.36) 9 Magnet coil, M1, brown L2 = 90 (3.54)
3 Shield 1S L2 = 60 (2.36) 10 Foil shield (D1, D2)
L1 maximum stripped length = 105 (4.10) 4 Shield 2S L2 = 60 (2.36) 11 Foil shield continuity wire (D1, D2)
1 Measurement potential 3, green L2 = 70 (2.76) 7 Data line, D1, orange L2 = 70 (2.76) 5 Signal line, E2, blue L2 = 60 (2.36) 12 Ground wire, steel
2 Signal line E1, violet L2 = 60 (2.36) 8 Magnet coil, M2, red L2 = 90 (3.54) 6 Data line, D2, yellow L2 = 70 (2.76) 13 SE clamp
3 Shield 1S L2 = 60 (2.36) 9 Magnet coil, M1, brown L2 = 90 (3.54) 7 Data line, D1, orange L2 = 70 (2.76)
4 Shield 2S L2 = 60 (2.36) 10 Ground wire, steel
5 Signal line, E2, blue L2 = 60 (2.36) 11 SE clamp
6 Data line, D2, yellow L2 = 70 (2.76)

OI/FEX300/FEX500-EN FEX300, FEX500 43 44 FEX300, FEX500 OI/FEX300/FEX500-EN


Electrical connections Electrical connections
5.3 Preparing the signal and magnet coil cable in the case of transmitters with single-compartment
housing Prepare the cable end on the transmitter side as shown in Fig. 37.

5.3.1 Cable with part number D173D027U01

• Twist the wire mesh shield of the cable and connect to the ground terminal.
• Connect the ground wire of the cable to the SE clamp of the terminal strip.
• Connect all other wires as shown in Fig. 37.

5.3.2 Cable with part number D173D031U01

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

Fig. 37: Transmitter side, dimensions in mm (inch)


1 Ground wire 5 Foil shield continuity wire D1, D2
2 Wire mesh shield (D173D027U01 only) (D173D031U01 only)
4 Twisted wire mesh shield (D173D027U01 only) 6 Foil shield D1, D2 (D173D031U01 only)

Terminal Description, wire color Length in mm (inch)


M1 Magnet coil, brown 70 (2.76)
M2 Magnet coil, red 70 (2.76)
D1 Data line, orange 70 (2.76)
D2 Data line, yellow 70 (2.76)
SE Shield -
3 Measurement potential, green 70 (2.76)
2S Shield for E2 60 (2.36)
E2 Signal line, blue 60 (2.36)
E1 Signal line, violet 60 (2.36)
1S Shield for E1 60 (2.36)

IMPORTANT (NOTE)
• Use wire end sleeves.
- Wire end sleeves 0.75 mm2 (AWG 19), for shielding (1S, 2S)
- Wire end sleeves 0.5 mm2 (AWG 20), for all other wires
• The shields may not touch (signal short circuit).
en

OI/FEX300/FEX500-EN FEX300, FEX500 45 46 FEX300, FEX500 OI/FEX300/FEX500-EN


Electrical connections Electrical connections
5.4 Connecting the flowmeter sensor
IMPORTANT (NOTE)
5.4.1 Metal terminal box for ProcessMaster and HygienicMaster The cable with the part number D173D027U01 can be used for all device designs.
The cable with the part number D173D031U01 can be used for all device designs.
Connections can only be made with the power supply switched off. • Sensor without explosion protection from nominal diameter DN 15 (models FEP321,
The device must be earthed according to instructions. The sensor is connected to the FEH321, FEP521, FEH521)
transmitter via the signal / magnetic coil cable (part no. D173D027U01 or D173D031U01). • Sensor for use in Zone 2, Div. 2 from nominal diameter DN 15 (models FEP325, FEH325,
FEP525, FEH525)

IMPORTANT (NOTE)
Use wire end sleeves.
• Wire end ferrules 0.75 mm2 (19 AWG), for shielding (1S, 2S)
• Wire end ferrules 0.5 mm2 (20 AWG), for all other wires
The shielding may not touch (signal short circuit).

Cable with part number D173D027U01


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

Cable with part number D173D031U01


• Connect the earth wire of the cable together with the continuity wire of the foil shield from
D1, D2 to the earth clamp
• Connect all other wires as shown in Fig. 38
Fig. 38
1 Earth wire. 5 Foil shield D1, D2 (D173D031U01 only).
5.4.2 Connection via cable conduit
2 Earth clamp. 6 Continuity wire of the foil shield (D1, D2)
4 Braided shield (D173D027U01 only). (D173D031U01 only). NOTICE - Condensate formation in terminal box
If the flowmeter sensor is permanently connected to cable conduits, there is a possibility that
Terminal Description, wire color moisture may get into the terminal box as a result of condensate formation in the cable
M1 Magnetic coil, brown conduit.
M2 Magnetic coil, red Ensure that the cable entry points on the terminal box are sealed.
D1 Data line, orange
D2 Data line, yellow
PE Shielding
3 Measurement potential, green
2S Shield for E2
E2 Signal line, blue
E1 Signal line, violet
1S Shield for E1

Fig. 39: Installation set for cable conduit

An installation set for sealing the cable conduit is available via order number
3KXF081300L0001.

OI/FEX300/FEX500-EN FEX300, FEX500 47 48 FEX300, FEX500 OI/FEX300/FEX500-EN


Electrical connections Electrical connections
5.4.3 IP rating IP 68 5.4.3.2 Potting the terminal box

For sensors with IP rating IP 68, the maximum flooding height is 5 m (16.4 ft). The supplied On sensors without explosion protection or explosion protection Zone 2, Div. 2, the terminal box
cable (part no. D173D027U01 or D173D031U01) fulfills all submersion requirements. can be subsequently potted.
If the terminal box is to be potted subsequently on-site, a special two-component potting
compound can be ordered separately (order no. D141B038U01). Potting is only possible if the
sensor is installed horizontally. Observe the following instructions during work activity:

WARNING - General dangers!


The two-component potting compound is toxic – observe all relevant safety measures!
Hazard warnings: R20, R36 / 37 / 38, R42 / 43
Harmful by inhalation. Avoid direct skin contact. Irritating to eyes.
Safety advice: P4, S23-A, S24 / 25, S26, S37, S38
Wear suitable protective gloves and ensure sufficient ventilation.
Follow the instructions that are provided by the manufacturer prior to starting any
preparations.

Fig. 40 Preparation
1 Max. flooding height 5 m (16.4 ft) • Complete the installation before potting in order to avoid moisture penetration. Before
starting, check all the connections for correct fitting and stability
The sensor is type-tested in accordance with EN 60529. Test conditions: 14 days at a flooding • Do not overfill the terminal box. Keep the potting compound away from the O-ring and the
height of 5 m (16.4 ft). gasket / groove (see fig. Fig. 41)
• Prevent the two-component potting compound from penetrating the cable conduit if an NPT
5.4.3.1 Connection 1/2" installation is used
1. Use the supplied cable to connect the sensor and the transmitter. Procedure
2. Connect the cable in the terminal box of the sensor. 1. Cut open the protective enclosure of the two-component potting compound (see packing).
3. Route the cable from the terminal box to above the maximum flooding height of 5 m (16.4 ft). 2. Remove the connection clamp of the potting compound.
4. Tighten the cable gland. 3. Knead both components thoroughly until a good mix is reached.
5. Carefully seal the terminal box. Make sure the gasket for the cover is seated properly. 4. Cut open the bag at a corner. Perform work activity within 30 minutes.
5. Carefully fill the terminal box with the two-component potting compound until the connection
cable is covered.
NOTICE – potential adverse effect on IP rating IP 68!
6. Wait a few hours before closing the cover in order to allow the compound to dry, and to
The IP rating IP 68 of the sensor may be adversely affected as a result of damage to the release any possible gas.
signal cable.
7. Ensure that the packaging material and the drying bag are disposed of in an environmentally
The sheathing of the signal cable must not be damaged. Otherwise, the IP rating IP 68 for the
sound manner.
sensor cannot be ensured.

IMPORTANT (NOTE)
As an option, the sensor can be ordered with the signal cable already connected to the sensor
and the terminal box already potted.

Fig. 41
1 Packing bag 4 Max. filling level
2 Connection clamp 5 Drying bag
3 Two-component potting compound

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Electrical connections Electrical connections
5.5 Connecting the transmitter 5.5.2 Transmitter with dual-compartment housing

IMPORTANT (NOTE) The terminals for the power supply can be found under the terminal cover (1).
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.

5.5.1 Connecting the power supply

The line voltage and power consumption are indicated on the name plate for the transmitter.
A circuit breaker with a maximum rated current of 16 A must be installed in the power supply
line of the transmitter.
The wire cross-sectional area of the power supply cable and the circuit breaker used must
comply with VDE 0100 and must be dimensioned in accordance with the current consumption of
the flowmeter measuring system. The cables must comply with IEC 227 and/or IEC 245.
The circuit breaker should be located near the transmitter and marked as being associated with
the device. Fig. 42
The power supply is connected to terminal L (phase), N (neutral), or 1+, 2-, and PE, as stated 1Terminal cover
on the name plate.
Connect the transmitter and sensor to functional earth. 5.5.3 Transmitter with single-compartment housing

IMPORTANT (NOTE)
• Observe the power supply limit values in accordance with the information on the name
plate and from chapter „Power supply“ on page 163
• Observe the voltage drop for large cable lengths and small conductor cross-sections. The
voltage at the terminals of the device may not fall below the minimum value required in
accordance with the information on the name plate and from chapter „Power supply“ on
page 163,
• Complete the electrical connection in accordance with the connection diagram

Fig. 43
1 Terminals (power supply)

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Electrical connections Electrical connections
5.5.4 Connecting the signal and magnet coil cables 5.6 Terminal connection diagrams

The outer shielding of the signal and magnet coil cable is attached to the busbar via the clip (4) 5.6.1 HART, PROFIBUS PA and FOUNDATION fieldbus protocol
(from the accessory bag in the connection area) (dual-compartment transmitter housing only).
In the case of the single-compartment transmitter housing, the outer shielding of the signal and IMPORTANT (NOTE)
magnet coil cable is connected to the corresponding terminal for the signal and magnet coil An additional document with Ex safety instructions is available for measuring systems that are
cable. used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
The shielding for the signal wires functions as a driven shield to transmit the measurement lists are also observed.
signal.
The cable is attached to the flowmeter sensor and transmitter according to the connection Important (Note)
diagram. For detailed information about earthing the transmitter and the sensor, please refer to chapter
4.6 "Ground" on page 35!

A = transmitter, B = sensor
Fig. 45
Ch ang e f ro m o ne to t wo co lum ns

Power supply connections Output connections

AC power supply Terminal Function / Notes


Dual-compartment transmitter housing Single-compartment transmitter housing
Terminal Function / Notes 31 / 32 Current / HART output
Fig. 44 L Live / Phase The current output is available in "active" or "passive"
N Neutral mode.
1 Terminal cover 6 SE terminal for signal and magnet coil cable shield
PE / Protective earth (PE) 97 / 98 Digital communication
2 Terminals for signal and magnet coil cable 7 Terminals for cable shields PROFIBUS PA (PA+ / PA-) or FOUNDATION
3 Signal and magnet coil cable fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
DC power supply
4 Clip 51 / 52 Digital output DO1 active / passive
Terminal Function / Notes
5 Busbar (SE) 1+ +
Function can be configured locally as „Pulse Output"
or „Digital Output". Factory setting is „Pulse Output".
2- -
81 / 82 Digital input / contact input
PE / Protective earth (PE)
IMPORTANT (NOTE) Function can be configured locally as „External
output switch-off“, „external totalizer reset“, „external
The power supply for the optional pre-amplifier is provided via terminals 1S and 2S. Sensor cable terminal connections totalizer stop“ or „other“.
The transmitter automatically detects the sensor and switches to the required supply voltage Only on remote mount design. 41 / 42 Digital output DO2 passive
on terminals 1S and 2S. Function can be configured locally as „Pulse Output"
Terminal Function / Notes Wire color or „Digital Output". Factory setting is „Digital Output",
M1 Magnet coil Brown flow direction signaling.
M2 Magnet coil Red Functional ground
D1 Data line Orange
D2 Data line Yellow
/ SE Shield -
E1 Signal line Violet
1S Schield for E1 -
E2 Signal line Blue
2S Schield for E2 -
3 Measurement potential Green
Ch ang e f ro m o ne to t wo co lum ns

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Electrical connections Electrical connections
5.7 Electrical data 5.7.5 Digital communication

5.7.1 Current / HART output

PROFIBUS PA (PA+ / PA-) FOUNDATION fieldbus (FF+ / FF-)


U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of
an error / FDE) an error / FDE)
The current / HART output can be operated in "active" or "passive" mode. Bus connection with integrated protection against polarity reversal. Bus connection with integrated protection against polarity reversal
A Active: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω The bus address can be set via the DIP switches in the device (with
B Passive: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω dual-compartment transmitter housing only), the transmitter display or
Supply voltage for the current output: minimum 11 V, maximum 30 V. the fieldbus.
The resistance R and condenser C form the bus termination. They must be installed when the device is connected to the end of the entire bus
cable. R = 100 Ω; C = 1 µF
For Ex zone 1 / Div. 1 the maximum load is 300 Ω. Max. permissible load (RB) as a function of the source
voltage (U 2) Fig. 50: (I = internal, E = external)
Fig. 46: (I = internal, E = external) 5.8 Connection examples
5.7.2 Digital output DO1 5.8.1 Digital output DO2
E.g., for system monitoring, max. / min. alarm, empty meter tube or forward / reverse signal, or counting pulses
(function can be configured using software)

The output can be configured as an "active (A)" or "passive (B)" output (in the case
of the transmitter with the dual-compartment housing, the output is configured
using the software; in the case of the transmitter with the single-compartment Fig. 51: (I = internal, E = external)
housing, it is configured by means of jumpers on the transmitter backplane).
5.8.2 Digital outputs DO1 and DO2
Configuration as "active" output:
- U = 19 ... 21 V, Imax = 220 mA , fmax ≤ 5250 Hz Separate forward and reverse pulses Separate forward and reverse pulses (alternative connection)
Configuration as "passive" output Max. permissible load (RB) as a function of the source
- Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz voltage (U 2). gg = Permissible range
Configuration as pulse output:
- Max. pulse frequency: 5250 Hz.
- Pulse width: 0.1 … 2000 ms.
- The pulse factor and pulse width are interdependent and are calculated
dynamically.
Configuration as contact output:
- Function: System alarm, empty pipe alarm, max. / min. alarm, flow direction
signaling, other
Fig. 47: (I = internal, E = external)

5.7.3 Digital output DO2 Fig. 52: (I = internal, E = external)


The output is always a "passive" output (optocoupler). 5.8.3 PROFIBUS PA - Connection via M12 plug
Data for the optocoupler:
Only in non-hazardous areas
Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz
Pin assignment
For maximum load see diagram Fig. 47. (Front view showing pin insert and pins)
PIN 1 = PA+
PIN 2 = nc
PIN 3 = PA-
PIN 4 = shield
Fig. 48: (I = internal, E = external)

5.7.4 Digital input DI


Data for the optocoupler:
16 V ≤ U ≤ 30 V, Ri = 2 kΩ
Fig. 53

IMPORTANT (NOTE)
Fig. 49: (I = internal, E = external) For additional information on configuring the current output, see chapter 7.2 „Configuring the
current output“

OI/FEX300/FEX500-EN FEX300, FEX500 55 56 FEX300, FEX500 OI/FEX300/FEX500-EN


Digital communication Digital communication
Ch ang e f ro m o ne to t wo co lum ns

6 Digital communication 6.2 PROFIBUS PA 6.3 FOUNDATION fieldbus (FF) 6.3.3 Bus address
The interface conforms to profile 3.01 (PROFIBUS standard, EN The bus address is automatically assigned or can be set in the system
50170, DIN 19245 [PRO91]). manually.
6.1 HART protocol The identifier (ID) is formed using a unique combination of
manufacturer ID, device ID, and device serial number.
The unit is registered with the HART Communication Foundation.

6.3.4 System integration


The following are required:
• DD (Device Description) file, which includes the device
description.
B = Linking device (incl. bus supply and termination)
• The CFF (Common File Format) file is required for engineering
Fig. 56: Example for FOUNDATION fieldbus interface connection the segment. Engineering can be performed online or offline.
A = Segment coupler (incl. bus supply and termination) Interoperability test ITK 5.20 The files can be downloaded from www.abb.com/flow.
Fig. 55: Example for PROFIBUS PA interface connection campaign no. The files required for operation can also be downloaded from
Manufacturer ID 0x000320 http://www.fieldbus.org.
PROFIBUS PA ID no 0x3430 Device ID 0x0124
Fig. 54
Alternative 0x9700 or 0x9740 Configuration • Directly on the device
standard ID no
Configuration Directly on the device • Via services integrated in the
Configuration Directly on the device system
Software DAT200 Asset Vision Basic
Software DAT200 Asset Vision Basic (+
(+ HART-DTM) • National configurator
PROFIBUS PA-DTM)
Transmission FSK modulation on current output Transmission signal Acc. to IEC 61158-2
Transmission signal Acc. to IEC 61158-2
4 ... 20 mA acc. to Bell 202 standard
Cable Shielded, twisted cable (acc. to IEC
Max. signal amplitude 1.2 mAss
61158-2, types A or B are preferred) 6.3.1 Bus topology
Current output load Min. 250 Ω, max. = 560 Ω
Cable AWG 24 twisted • Tree and/or line structure
Max. cable length 1500 m 6.2.1 Bus topology • Bus termination: passive at both ends of the main bus line (RC
Baud rate 1,200 baud element R = 100 Ω, C = 1 µF)
• Tree and/or line structure
Display Log. 1: 1,200 Hz
• Bus termination: passive at both ends of the main bus line (RC
Log. 0: 2,200 Hz element R = 100 Ω, C = 1 µF) 6.3.2 Voltage / current consumption
For additional information, see separate interface documentation. • Average current consumption: 10 mA
6.2.2 Voltage / current consumption • In the event of an error, the integrated FDE function (=Fault
Disconnection Electronic) integrated in the device is ensures that
6.1.1 System integration • Average current consumption: 10 mA the current consumption can rise to a maximum of 13 mA.
• In the event of an error, the integrated FDE function (=Fault • Upper current limit: electronically restricted.
In conjunction with the DTM (Device Type Manager) available for the Disconnection Electronic) integrated in the device is ensures that
device, communication (configuration, parameterization) can occur • The voltage on the bus line must lie in the range of 9 ... 32 V DC.
the current consumption can rise to a maximum of 13 mA. Ch ang e f ro m o ne to t wo co lum ns

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

The GSD files can be downloaded from www.abb.com/flow.


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

OI/FEX300/FEX500-EN FEX300, FEX500 57 58 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.2.1 Transmitter with dual-compartment housing
7 Commissioning
IMPORTANT (NOTE)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.

7.1 Preliminary checks prior to start-up

The following points must be checked before commissioning:


• The supply power must be switched off.
• The supply power must match information on the name plate.
• The pin assignment must correspond to the connection diagram.
• Sensor and transmitter must be grounded properly.
• The temperature limits must be observed.
• The sensor must be installed at a largely vibration-free location.
• The housing cover and its safety locking device must be sealed before switching on the
supply power.
• For devices with remote mount design and an accuracy of 0.2 % of rate make sure that the
flowmeter sensor and the transmitter match correctly.
For this purpose, the final characters X1, X2, etc. are printed on the name plates of the
flowmeter sensors, whereas the transmitters are identified by the final characters Y1, Y2,
etc.
Devices with the end characters X1 / Y1 or X2 / Y2, etc. fit with each other. Fig. 57
A Integral mount design 4 Backplane (in the transmitter housing)
7.2 Configuring the current output B Remote mount design 5 Jumper (BR901) for active / passive current output
1 Housing cover 6 Jumper (BR903) for integral / remote mount design
The factory setting for the current output is 4 ... 20 mA. 2 Transmitter plug-in module 7 Jumper (BR902) for hardware write protection
3 Fixing screws
For devices without explosion protection or for operation in Zone 2 / Div. 2 the following
is valid: IMPORTANT (NOTE)
The signal can be configured in "active" or "passive" mode. The current setting is contained in The backplane is mounted in the transmitter housing (not the transmitter plug-in module).
the order confirmation.
Configure the outputs as follows:
For devices for operation in Zone 1 / Div. 1 the following is valid: 1. Switch off power supply.
For devices designed for use in Ex Zone 1 / Div.1, the current output cannot be reconfigured 2. Open the housing cover.
subsequently. The configuration required for the current output (active / passive) must be 3. Remove the mounting screws for the transmitter electronics unit
specified when the order is placed. 4. Pull out the transmitter electronics unit
For the correct current output design (active / passive), see the marking contained in the 5. Set jumpers on backplane in accordance with the following table.
device's terminal box.
If the signal is configured in "active" mode, no external power may be supplied to the current
Jumper Number Function
output.
If the signal is configured in "passive" mode, external power must be supplied to the current BR901 active Current output 31 / 32 active
output (similar to pressure and temperature transmitters). passive Current output 31 / 32 passive
BR902 Read only Hardware write protection active
BR903 integral Transmitter with integral mount design
remote Transmitter with remote mount design

6. Reinstall the transmitter electronic unit in reverse order

OI/FEX300/FEX500-EN FEX300, FEX500 59 60 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.2.2 Transmitter with single-compartment housing 7.3 Start-up of PROFIBUS PA units

For units with PROFIBUS PA, the bus address must be checked or configured prior to start-up.
If no bus address information was supplied by the customer, the unit was shipped with its BUS
address set to “126”.
The address must be set during start-up to a number within the valid range (0 … 125).

IMPORTANT (NOTE)
The address selected may only appear once in the segment.

The PROFIBUS PA interface of the device conforms with Profile 3.01 (fieldbus standard
PROFIBUS, EN 50170, alias DIN 19245 [PRO91]).
The transmitter transmission signal is designed according to IEC 61158-2.

IMPORTANT (NOTE)
The manufacturer-specific PROFIBUS PA ID no. is: 0x3430.
The unit can also be operated with the PROFIBUS standard ID nos. 0x9700 or 0x9740.

Address setting in the case of transmitters with dual-compartment housing


The address can be set either locally on the device (via the DIP switches on the backplane),
using system tools, or via a PROFIBUS DP master class 2 such as Asset Vision Basic
(DAT200).
Fig. 58: Jumpers in the single-compartment housing The factory setting for DIP switch 8 is OFF, i.e., the address is set using the fieldbus.
A Integral mount design 5 Jumpers (BR905, BR906) for communication The front cover must be unscrewed to change the settings. It is also possible to set the address
B Remote mount design 6 Jumper (BR901) for active / passive current output via menu by using the keys on the display board.
1 Housing cover 7 Jumper (BR904) for active / passive pulse output
2 Transmitter plug-in module 8 Jumper (BR903) for integral / remote mount design Address setting in the case of transmitters with single-compartment housing
3 Fixing screws 9 Jumper (BR902) for hardware write protection
4 Backplane (in the transmitter housing) The address can be set using system tools or via a PROFIBUS DP master class 2 such as
Asset Vision Basic (DAT200).
IMPORTANT (NOTE)
It is also possible to set the address via a menu by using the transmitter LCD display (refer to
The backplane is mounted in the transmitter housing (not the transmitter plug-in module). the the "Parameterization" section).
Configure the outputs as follows: It is not possible to set the address locally via DIP switch because there are no DIP switches
1. Switch off power supply. present in the case of transmitters with single-compartment housing.
2. Open the housing cover.
3. Remove the mounting screws for the transmitter electronics unit
4. Pull out the transmitter electronics unit
5. Set jumpers on backplane in accordance with the following table.
Jumper Number Function
BR901 active Current output 31 / 32 active
passive Current output 31 / 32 passive
BR902 Read only Hardware write protection active
BR903 integral Transmitter with integral mount design
remote Transmitter with remote mount design
BR904 active Pulse output 51 / 52 active
passive Pulse output 51 / 52 passive
BR905, BR906 HART Digital communication via HART protocol
PA/FF Digital communication via PROFIBUS PA or
FOUNDATION Fieldbus

6. Install the transmitter in reverse order.

OI/FEX300/FEX500-EN FEX300, FEX500 61 62 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.3.1 Local address setting in the case of transmitters with dual-compartment housing 7.3.2 Configuration in the case of transmitters with single-compartment housing

Integral mount design Remote mount design

Fig. 59: Position of DIP switches


1 Transmitter plug-in module 2 DIP switch
Switch assignments
Switch Assignment
1…7 PROFIBUS address Fig. 60:
8 Defines the addressing mode: A Integral mount design 5 Jumpers (BR905, BR906) for communication
Off = Set address via bus (factory setting) B Remote mount design 6 Jumper (BR901) for active / passive current output
On = Set address via DIP switches 1 ... 7 (local) 1 Housing cover 7 Jumper (BR904) for active / passive pulse output
2 Transmitter plug-in module 8 Jumper (BR903) for integral / remote mount design
3 Fixing screws 9 Jumper (BR902) for hardware write protection
Device behavior with power supply switched on 4 Backplane (in the transmitter housing)
After the power supply has been switched on, DIP switch 8 is polled:
Status Set jumpers on backplane in accordance with the following table.
ON The address defined by DIP switches 1 ... 7 applies.
The address can no longer be changed via the bus once the device is in operation,
Jumper Number Function
since DIP switch 8 is polled only once when the power supply is turned on.
OFF The transmitter uses the address stored in the FRAM of the gateway. At shipment BR901 passive For PROFIBUS PA, set position to "passive"
(Default) the address is set to “126” or to the address specified by the customer. BR903 integral Transmitter with integral mount design
Once the unit is in operation, the address can be changed via the bus or directly on remote Transmitter with remote mount design
the unit using the keys on the display board. The unit must be connected to the bus. BR904 active For PROFIBUS PA without function
passive
BR905, BR906 PA/FF Digital communication via PROFIBUS PA
Address setting
Switches 1, 5, 7 = ON means: 1+16+64 = 81 ΰ Bus address 81

Switch 1 2 3 4 5 6 7 8
Status Device address Address mode
Off 0 0 0 0 0 0 0 Bus
On 1 2 4 8 16 32 64 Local

OI/FEX300/FEX500-EN FEX300, FEX500 63 64 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.3.3 Voltage / current consumption 7.4 Start-up of FOUNDATION FIELDBUS devices
• Average current consumption: 10 mA. For devices with a FOUNDATION Fieldbus, the settings of the DIP switch must be checked
• In the event of an error, the integrated FDE (= Fault Disconnection Electronic) function prior to start-up.
integrated in the device ensures that the current consumption can rise to a maximum of 13 The DIP switches on the unit must be set correctly as follows:
mA.
• DIP switch 1 must be OFF.
• The upper current limit is restricted electronically.
• DIP switch 2 must be OFF.
• The voltage on the bus line must lie in the range of 9 ... 32 V DC.
Otherwise, the hardware write protection and the process control system prevent the unit from
recording information.
7.3.4 System integration When integrating the unit in a process control system, a DD file (device description) and a CFF
file (common file format) are required. The DD file contains the device description. The CFF file
Use of PROFIBUS PA profile B, B3.01 ensures interoperability and interchangeability of is required for segment engineering. Engineering can be performed online or offline.
devices. Interoperability means that devices from different manufacturers can be physically The DD and CFF files are available to download from the ABB homepage
connected to a bus and are communication-ready. In addition, third-party devices can be http://www.abb.com/flow.
interchanged without having to reconfigure the process control system. The FOUNDATION Fieldbus interface for the device is compliant with the standards FF-890/891
To support interchangeability, ABB provides three different GSD files (equipment master data) and FF-902/90. The transmission signal of the transmitter is designed in accordance with IEC
that can be integrated in the system. 61158-2.
Users decide at system integration whether to install the full range of functions or only part. The device is registered with the FOUNDATION fieldbus.
Registration for the FOUNDATION fieldbus is recorded under Manufacturer ID 0x000320 and
IMPORTANT (NOTE) Device ID 0x0124.
Devices are interchanged using the parameter "ID number selector", which can only be
modified on an acyclical basis.

The following table describes the available GSD files:

Number and type of


ID number GSD file name
function blocks
1 x AI 0x9700 PA139700.gsd
1 x AI; 1 x TOT 0x9740 PA139740.gsd
4 x AI, 2 x TOT,
1 x AO, 1 x DI, 1 x DO
0x3430 ABB_3430.gsd
and all manufacturer-specific
parameters

The manufacturer-specific GSD file "ABB_3430.gsd" is available to download from the ABB
homepage http://www.abb.com/flow.

The standard "PA1397xx.gsd" GSD files are available for download from the Profibus
International homepage: http://www.profibus.com

OI/FEX300/FEX500-EN FEX300, FEX500 65 66 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.4.1 Configuration of transmitters with dual-compartment housing 7.4.2 Configuration of transmitters with single-compartment housing

Fig. 61: Position of DIP switches


1 Transmitter plug-in module 2 DIP switch

Assigning of DIP switches


DIP switch 1:
Enables the simulation of the AI function blocks. Fig. 62:
A Integral mount design 5 Jumpers (BR905, BR906) for communication
DIP switch 2: B Remote mount design 6 Jumper (BR901) for active / passive current output
Hardware write protection for write access via bus (locks all blocks). 1 Housing cover 7 Jumper (BR904) for active / passive pulse output
2 Transmitter plug-in module 8 Jumper (BR903) for integral / remote mount design
3 Fixing screws 9 Jumper (BR902) for hardware write protection
DIP switch 1 2 4 Backplane (in the transmitter housing)
Status Simulation Mode Write Protect
Off Disabled Disabled
Set jumpers on backplane in accordance with the following table.
On Enabled Enabled

Jumper Number Function


BR901 passive For FOUNDATION Fieldbus, set position to
"passive"
BR903 integral Transmitter with integral mount design
remote Transmitter with remote mount design
BR904 active For FOUNDATION Fieldbus without function
passive
BR905, BR906 PA/FF Digital communication via
FOUNDATION Fieldbus

OI/FEX300/FEX500-EN FEX300, FEX500 67 68 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.4.3 Bus address settings
7.5 Commissioning the unit
The bus address is automatically allocated at the FF via LAS (link active scheduler). For
address detection, a unique number is used (DEVICE_ID). This number is a combination of 7.5.1 Downloading the system data
manufacturer ID, device ID and device serial number.
1. Switch on the power supply. After switching on the power supply, the following messages
The behavior when switching on the unit corresponds to Draft DIN IEC/65C/155/CDV of June
appear in succession on the LCD display:
1996.
The mean current consumption of the device is 10 mA.
The voltage on the bus line must lie in the range of 9 … 32 V DC. System Startup System Startup System Startup
LOADING SYSTEM DATA VERIFYING SYSTEM DATA INSTALLATION CHANGED
Identify Changed Item
IMPORTANT (NOTE)
The upper limit of the current is electronically limited. In the event of an error, the FDE (= Fault Transmitter Sensor
Disconnection Electronic) function integrated in the device ensures that the current
consumption cannot exceed a maximum of 13 mA.
2. Download the system data as follows:

For a completely new system or initial start-up


• The calibration data of the flowmeter sensor and the transmitter settings are loaded from the
SensorMemory 1) into the transmitter.

After replacing the complete transmitter or transmitter electronic unit


• Select "Transmitter" with . The calibration data of the flowmeter sensor and the
transmitter settings are loaded from the SensorMemory 1) into the transmitter.

After replacing the sensor


• Select "Sensor" with . The calibration data of the flowmeter sensor are loaded from the
SensorMemory 1) into the transmitter. The transmitter settings are stored in the
1)
SensorMemory . If the new sensor is a different size, check the currently configured flow
range.

3. The flowmeter is ready for operation and will operate with factory settings or settings
requested by the customer. To change the factory settings, refer to chapter 8
"Parameterization".
1) The SensorMemory is a data memory integrated in the flowmeter sensor.

IMPORTANT (NOTE)
System data must only be loaded during initial start-up. If the power supply is later switched
off, the transmitter automatically loads all data the next time the power supply is switched on
again.
A selection as described below (1-3) is not required.

OI/FEX300/FEX500-EN FEX300, FEX500 69 70 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
7.5.1.1 Error message "Incompatible sensor" 7.5.2 Parameterization via the "Commissioning" menu function

IMPORTANT (NOTE) The device can be factory parameterized to customer specifications upon request.
When commissioning the device, make sure that the transmitter is assigned to the sensor If no customer information is available, the device is delivered with factory settings.
correctly. It is not possible to operate a flowmeter sensor of the 300 series with a transmitter of The setting of the most current parameters is summarized in the "Commissioning" menu. This
the 500 series. menu provides the quickest way to configure the device.
The "Commissioning" menu allows you to select the language, the physical unit for flow rate, the
If the transmitter is operated with a flowmeter sensor of another series, the following message measuring range, the totalizer unit, the pulse / frequency mode, the pulse per unit, the pulse
appears on the transmitter display: width, damping, and the status of the current output during an alarm (Iout for alarm, Iout: Low
Alarm, Iout: High Alarm).
For detailed descriptions of these menus and parameters, see the chapter on the "Parameter
Boiler 9 In the process display, a flow of zero flow is indicated, no
overview".
Q 0.00 l/min flow measurement is performed.
Σ+ 1403.09 m3 The following section describes parameterization via the "Easy Setup" menu function.
Σ- 591.74 m3 1. Use to switch to the information level.
Boiler 9
Q 0.00 l/s 4. Use to switch to the configuration level.
Sensor
Σ+ 0000.00 m³
Σ- 0000.00 m³
-Operator Menu- 2. Use or , select the "Diagnostics" submenu.
Diagnostics
3. Use to confirm your selection.
Operator Page 1
Operator Page 2 Access levels 5. Use or to select "Standard".
Back Select Read only
Standard 6. Confirm the selection with .
Advanced mode
Back Select
Sensor When attempting to commission a mixed installation, the
-- F248.036-- shown error message appears.
Incompatible sns
The device cannot measure.
Tx+snr are not Enter password
the same series The indicated value for the current flowrate is zero flow. ********** 7. Use to confirm the password. A password is not
Back Exit The current output assumes its pre-configured state (Iout RSTUVWXYZ 012345 available as factory default; you can continue without
for alarm). entering a password.
Next OK
Make sure that the flowmeter sensor and the transmitter
are from the same series.
(e.g., flowmeter sensor ProcessMaster 300, transmitter
ProcessMaster 300) Menu 8. Use or to select "Commissioning".
Easy Setup
9. Confirm the selection with .

Exit Select

OI/FEX300/FEX500-EN FEX300, FEX500 71 72 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning

Easy Setup Easy Setup


Language 10. Use to call up the edit mode. 25. Use to call up the edit mode.
Pulses per Unit
German 11. Use or to select the desired language. 10.000 / m³ 26. Use or to set the desired value.
12. Confirm the selection with . 27. Use to confirm your setting.
Next Edit Next Edit

Easy Setup Easy Setup


Q (Flowrate) Unit 13. Use to call up the edit mode. 28. Use to call up the edit mode.
Pulse Width
l/s 14. Use or to select the desired unit. 30.00 ms 29. Use or to set the required pulse width.

Next Edit
15. Confirm the selection with . 30. Use to confirm your setting.
Next Edit

Easy Setup Easy Setup


Qmax 16. Use to call up the edit mode. 31. Use to call up the edit mode.
Damping
25.000 l/s 17. Use or to set the desired upper range value. 30.00 ms 32. Use or to set the desired damping.

Next Edit
18. Use to confirm your setting. 33. Use to confirm your setting.
Next Edit

Easy Setup Easy Setup


Totalizer/Pulse Unit 19. Use to call up the edit mode. 34. Use to call up the edit mode.
Iout at Alarm
m³ 20. Use or to select the desired unit. High Alarm 35. Use or to select the alarm mode.

Next Edit
21. Confirm the selection with . 36. Confirm the selection with .
Next Edit

Easy Setup Easy Setup


Operation 22. Use to call up the edit mode. 37. Use to call up the edit mode.
Low Alarm Value
Pulse Mode 23. Use or to select the required operating mode. 3.5000 mA 38. Use or to set the required current for Low
• "Pulse Mode": In pulse mode, pulses per unit are Alarm.
Next Edit output. The relevant settings are provided in the next Next Edit
menu 39. Confirm the selection with .
• "Fullscale Frequency": In frequency mode, a frequency
proportional to the flow rate is output. The maximum Easy Setup
frequency can be configured according to the flow High Alarm Value 40. Use to call up the edit mode.
measuring range 21.800 mA 41. Use or to set the required current for High
The factory default for the operating mode is "Pulse Mode". Alarm.
Next Edit
24. Confirm the selection with . 42. Confirm the selection with .

OI/FEX300/FEX500-EN FEX300, FEX500 73 74 FEX300, FEX500 OI/FEX300/FEX500-EN


Commissioning Commissioning
Instructions on using the Qmax menu (flow range end value)
Easy Setup
43. Use to start automatic balancing of the zero point The device is factory calibrated to the flow range end value QmaxDN, unless other customer
System Zero
for the system. information is available. The ideal flow range end values are approximately 2-3 m/s (0.2 ... 0.3 x
███████
QmaxDN).
Next OK The smallest and largest possible flow range end values are shown in the table in chapter 7.6
"Flowmeter sizes, flow range".
IMPORTANT (NOTE)
Prior to starting the zero point balancing, make sure
that: Information regarding factory settings for further parameters (unless customer has
requested a specific parameterization)
• There is no flow through the sensor (close all
valves, shut-off devices etc.) Possible parameter settings Factory setting
• The sensor is completely filled with the medium to Qmax Depending on the size (see QmaxDN (see table)
be measured table)
Sensor TAG Alphanumeric, max. None
20 characters
Easy Setup Enter the signal cable length between the transmitter and
Cable length Sensor Location TAG Alphanumeric, max. None
the sensor. For devices with an integral mount design 20 characters
5.0000 m 0.01 m must be entered. Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; l/min
Next Edit 44. Use to call up the edit mode. m3/s; m3/min; m3/h; m3/d;
hl/h; g/s; g/min; g/h; kg/s;
45. Use or to set the signal cable length.
kg/min; kg/h; kg/d; t/min; t/h;
46. Confirm the selection with . t/d
Totalizer/Pulse Unit m3; l; ml; hl; g; kg; t l
Pulses per Unit 1
Menu Once all parameter have been set, the main menu appears Pulse Width 0,1 ... 2,000 ms 100 ms
Easy Setup again. The most important parameters are now set. Damping ( 1 Tau) 0,02 ... 60 sec. 1
DO1 Alarm Config Pulse F/Pulse R, Pulse F, Pulse F/Pulse R
47. Use to switch to the process display.
General Alarm, Min. Flowrate
Exit Select Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE
Only available for
FEP500 / FEH500 are:
IMPORTANT (NOTE)
Gas Bubble, Conductivity,
• For additional information regarding operation of the LCD display, refer to chapter "8.1
Coating, Sensor Temp
„Operation".
DO1 Action Active, Passive Passive
• For detailed descriptions of all menus and parameters, see chapter 8.4 „Description of
parameters“. DO2 Alarm Config F/R Signal, Pulse R, General F/R Signal
Alarm, Min. Flowrate Alarm,
Max. Flowrate Alarm, Empty
The LCD display is provided with capacitive control buttons. These enable you to control the Pipe, TFE
device through the glass of the closed cover.
Only available for
FEP500 / FEH500 are:
IMPORTANT (NOTE)
Gas Bubble, Conductivity,
The transmitter automatically calibrates the capacitive control buttons on a regular basis. If the Coating, Sensor Temp
cover should be opened during operation, the buttons' sensitivity is at first increased. As a
result, operating errors may occur. The button sensitivity will return to normal during the next
automatic calibration.

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Commissioning Commissioning
7.6 Flowmeter sizes, flow range
Possible parameter settings Factory setting
The flow range end value can be set between 0.02 x QmaxDN and 2 x QmaxDN.
Digital Input Setup No Function, Totalizer Flowrate to Zero
Reset(All), Flowrate to Zero, Nominal diameter Min. flow range end value QmaxDN Max. flow range end value
System Zero Adjust, Totalizer DN " 0.02 x QmaxDN (≈ 0.2 m/s) 0 … ≈ 10 m/s 2 x QmaxDN (≈ 20 m/s)
Stop(All), Only available for 1 1/25 0,012 l/min (0,0032 US gal/min) 0,6 l/min (0,16 US gal/min) 1,2 l/min (0,32 US gal/min)
FEP500 / FEH500 are:
1,5 1/16 0,024 l/min (0,0063 US gal/min) 1,2 l/min (0,32 US gal/min) 2,4 l/min (0,63 US gal/min)
Dual Range, Start/Stop
2 1/12 0,04 l/min (0,0106 US gal/min) 2 l/min (0,53 US gal/min) 4 l/min (1,06 US gal/min)
Batching
3 1/10 0.08 l/min (0.02 US gal/min) 4 l/min (1.06 US gal/min) 8 l/min (2.11 US gal/min)
Current Output 4 … 20 mA, 4 … 12 … 20 mA 4 - 20 mA 4 5/32 0.16 l/min (0.04 US gal/min) 8 l/min (2.11 US gal/min) 16 l/min (4.23 US gal/min)
Iout at Alarm High Alarm, can be set to High Alarm, 21.8 mA 6 1/4 0.4 l/min (0.11 US gal/min) 20 l/min (5.28 US gal/min) 40 l/min (10.57 US gal/min)
21 … 23 mA or 8 5/16 0.6 l/min (0.16 US gal/min) 30 l/min (7.93 US gal/min) 60 l/min (15.85 US gal/min)

Low Alarm, can be set to 10 3/8 0.9 l/min (0.24 US gal/min) 45 l/min (11.9 US gal/min) 90 l/min (23.78 US gal/min)
For details refer to Section
3.5 … 3.6 mA 15 1/2 2 l/min (0.53 US gal/min) 100 l/min (26.4 US gal/min) 200 l/min (52.8 US gal/min)
9.2.
20 3/4 3 l/min (0.79 US gal/min) 150 l/min (39.6 US gal/min) 300 l/min (79.3 US gal/min)
Iout at Flow >103% Off (no signaling, current Off 25 1 4 l/min (1.06 US gal/min) 200 l/min (52.8 US gal/min) 400 l/min (106 US gal/min)
output holds 20.5 mA), High 32 1 1/4 8 l/min (2.11 US gal/min) 400 l/min (106 US gal/min) 800 l/min (211 US gal/min)
Alarm, Low Alarm 40 1 1/2 12 l/min (3.17 US gal/min) 600 l/min (159 US gal/min) 1200 l/min (317 US gal/min)
Low Flow Cut Off 0 … 10 % 1% 50 2 1.2 m3/h (5.28 US gal/min) 60 m3/h (264 US gal/min) 120 m3/h (528 US gal/min)
65 2 1/2 2.4 m 3/h (10.57 US gal/min) 120 m3/h (528 US gal/min) 240 m3/h (1057 US gal/min)
Empty Pipe Detector On / Off Off 80 3 3.6 m3/h (15.9 US gal/min) 180 m3/h (793 US gal/min) 360 m3/h (1585 US gal/min)
TFE Detector On / Off Off 100 4 4.8 m3/h (21.1 US gal/min) 240 m3/h (1057 US gal/min) 480 m3/h (2113 US gal/min)
125 5 8.4 m 3/h (37 US gal/min) 420 m3/h (1849 US gal/min) 840 m3/h (3698 US gal/min)
150 6 12 m3/h (52.8 US gal/min) 600 m 3/h (2642 US gal/min) 1200 m3/h (5283 US gal/min)
For PROFIBUS PA version 200 8 21.6 m3/h (95.1 US gal/min) 1080 m3/h (4755 US gal/min) 2160 m3/h (9510 US gal/min)
Possible parameter settings Factory setting 250 10 36 m3/h (159 US gal/min) 1800 m3/h (7925 US gal/min) 3600 m3/h (15850 US gal/min)
300 12 48 m3/h (211 US gal/min) 2400 m3/h (10567 US gal/min) 4800 m3/h (21134 US gal/min)
PA Addr. (BUS) 0 … 126 126
350 14 66 m3/h (291 US gal/min) 3300 m3/h (14529 US gal/min) 6600 m3/h (29059 US gal/min)
ID Nr Selector 0x9700, 0x9740, 0x3430 0x3430 400 16 90 m3/h (396 US gal/min) 4500 m3/h (19813 US gal/min) 9000 m3/h (39626 US gal/min)
450 18 120 m3/h (528 US gal/min) 6000 m3/h (26417 US gal/min) 12000 m3/h (52834 US gal/min)
500 20 132 m3/h (581 US gal/min) 6600 m3/h (29059 US gal/min) 13200 m3/h (58117 US gal/min)
600 24 192 m3/h (845 US gal/min) 9600 m3/h (42268 US gal/min) 19200 m3/h (84535 US gal/min)
700 28 264 m 3/h (1162 US gal/min) 13200 m3/h (58118 US gal/min) 26400 m3/h (116236 US gal/min)
760 30 312 m 3/h (1374 US gal/min) 15600 m3/h (68685 US gal/min) 31200 m3/h (137369 US gal/min)
800 32 360 m 3/h (1585 US gal/min) 18000 m3/h (79252 US gal/min) 36000 m3/h (158503 US gal/min)
900 36 480 m 3/h (2113 US gal/min) 24000 m3/h (105669 US gal/min) 48000 m3/h (211337 US gal/min)
1000 40 540 m 3/h (2378 US gal/min) 27000 m3/h (118877 US gal/min) 54000 m3/h (237754 US gal/min)
1050 42 616 m 3/h (2712 US gal/min) 30800 m3/h (135608 US gal/min) 61600 m3/h (271217 US gal/min)
1100 44 660 m 3/h (3038 US gal/min) 33000 m3/h (151899 US gal/min) 66000 m3/h (290589 US gal/min)
1200 48 840 m 3/h (3698 US gal/min) 42000 m3/h (184920 US gal/min) 84000 m3/h (369841 US gal/min)
1400 54 1080 m3/h (4755 US gal/min) 54000 m3/h (237755 US gal/min) 108000 m3/h (475510 US gal/min)
1500 60 1260 m3/h (5548 US gal/min) 63000 m3/h (277381 US gal/min) 126000 m3/h (554761 US gal/min)
1600 66 1440 m3/h (6340 US gal/min) 72000 m3/h (317006 US gal/min) 144000 m3/h (634013 US gal/min)
1800 72 1800 m3/h (7925 US gal/min) 90000 m3/h (396258 US gal/min) 180000 m3/h (792516 US gal/min)
2000 80 2280 m3/h (10039 US gal/min) 114000 m3/h (501927 US gal/min) 228000 m3/h (1003853 US gal/min)

OI/FEX300/FEX500-EN FEX300, FEX500 77 78 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization

8 Parameterization 8.2 Menu levels

Two levels exist under the process display.


8.1 Operation
The LCD display is provided with capacitive control buttons. These enable you to control the
device through the glass of the closed cover. Process display

IMPORTANT (NOTE)
The transmitter automatically calibrates the capacitive control buttons on a regular basis. If the
cover should be opened during operation, the buttons' sensitivity is at first increased. As a
result, operating errors may occur. The button sensitivity will return to normal during the next Information level Configuration level
automatic calibration.
Diagnostics Easy Setup
Operator Page 1 ... 3 Device Info
8.1.1 Menu navigation
Autoscroll Device Setup
Signals View Display
2 -----------------Menu---------------- 3
Input/Output

4 Process Alarm
Communication
5 Exit Select 5
Diagnostics
Totalizer
Fig. 63: LCD-indicator
1 Control buttons for menu navigation 4 Marker for indicating relative position
Fig. 64: Menu levels
2 Menu name within the menu
3 Menu number Process display
5 Function currently assigned to the
The process display shows the current process values.
and control buttons
Information level
The information level contains the parameters and information that are relevant for the user.
You can use the or control buttons to browse through the menu or select a number or
The device configuration cannot be changed on this level.
character within a parameter value.
Configuration level
Different functions can be assigned to the and control buttons. The function that is The configuration level contains all the parameters required for device commissioning and
currently assigned to them (5) is shown on the display. configuration. The device configuration can be changed on this level.

8.1.1.1 Control button functions Note


Meaning For a detailed description of the individual parameters and menus on the configuration level
refer to the sections 8.3 "Overview of parameters on the configuration level" and 8.4
Exit Exit menu "Description of parameters".
Back Go back one submenu
Cancel Cancel a parameter entry
Next Select the next position for entering numerical and alphanumeric values

Meaning

Select Select submenu / parameter


Edit Edit parameter
OK Save parameter entered

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Parameterization Parameterization
8.2.1 Process display 8.2.2 Switching to the information level (operator menu)

On the information level, the operator menu can be used to display diagnostic information and
choose which operator pages to display.
Process display
1. Use to switch to the information level.

Fig. 65: Process display (example) Operator Menu 2. Use or to select a submenu.
1 Measuring point identifier 3 Symbol indicating button function Diagnostics
Operator Page 1 3. Use to confirm your selection.
2 Current process values 4 Symbol indicating "Parameterization
protected" Operator Page 2
Back Select
The process display appears on the LC display when the device is switched on. It shows
information about the device and current process values.
The way in which the current process values (2) are shown can be adjusted on the configuration Menu Description
level.
8.2.1.1 Description of symbols ... / Operator Menu
Symbol Description Diagnostics Selects the "Diagnostics" submenu, see also Chapter
8.2.2.1 "Error messages on the LCD display".
Call up information level. Operator Page 1 Selects the operator page to be displayed
When Autoscroll mode is enabled, a P symbol appears here and the operator
pages are automatically displayed one after the other. Operator Page 2
Operator Page 3
Call up configuration level. Operator Page 4
The device is protected against changes to the parameter settings. Autoscroll When "Multiplex Mode" is enabled, this initiates automatic
switching of the operator pages on the process display.
Signals View Selects the "Signals View" submenu (for service, only).
Q Display of the current flowrate
Σ+ Totalizer status in forward direction
Σ- Totalizer status in reverse direction

OI/FEX300/FEX500-EN FEX300, FEX500 81 82 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization
8.2.2.1 Error messages on the LCD display 8.2.2.2 Invoking the error description
In case of an error, a message consisting of an icon and text appears at the bottom of the Additional details about the occurred error can be called up on the information level.
process display. The text displayed provides information about the area in which the error has Process display
occurred. 1. Use to switch to the information level.

Process display
Electronics

Electronics
Operator Menu 2. Use or , select the "Diagnostics" submenu.
Diagnostics
Operator Page 1 3. Use to confirm your selection.
Operator Page 2
The error messages are divided into four groups in accordance with the NAMUR classification
scheme: Back Select

Symbol Description
Error / Failure
Electronics The first line shows the area in which the error has
F123,321 occurred.
Functional check
Brief description
The second line shows the unique error number.
Information
Out of specification Back Exit The next lines show a brief description of the error and
information on how to remedy it.
Maintenance required

Note
Additionally, the error messages are divided into the following areas: For a detailed description of the errors and information on their remedy refer to Chapter 10
"Error messages".
Area Description
Electronics Error / alarm of the electronics.
Sensor Error / alarm of the flowmeter sensor.
Status Alarm due to the current device status.
Operation Error / alarm due to the current operating conditions.

OI/FEX300/FEX500-EN FEX300, FEX500 83 84 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization
g

8.2.3 Switching to the configuration level (parameterization) 8.2.4 Hardware write protection

The device parameters can be displayed and changed on the configuration level. In addition to password protection, it is possible to activate hardware write protection.
Process display
1. Use to switch to the information level. Transmitter with dual-compartment housing

Access Level 2. Use or to select the access level.


Read Only
Standard 3. Use to confirm your selection.
Advanced

Next OK

IMPORTANT (NOTE)
There are four access levels: For the "Standard" and "Advanced" levels you can define
passwords. There are no factory default passwords.
• On the „Read Only“ level all entries are disabled. Parameters are read only and cannot be
modified.
• On the "Standard" level you can edit all parameters described in Chapter 8.4 "Description
of parameters" except for those written in italics.
• On the "Advanced" level all parameters can be modified.
• The Service menu is reserved to the customer service.

Once you have logged on to the corresponding access level, you can edit or reset the
password. Resetting to the "No password defined" state is done by selecting "-" as the Transmitter with single-compartment housing
password. Fig. 66: Jumper for hardware write protection
A Integral mount design 1 Housing cover
Enter Password 4. Enter the corresponding password (see Chapter B Remote mount design 2 Jumper (BR902) for hardware write protection
******** "Selecting and changing parameters").
There is no factory default for the password. You can 1. Switch off power supply.
QRSTUVWXYZ 0123456 switch to the configuration level without entering a
Next OK
2. Open the housing cover.
password.
3. Remove the mounting screws for the transmitter electronics unit
The selected access level remains active for 3 minutes.
Within this time period you can toggle between the 4. Pull out the transmitter electronics unit
process display and the configuration level without re- 5. Set jumpers on backplane in accordance with the following table.
entering the password.
5. Use to confirm your password. Jumper Number Function
The LCD display now indicates the first menu item on the BR902 Read only Hardware write protection active
configuration level.
6. Use or to select a menu. 6. Reinstall the transmitter electronic unit in reverse order

7. Use to confirm your selection.

OI/FEX300/FEX500-EN FEX300, FEX500 85 86 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization
8.2.5 Selecting and changing parameters 8.2.5.3 Alphanumeric entry
When an alphanumeric entry is made, a value is set by entering the individual decimal
8.2.5.1 Entry from table positions.
When an entry is made from a table, a value is selected from a list of parameter values. -----Menu name---- 1. Select the parameters you want to set in the menu.
Menu name 1. Select the parameters you want to set in the menu. Parameter name
Parameter name Value currently set 2. Use to call up the parameter value for editing. The
Value currently set 2. Use to call up the list of available parameter position that is currently selected is highlighted.
values. The parameter value that is currently set is Next Edit
Next Edit highlighted.

-----Parameter name----
Parameter name ABC.......................... 3. Use to select the position to be changed.
3. Use or to select the required value.
Parameter 1 4. Use or to select the required character.
Parameter 2 4. Use to confirm your selection. ABCDEFGHIJKLMNOPQ
Parameter 3 Next OK 5. Use to select the next position.
This concludes the procedure for selecting a parameter
value. 6. If necessary, select and set other decimal positions
Cancel OK
using the same procedure as described in steps 3 and 4.
7. Use to confirm your setting.
This concludes the procedure for changing a parameter
8.2.5.2 Numerical entry
value.
When a numerical entry is made, a value is set by entering the individual decimal positions.
----Menu name---- 1. Select the parameters you want to set in the menu. 8.2.5.4 Exiting the setup
Parameter name
1 2 .3 4 5 6 [unit] 2. Use to call up the parameter for editing. The For some menu items, values must be entered. If you don't want to change the parameter, you
position that is currently selected is highlighted. can exit the menu as described below.
Next Edit

1 By pressing (Next) repeatedly you can move the cursor to the right. Once the cursor
reaches the end position, "Cancel" is displayed in the lower right.
-----Parameter name----
1 2 .3 4 5 6 [unit] 3. Use to select the decimal position to be changed. 2 With you can terminate editing and exit the menu item. With you can return to the
4. Use or to set the required value. start.

Next OK 5. Use to select the next decimal position.


6. If necessary, select and set other decimal positions IMPORTANT (NOTE)
using the same procedure as described in steps 3 and The LCD display automatically returns to the process display three minutes after the last
4. button has been actuated.
7. Use to confirm your setting.
This concludes the procedure for changing a parameter
value.

OI/FEX300/FEX500-EN FEX300, FEX500 87 88 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization
8.3 Overview of parameters on the configuration level
Analog Range Amplifier
IMPORTANT (NOTE)
This overview of parameters shows all the menus and parameters available on the device. Depending on the version Adjust CMReject CMR Value
and configuration of the device, not all of the menus and parameters may be visible on it.

Easy Setup 1 Language Adjust Gain 1...64 Adjust Gain 1


Q (Flowrate) Unit
Adjust Gain 8
Qmax
Adjust Gain 32
Totalizer/Pulse Unit Adjust Gain 64
Pulse Mode
Pulses per Unit Transmitter Device Version
Pulse Width ScanMaster Option
Damping Tx Typ
Iout at Alarm Tx Spanne
Low Alarm Value Tx Nullpunkt
High Alarm Value Offset Iout
Gain Iout
System Zero Manual Simulator
Automatic Transmitter ID
SAP / ERP Nr.
Cable length
Tx Version TX Firmware Ver
TX Hardware Ver
Device Info 2 Sensor Sensor Type TX Run Hours Com Controller Ver
Sensor Model
Bootloader Ver
Acquisition Sensor Size
QmaxDN
Qmax Calibration First Cal. Date
Qmax2 Last Cal. Date
Span Ss Manufacturer Cal. Cert. No.
Zero Sz Street First Cal. Location
User Span City Last Cal. Location
Mains Frequency Phone
Excitation Freq.
Coil Current
Pre-Amp Device Setup 3 Access Control Standard Password
Sensor ID
Advanced Password
SAP / ERP No.
Term Board S/W Read Only Switch
Sensor Run Hours Custody Switch
Calibration First Cal. Date
Last Cal. Date
Cal. Cert. No. Sensor QmaxDN
First Cal. Location Qmax
Last Cal. Location Qmax2
Cal. Mode Range Mode
Cal. Status Sensor Location TAG
Sensor TAG
Properties Electrode Material
Lining Material Transmitter Units Totalizer/Pulse Unit
Q (Flowrate) Unit
Damping Velocity Unit
Density Custom Vol. Type
Rate ADC Custom Vol. Factor
Custom Vol. String
Analog Reset Noise Reset Max
Custom Tot. Type
Noise-Reset ON
Custom Tot. Factor
Custom Tot. String
Driver Driver DAC
Loop Control Mode Low Flow Cut Off
Diff Current Control Flow Cut Off Level
Control Timer TX Location TAG Hysteresis
TX TAG

italics = Parameter can only be changed at the "advanced" password level.


italics = Parameter can only be changed at the "advanced" password level.

OI/FEX300/FEX500-EN FEX300, FEX500 89 90 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization

Operating Mode Meter Mode DO2 Alarm Config General Alarm,


Flow Indication Min. Flowrate Alarm,
Max. Flowrate Alarm,
System Zero Manual Adjust Empty Pipe
Auto Adjust TFE
Gas Bubble
Conductivity
Noise Reduction Off
Coating
Mean Filter
Sensor Temp
Notch Filter
Lowpass V=Auto
Lowpass V=1
DO2 Action Normally Open,
Normally Closed
Display 4 Language
Contrast
Pulse Setup Pulse Mode
Operator Pages Operator Page 1 Display Mode
1st Line Pulses per Unit
Autoscroll Operator Page 2 2nd Line Pulse Width
Flowrate Format 3st Line Limit Frequency
Volume Format Bargraph Fullscale Frequency
Operator Page 3
Date/Time Format
Display Test Digital Input Setup No Function,
Operator Page 4
Totalizer Reset(All),
Flowrate to Zero,
System Zero Adjust,
Input / Output 5 Digital Out Mode DO1 / DO2 Function Pulse F/Pulse R, Totalizer Stop(All)
Pulse F/Logic, Dual Range
Pulse VR/Logic, Start/Stop Batching
Logic/Logic

DO1 Drive Passive, Current Output Iout at Alarm High Alarm,


Active Low Alarm

Logic Setup DO1 Signal No Function, Low Alarm Value


F/R Signal, High Alarm Value
Alarm Signal Iout at EP Alarm
Dual Range Iout at Flow >103%
Batch end contact Iout at TFE Alarm
Iout Mode

DO1 Alarm Config General Alarm,


Min. Flowrate Alarm, italics = Parameter can only be changed at the "advanced" password level.
Max. Flowrate Alarm,
Empty Pipe
TFE
Gas Bubble
Conductivity
Coating
Sensor Temp

DO1 Action Normally Open,


Normally Closed

DO2 Signal No Function,


F/R Signal,
Alarm Signal
Dual Range
Batch end contact

italics = Parameter can only be changed at the "advanced" password level.

OI/FEX300/FEX500-EN FEX300, FEX500 91 92 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization

Process Alarm 6 Clear Alarm History FF


Show FF Address
AI1-Q Flowrate
Group Masking Maintenance Required
INT1-Q Flowrate
Function Check
AI2-Internal Tot Fwd
Out of Specification
AI3-Internal Tot Rev
AI4-Diagnostics
Individual Masking Min Flowrate Alarm AO-Density Adjust
Max Flowrate Alarm DI-Alarm Info
Flow >103% DO-Cyclic Control
Com Controller Alarm
TFE Alarm
Empty Pipe Alarm Diagnostics 8 Diagnosis Control Empty Pipe Detector Empty Pipe Detector
Adjust EP
Manual Adjust EP F.
Alarm Simulation Off Threshold
On Detector EP Value

Communication 7 HART Device Address Sensor Measurements


HART Tag Sensor Measurements
HART Descriptor One shot Sensor Mea
HART Message Coil Current
HART Manf. ID Coil Resistor
HART Device ID Coil Voltage
Last HART Command Coil R. Max Alarm
Coil R. Min Alarm
Signal-Cable length
Cyclic Data Out Cyclic Upd. Rate Sensor Temp Value
Adj. Sensor T. Value
Sensor T. Min Alarm
Cyclic Upd. Select Flow Group Sensor T. Max Alarm
Outputs Group
Status Group
Coil Group Gas Bubble Detector Gas Bubble Detector
TX Group Adjust Gas Bubble
Vol. Totals Group Threshold Gas Bubble
Electrodes Group Gas Bubble Value

Coating Detector Coating Detector


Service Port Max Baud Rate
HART Access One shot Coating
Coating Value QE1
Coating Value QE2
PROFIBUS PA PA Addr. (BUS)
Coating QE Min Alarm
Ident Nr. Selector
Coating QE Max Alarm
Comm State
AI1-Q Durchfluss
TOT1-Q Durchfluss Cond. Detection
TOT2-Q Durchfluss Cond. Detection
AI2-Interner Tot Vor One shot Cond.
AI3-Interner Tot Rev Cond. Value
AI4-Diagnose Adj. Cond. Value
AI4-Channel Cond. Min Alarm
AO-Dichte Cond. Max Alarm
DI-Alarm Info Elec. Imp. E1-GND
DI-Channel Elec. Imp. E2-GND
DO-Cyclic Control Elec. Imp Min Alarm
DO-Channel Elec. Imp Max Alarm

italics = Parameter can only be changed at the "advanced" password level.


italics = Parameter can only be changed at the "advanced" password level.

OI/FEX300/FEX500-EN FEX300, FEX500 93 94 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization

Grounding Check Grounding Check Trend Conductivity


Power Spectrum Electrode Coat. QE1
Amplitude 1 Value Electrode Coat. QE2
Amplitude 2 Value Logtime Interval
Amplitude 3 Value Trend-Logging
Amplitude 4 Value
Flowrate Alarm Max. Flowrate Alarm
TFE Detector TFE Detector Min. Flowrate Alarm
Adjust TFE Full
SIL detector TFE Threshold Simulation Mode Off, Flow Simulation,
TFE Value Q [Unit],
Q [%],
CurrentOut,
Diagnosis Values
SNR Value Pulse on DO1,
Slope Value Pulse on DO2,
Slope Variation Logic on DO1,
Reference Logic on DO2,
Signal Ratio HART Freq,
Signal max Digital input
Signal min
NV Resets/sec
Amplification Int.

Fingerprints Factory F.P. Output Readings Current


Sensor Coil R. DO1 Frequency
Elec. Coat. QE1 DO1 State
Elec. Coat, QE2 Digital In State
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s Totalizer 9 Reset Vol. Totals Totalizer Fwd
Totalizer Rev
Totalizer Net
Startup F.P. All Vol. Totalizer
Startup F.P.
Sensor Coil R
Elec. Coat. QE1 Batching Damping
Elec. Coat. QE2 Preset Batch Tot.
Elec. Imp. E1-GND Lag Corr. Mode
Elec. Imp. E2-GND Lag Corr. Quantity
Start Tx Startup F.P Batch Tot.
Tx check CMR Total Batch Counter
Tx check 5 m/s Reset Batch Counter
Tx check 10 m/s Start/Stop Batching

On demand F.P.
Start On demand F.P. Edit Vol. Totals Edit Totalizer Fwd
Sensor Coil R Edit Totalizer Rev
Elec. Coat. QE1 Edit Totalizer Net
Elec. Coat. QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND italics = Parameter can only be changed at the "advanced" password level.
Start Tx Startup F.P
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s

italics = Parameter can only be changed at the "advanced" password level.

OI/FEX300/FEX500-EN FEX300, FEX500 95 96 FEX300, FEX500 OI/FEX300/FEX500-EN


Parameterization Parameterization
8.4 Description of parameters
Menu / Parameter Value range Description
8.4.1 Menu: Easy Setup
Easy Setup (continued) "Easy Setup" Menu
Menu / Parameter Value range Description
Pulse Width 0.1 ... 2000 ms Select the pulse width for the digital output. The pulse
factor and pulse width are interdependent and are
Easy Setup "Easy Setup" Menu calculated dynamically.
Language Deutsch, English, Français, Select the menu language. Damping 0.02 ... 60 s Select the damping.
Español, Italiano, Dansk, The value set here relates to 1 Τ (Tau).
Svenska, Polski, Russki, The value refers to the response time for a step
Zhongweng, Turkce flowrate change. It affects the instantaneous value in
Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; Select the unit for the flow indicator. the display and at the current output.
m3/s; m3/min; m3/h; m3/d; Default setting: l/min Default setting: 1 second
Ml/d; ft3/s; ft3/min; ft3/h; ft3/d; Iout at Alarm Low, High Status of the current output during an error.
ugal/s; ugal/min; ugal/h; The “low” or “high” status is set in the subsequent
ugal/d; Mugal/d; igal/s; menu.
igal/min; igal/h; igal/d; bls/s;
Default setting: "High".
bls/min; bls/h; bls/d; hl/h; g/s;
g/min; g/h; kg/s; kg/min; kg/h; Low Alarm Value 3.5 ... 3.6 mA Current for Low Alarm.
kg/d; t/min; t/h; t/d; lb/s; Default setting: 3.5 mA
lb/min; lb/h; lb/d; custom/s High Alarm Value 21 ... 23 mA Current for High Alarm.
Qmax Min. flow range: 0 ... 0.2 m/s Select the flow range for forward and reverse flow. Default setting: 21.8 mA
(0 ... 0.02 x Q maxDN) Default setting: 1 x Q maxDN. System Zero Select the "System Zero" submenu.
Max. flow range: 0 ... 20 m/s italics = Parameter can only be viewed at the "Advanced" password level.
(0 ...2 x Q max DN)
Totalizer/Pulse Unit m3; l; ml; ft3; hl; g; kg; t; lb; Select the unit for the flowmeters. 1) Parameter / menu only available for FEP500 / FEH500.
igal; ugal; bls; Ml; Mugal; Default setting: l
custom
Operation Pulse Mode, Fullscale Select the operating mode for the digital output.
Frequency There are two operating modes available:
• „Pulse Mode“: In pulse mode, pulses per unit are
output (e.g., 1 pulse per m 3).
• „Fullscale Frequency“: In frequency mode, a
frequency proportional to the flowrate is output.
The maximum frequency corresponding to the flow
range end value is configurable (max. 5.25 kHz).
Default setting: „Pulse Mode“
Pulses per Unit - Display of the pulses per unit output by the digital
output. The max. possible number of pulses is 5250
per second.
Fullscale Frequency 0 ... 5250 Hz Set the frequency for the flow range end value in
Fullscale Frequency operating mode.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.2 Menu: Device Info
Menu / Parameter Value range Description
IMPORTANT (NOTE)
This menu is used only to display the device parameters. The parameters are displayed
Easy Setup (continued) "Easy Setup" Menu
independently of the configured access level, but cannot be changed.
Cable length 0.01 ... 200 m Enter the signal cable length between the transmitter
and the flowmeter sensor.
Menu / Parameter Value range Description
For devices with a compact design
(FEP311, FEH311, FEP315, FEH315) 0.01 m must be
entered. Device Info
IMPORTANT (NOTE) Sensor Select the "Sensor" submenu.
The entry is required for FEP500, FEH500 if the Acquisition Select the "Acquisition" submenu.
diagnostic functions are to be used.
Analog Range Select the "Analog Range" submenu.
When using the ScanMaster verification software
you also have to enter the signal cable length. Transmitter Select the "Transmitter" submenu.

Easy Setup / System Zero Submenu "System Zero" Device Info / Sensor
Manual Starts the manual zero adjustment. Sensor Type - Type of flowmeter sensor (ProcessMaster 300 / 500,
Automatic Starts the automatic zero adjustment. HygienicMaster 300 / 500).
IMPORTANT (NOTE)
IMPORTANT (NOTE)
When commissioning the device, make sure that
Prior to starting the zero adjustment, make sure
the transmitter is assigned to the sensor
that:
correctly. It is not possible to operate a flowmeter
• There is no flow through the flowmeter sensor sensor of the 300 series with a transmitter of the
(close all valves, shut-off devices, etc.) 500 series.
• The flowmeter sensor is completely filled with Sensor Model - Indication of model number (e.g., FEP315)
the fluid to be measured.
Sensor Size - Size of sensor.
italics = Parameter can only be viewed at the "Advanced" password level. QmaxDN - This value is the maximum flow at a velocity of 10
m/s.
1) Parameter / menu only available for FEP500 / FEH500.
The value is set automatically via the selected
flowmeter size.
Qmax - Set flow range end value for flow range 1.
Factory setting: Flow range 1 activated.
Qmax2 - Set flow range end value for flow range 2.
Factory setting: Flow range 2 deactivated.
IMPORTANT (NOTE)
The switchover between the two measuring
ranges is done via the digital input or via the
menu "Config. Device / Sensor / 2 flow ranges“
Span Ss - Calibration value for the sensor (span)
Zero Sz - Calibration value for the sensor (zero)
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Device Info / Sensor Device Info / Acquisition


User Span Indication of the correction value for the sensor span Rate ADC - Display for service purposes, only.
Mains Frequency - Mains frequency for the supply power. Analog Reset Select the "Analog Reset" submenu.
Excitation Freq. - Frequency used to operate the magnet coils of the Driver Select the "Driver" submenu.
flowmeter sensor.
Coil Current - Current used to operate the magnet coils of the
flowmeter sensor. Device Info / Acquisition / Analog Reset
Pre-Amp - Indication whether a preamplifier exists in the Noise Reset Max - Display for service purposes, only.
flowmeter sensor or not (Yes / No). Noise Reset On -
Sensor ID - ID number of the sensor.
SAP / ERP No. - Order number of the sensor. Device Info / Acquisition / Driver
Term Board S/W - Software version of the sensor memory integrated in Driver DAC - Display for service purposes, only.
the sensor.
Loop Control Mode -
Sensor Run Hours - Run hours of the flowmeter sensor. Diff Current Control -
Calibration Select the "Calibration" submenu.
Control Timer -
Properties Select the "Properties" submenu.
Device Info / Analog Range
Device Information / Sensor / Calibration Amplifier - Display for service purposes, only.
First Cal. Date - Date of first calibration of sensor (calibration of new Adjust CMReject Select the "Adjust CMReject" submenu.
device). Adjust Gain 1 ... 64 Select the "Adjust Gain" submenu.
Last Cal. Date - Date of last calibration of sensor.
Cal. Cert. No. - Identification (no.) of the relevant calibration
certificate. Device Info / Analog Range / Adjust CMReject
First Cal. Location - Place of first calibration of the sensor. CMR Value - Display for service purposes, only.
Last Cal. Location - Place of last calibration of sensor.
Cal. Mode - Calibration mode of the sensor. Device Info / Analog Range / Adjust Gain 1 ... 64
Cal. Status - Calibration status of the sensor. Adjust Gain 1 - Display for service purposes, only.
Adjust Gain 8
Device Info / Sensor / Properties Adjust Gain 16
Electrode Material - Electrode material of the sensor. Adjust Gain 64
Lining Material - Liner material of the sensor. italics = Parameter can only be viewed at the "Advanced" password level.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.3 Menu: Device Setup
Menu / Parameter Value range Description
Menu / parameter Value range Description
Device Info / Transmitter
Device Version Indication of the transmitter series (300 HART series, Device Setup
300 PA series, 300 FF series, 500 HART series, 500 ....Access Control Select the "....Access Control" submenu.
PA series, 500 FF series)
....Sensor Select the "....Sensor" submenu.
Scanmaster option Indication whether the ScanMaster option is activated
or not. ....Transmitter Select the "....Transmitter" submenu.
For diagnostics or verification, the device can be
checked with a separate tool (ScanMaster). This
option is available for an extra charge and must be Device Setup / ....Access Control
activated in the transmitter. Standard Password Alphanumeric Enter / change the password for the "Standard"
TX Type - Display the transmitter type. access level.
TX Span - Calibration value for the transmitter (span) Advanced Password Alphanumeric Enter / change the password for the "Advanced"
TX Zero - Calibration value for the transmitter (zero) access level.
Offset Iout Indication of the adjustment value for the current Read Only Switch Display only (ON / OFF) Display of switch position of BR902 (hardware write
output (zero). protection).
Gain Iout Indication of the adjustment value for the current See Chapter 8.2.4 "Hardware write protection" on
output (span). page 86.
Simulator Display for service purposes, only. Custody Switch Display only (ON / OFF) Display of the switch position of the calibration circuit
breaker
Transmitter ID - ID number of the transmitter.
(must be activated for calibrated devices).
SAP / ERP No. - Order number of the transmitter.
TX Version Select the "TX Version" submenu.
Device Setup / ....Sensor
TX Run Hours - Run hours of the transmitter. Read only The displayed value is the flow rate at a flow velocity
QmaxDN
Calibration Select the "Calibration" submenu. of 10 m/s. The value is determined automatically via
Manufacturer - Name of manufacturer the selected nominal diameter.
Street - Address of manufacturer (street). Qmax Min. measuring range: Select the upper range value measuring range 1) for
0 ... 0.2 m/s forward and reverse flow.
City - Address (town) of manufacturer.
(0 ... 0.2 x QmaxDN) Default setting: 1 x Q maxDN.
Phone - Phone number of manufacturer
Max. measuring range:
0 ... 20 m/s (0 ...2 x Q maxDN)
Device Info / Transmitter / TX Version
Qmax2 See Q max Select the upper range value measuring range 2) for
TX Firmware Ver. - Software version of the transmitter. forward and reverse flow.
TX Hardware Ver. - Hardware version of the transmitter. Default setting: 1 x Q maxDN, measuring range 2 is
Com-Controller Ver. - Software version of the COM controller. deactivated.
Bootloader Ver. - Software version of the bootloader. IMPORTANT (NOTE)
The switchover between the two measuring
Device Info / Transmitter / Calibration ranges is performed via the digital input or via the
First Cal. Date - Date of first calibration for transmitter (calibration of menu "Device Setup / ....Sensor / Range Mode".
new device). italics = Parameter can only be viewed at the "Advanced" password level.
Last Cal. Date - Date of last calibration of transmitter.
Cal. Cert. No. - Identification (no.) of the relevant calibration 1) Parameter / menu only available for FEP500 / FEH500.
certificate.
First Cal. Location - Place of first calibration for the transmitter.
Last Cal. Location - Place of last calibration of transmitter.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / parameter Value range Description Menu / parameter Value range Description

Device Setup / ....Sensor (continued) Device Setup / ....Transmitter / ....Units


Range Mode Qmax enabled Manual switchover between flow ranges Qmax and Totalizer/Pulse Unit m3, l, ml, ft3, hl, g, kg, t, lb, Select the unit for the flowmeters.
Qmax2. igal, ugal, bls, Ml, Mugal, IMPORTANT (NOTE)
Qmax2 enabled
customer-specific unit
If a mass flow unit is selected, the corresponding
Sensor Location TAG Alphanumeric, max. Enter the measuring point tag of the sensor (the density must be set in the "Device Setup /
20 characters measuring point tag is shown in the upper left-hand ....Transmitter / Density" menu.
corner of the process display).
Q (Flowrate) Unit l/s, l/min, l/h, ml/s, ml/min, Select the unit for the flow indicator.
Sensor TAG Alphanumeric, max. Enter the TAG number of the sensor. m3/s, m3/min, m3/h, m3/d, IMPORTANT (NOTE)
20 characters
Ml/d, ft3/s, ft3/min, ft3/h, ft3/d,
If a mass flow unit is selected, the corresponding
ugal/s, ugal/min, ugal/h,
density must be set in the "Device Setup /
Device Setup / ....Transmitter ugal/d, Mugal/d, igal/s,
....Transmitter / Density" menu.
Select the "....Units" submenu. igal/min, igal/h, igal/d, bls/s,
....Units
bls/min, bls/h, bls/d, hl/h, g/s,
Damping 0,02 ... 60 s Set the damping (the value relates to 1 T (Tau). g/min, g/h, kg/s, kg/min, kg/h,
The value relates to a step flow rate change. kg/d, t/min, t/h, t/d, lb/s,
It affects the instantaneous value in the display and at lb/min, lb/h, lb/d, customer-
the current output. specific unit
Default setting: 1 second Velocity Unit m/s, m/min, cm/s, cm/min, Select the unit for the display of the flow velocity.
Density 0,01 ... 5,0 g/cm³ If the flow is measured and indicated in the units g/s, feet/s, feet/min, inch/s,
g/min, g/h, kg/s, kg/min, kg/h, kg/d, t/min, t/h, t/d, lb/s, inch/min
lb/min, lb/h and lb/d, a fixed density must be taken into Custom Vol. Type Volume flow Select whether the user-defined flow unit is displayed
account for the calculations. Mass flow as a mass flow rate (with density) or volume flow rate
To convert the flow rate to mass flow units, a density (without density).
value from 0.01 to 5.0 g/cm³ can be entered. IMPORTANT (NOTE)
....Low Flow Cut Off Select the "....Low Flow Cut Off" submenu. If a mass flow unit is selected, the corresponding
density must be set in the "Device Setup /
TX Location TAG Alphanumeric, max. Enter the measuring point tag for the transmitter.
....Transmitter / Density" menu.
20 characters
Custom Vol. Factor 0,0001 ... 100000 l/s Enter the factor for a user-defined flow unit. The factor
TX TAG Alphanumeric, max. Enter the TAG number for the transmitter. relates to the flow per liter.
20 characters
Custom Vol. String Alphanumeric, max. Enter the name for the user-defined flow unit.
....Operating Mode Select the "....Operating Mode" submenu.
20 characters
....System Zero Select the "....System Zero" submenu.
Custom Tot. Type Volume flow Select whether the user-defined totalizer unit is
Noise Reduction Off Activates noise reduction in case of unstable flow Mass flow displayed as a mass flow rate (with density) or volume
signal. Activating noise reduction increases the flow rate (without density).
Mean Filter
response time. IMPORTANT (NOTE)
Notch Filter Factory setting: Off If a mass flow unit is selected, the corresponding
Lowpass V=Auto
density must be set in the "Device Setup /
Lowpass V=1 ....Transmitter / Density" menu.
italics = Parameter can only be viewed at the "Advanced" password level. Custom Tot. Factor 0,0001 ... 100000 l Enter the factor for a user-defined totalizer unit. The
factor relates to the flow per liter.
1) Parameter / menu only available for FEP500 / FEH500. Custom Tot. String Alphanumeric, max. Enter the name for the user-defined totalizer unit.
20 characters
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.4 Menu: Display
Menu / parameter Value range Description
Menu / Parameter Value range Description
Device Setup / ....Transmitter / ....Low Flow Cut Off
Display
Threshold 0 ... 10 % Select the switching threshold for leak flow volume
monitoring. Language Deutsch, English, Français, Select the menu language.
If the flow rate is below the switching threshold, there Español, Italiano, Dansk,
is no flow measurement. The current output is set to Svenska, Polski, Russki,
zero. Zhongweng, Turkce
The switching threshold for low flow monitoring is Contrast 0 ... 100 % Contrast setting for the LCD display
dependent on the currently set measuring range. Operator Pages Select the "Operator Pages" submenu.
Default setting: 1 %
IMPORTANT (NOTE)
Hysteresis 0 ... 50 % Set the hysteresis for the leak flow volume.
Up to four user-specific operator pages (layouts)
can be configured for the process display. If
Device Setup / ....Transmitter / ....Operating Mode several operator pages have been configured,
these can be scrolled manually. In the factory
Meter Mode Forward only, Forward and Setting of the measuring direction for the sensor.
setting only Operator Page 1 is enabled.
Reverse • "Forward only": The device measures and counts
in the forward direction only Autoscroll On / Off If Multiplex mode is enabled, you can also activate the
• "Forward and Reverse": The device measures and "Autoscroll" function on the information level.
counts in both directions In this function, operator pages appear on the LCD
Default setting: "Forward and Reverse" window in ten-second intervals. Manual scrolling
through pre-configured operator pages as described
Flow Indication Normal, Reverse Inverts the flow direction displayed. above is no longer necessary.
Default setting: "Normal" When Autoscroll mode is enabled, the P icon is
displayed on the lower left.
Device Setup / ....Transmitter / ....System Zero Default setting: Off
Manual Adjust -50 ... +50 mm/s Enter the flow velocity for system zero. Flowrate Format x, x.x, x.xx, x.xxx, x.xxxx Select the decimal places for the flow indicator.
Starts the automatic zero point balancing. Default setting: x.xx
Auto Adjust
Volume Format x, x.x, x.xx, x.xxx, x.xxxx Select the decimal places for the flow totalizer.
IMPORTANT (NOTE) Factory setting: x.xx
Prior to starting the zero point balancing, make Date/Time Format DD-MM-YYYY, MM-DD- Set the display format for the date and time. Factory
sure that: YYYY, YYYY-MM-DD setting: YYYY-MM-DD
• There is no flow through the sensor (close all Display Test Start the test of the LCD display with "OK".
valves, shut-off devices etc.)
• The sensor is completely filled with the
medium to be measured Display / Operator Pages
italics = Parameter can only be viewed at the "Advanced" password level. Operator Page 1 Select the "Operator Page 1" submenu.
Operator Page 2 Select the "Operator Page 2" submenu.
1) Parameter / menu only available for FEP500 / FEH500.
Operator Page 3 Select the "Operator Page 3" submenu.
Operator Page 4 Select the "Operator Page 4" submenu.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.5 Menu: Input/Output
Menu / Parameter Value range Description
Menu / parameter Value range Description
Display / Operator Pages / Operator Page 1 (n)
Input/Output
Display Mode • 1 line with 6 characters. Configure each operator page. The following variants
• 1 line with 6 characters + in the value range can be selected: ....Digital Out Mode Select the "....Digital Out Mode" submenu.
bar graph. Select the "....Logic Setup" submenu.
....Logic Setup
• 1 line with 9 characters.
• 1 line with 9 characters + ....Pulse Setup Select the "....Pulse Setup" submenu.
bar graph. Select the operating mode for the digital output. There
Digital Input Setup No Function, Totalizer
• 2 lines with 9 characters. are four operating modes available:
Reset(All), Flowrate to Zero,
• 2 lines with 9 characters + System Zero Adjust, Totalizer • Totalizer reset for all totalizers (forward, reverse
bar graph. Stop(All), Dual Range, and difference totalizer)
• 3 lines with 9 characters Start/Stop Batching 1) • External switch-off
(factory default). • External zero point balancing
• Graphic (line recorder) • External totalizer stop for all totalizers (forward,
• Off (the option disables the reverse and difference totalizer)
respective operator page) • Switchover between measuring ranges 1 and 2
1st Line • Flowrate [%] Select the value displayed in each line. The following (Qmax and Qmax2)
• Flowrate [Unit] variants in the value range can be selected:
• Start / stop of the fill function (batch) 1).
• Totalizer Fwd
Default setting: external switch-off
• Totalizer Rev
• Totalizer Net IMPORTANT (NOTE)
• Flow Velocity [Unit] If the fill operation is stopped before the set fill
2nd Line quantity is reached, the fill totalizer is set to zero.
• Current Output [mA]
• SignalProportion When the fill function is restarted, the interrupted
fill operation is not continued.
• Reference
• Signal Max Current Select the "Current" submenu.
• Signal Min italics = Parameter can only be viewed at the "Advanced" password level.
3st Line • Amplification
• Noise Reset Counter 1) Parameter / menu only available for FEP500 / FEH500.
• Total Batch Counter 1
• Batch Totalizer 1
• Conductivity 1
• Sensor Temp 1
Bargraph • Flowrate [%] Select the value displayed in the bar graph. The
• Current Output [mA] measuring values in the value range can be selected.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / parameter Value range Description Menu / parameter Value range Description

Input/Output / ....Digital Out Mode Input/Output / ....Logic Setup


DO1/DO2 Function Pulse F/Pulse R, Pulse Select the functions for the digital outputs DO1 and DO1 Signal No Function, F/R Signal, The menu is displayed only if the binary / binary
F/Logic, Pulse FR/Logic, DO2. Alarm Signal, Dual Range 1, function is set in the "Function DO1 / DO2" menu.
Logic/Logic • Pulse F/Pulse R: Batch end contact 1 This menu is not displayed in the factory setting.
- DO1 = Pulse output for the forward direction. • F/R Signal:
- DO2 = Pulse output for the reverse direction. The digital output signals the flow direction.
• Pulse F/Logic: • Alarm Signal:
The digital output functions as an alarm output.
- DO1 = Pulse output for the forward direction. The alarm type is set in the "DO1 Alarm Config"
- DO2 = Binary output. menu.
• Pulse FR/Logic: • Range Mode:
- DO1 = Pulse output for the forward and reverse The digital output is activated when measuring
direction. range 2 (Qmax2) is selected
- DO2 = Binary output.
• Batch end contact:
• Logic/Logic: The digital output is activated when the set fill
- DO1 = Binary output. quantity is reached
- DO2 = Binary output. Default setting: forward / reverse signal.
Default setting: pulse VR / binary. .... DO1 Alarm Config Select the ".... DO1 Alarm Config" submenu.
IMPORTANT (NOTE) The menu is displayed only if the "Alarm Signal"
The function for the binary outputs is defined in function is set in the "DO1 Signal" parameter.
the "....Logic Setup" menu. DO1 Action Normally Open, Normally Select the switching behavior for the digital output.
DO1 Drive Passive, Active The digital output DO1 can be configured as an Closed Default setting: Normally Open.
"active" or "passive" output. For information on the Refer to the description "DO1 Signal".
DO2 Signal No Function, F/R Signal,
current configuration, refer to the order confirmation.
Alarm Signal, Dual Range 1,
Default setting: passive Batch end contact 1
IMPORTANT (NOTE) Select the ".... DO2 Alarm Config" submenu.
.... DO2 Alarm Config
In the case of devices with a transmitter with The menu is displayed only if the "Alarm Signal"
single-compartment housing and devices for use function is set in the "DO2 Signal" parameter.
in Zone 1, Div. 1, this parameter is disabled.
DO2 Action Normally Open, Normally Refer to the description "DO1 Action".
In the case of devices with a transmitter with
single-compartment housing, configuration is Closed
performed via jumpers on the transmitter italics = Parameter can only be viewed at the "Advanced" password level.
backplane (refer to the "Commissioning" 1) Parameter / menu only available for FEP500 / FEH500.
chapter).
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / parameter Value range Description Menu / parameter Value range Description

Input/Output / ....Logic Setup / .... DO1 Alarm Config Input/Output / Current


General Alarm ON / OFF Each alarm can be activated separately. This allows Iout at Alarm High Alarm, Select the status of the current output in error
Min Flowrate Alarm ON / OFF for individual configuration when the digital output condition.
Low Alarm
Max Flowrate Alarm DO1 signals an alarm. The output "low" or "high" current is set in the
ON / OFF
subsequent menu.
Empty Pipe Alarm ON / OFF
Default setting: "High".
TFE ON / OFF
Low Alarm Value 3,5 ... 3,6 mA Select the current for Low Alarm.
Gas Bubble 1) ON / OFF Default setting: 3.5 mA.
Conductivity 1) ON / OFF
Coating 1) ON / OFF High Alarm Value 21 ... 23 mA Select the current for High Alarm.
Sensor Temp 1) ON / OFF Factory setting: 21.8 mA.
Iout at EP Alarm Off, Q=0%, Select the status of the current output for an empty
meter tube.
Input/Output / ....Logic Setup / .... DO2 Alarm Config High Alarm,
• Off:
- - Refer to the description ".... DO1 Alarm Config". Low Alarm
Error is not output at the current output.
• Q = 0 %:
Input/Output / ....Pulse Setup The current output assumes the value for "No
Operating mode The menu is displayed only if a pulse ... function has flow".
Pulse Mode, Fullscale
Frequency been selected under "Input/Output / ....Digital Out • High Alarm:
Mode / DO1/DO2 Function". The current output assumes the value for "High
Select the operating mode for the digital output. Alarm".
There are two operating modes available: • Low Alarm:
• In pulse mode, pulses per unit are output The current output assumes the value for "Low
(e.g. 1 pulse per mPulse Mode3) Alarm".
• "Fullscale Frequency": In frequency mode, a Default setting: Off.
frequency proportional to the flow rate is output. Select the status of the current output for overshoot of
Iout at Flow >103% Off, High Alarm, Low Alarm
The maximum frequency corresponding to the the upper range value.
upper range value is configurable (max. 5 kHz).
• Off:
Default setting: "Pulse Mode"
Error is not output at the current output.
Pulses per Unit 1 ... 5250/s Set the pulses per unit in the "Pulse Mode" operating
• High Alarm:
mode.
The current output assumes the value for "High
Pulse Width 0.1 ... 2000 ms Set the pulse width in the "Pulse Mode" operating Alarm".
mode. The pulse factor and pulse width are
• Low AlarmThe current output assumes the value
interdependent and are calculated dynamically.
for "Low Alarm".
Limit Frequency Read only Display of the limiting frequency for the pulse output.
Default setting: Off.
Fullscale Frequency 0 ... 5000 Hz Set the frequency for the upper range value in italics = Parameter can only be viewed at the "Advanced" password level.
"Fullscale Frequency" operating mode. 1) Parameter / menu only available for FEP500 / FEH500.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.6 Menu: Process Alarm
Menu / parameter Value range Description
Menu / Parameter Value range Description
Input/Output / Current (continued)
Process Alarm
Iout at TFE Alarm Off, Q=0%, Select the status that the current output shall assume
in the case of a partial filling alarm. Clear Alarm History - Allows you to clear the alarm list.
High Alarm,
• Off: Group Masking Select the "Group Masking" submenu.
Low Alarm
Error is not output at the current output. Individual Masking Select the "Individual Masking" submenu.
• Q = 0 %:
Alarm Simulation Off, ... A variety of alarm messages and output conditions
The current output assumes the value for "No
flow". can be simulated.
• High Alarm: For further information read and observe chapter
The current output assumes the value for "High “Alarm simulation”.
Alarm".
• Low Alarm:
Process Alarm / Group Masking
The current output assumes the value for "Low
Alarm". Maintenance Required On / Off Alarm messages are divided into groups. If masking is
Default setting: Off. Function Check On / Off activated for a group (On), no alarm occurs.
Iout Mode 4 ... 20 mA, 4 - 12 - 20 mA Select the operating mode for the current output. Out of Specification On / Off For further information read and observe Chapter
• 4 ... 20 mA "Error conditions and alarms".
- 4 mA = No flow
- 20 mA = Maximum flow Process Alarm / Individual Masking
• 4 - 12 - 20 mA Min Flowrate Alarm On / Off Individual alarm messages can also be masked.
- 4 mA = Maximum reverse flow Max Flowrate Alarm On / Off These are not included in the masking for the group. If
- 12 mA = No flow Flow >103% On / Off masking is activated for an alarm (On), no alarm
- 20 mA = Maximum forward flow occurs.
Com Controller Alarm On / Off
For further information read and observe chapter
italics = Parameter can only be viewed at the "Advanced" password level. TFE Alarm On / Off
"Error conditions and alarms".
1) Parameter / menu only available for FEP500 / FEH500. Empty Pipe Alarm On / Off
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.7 Menu: Communication
Menu / Parameter Value range Description
Menu / Parameter Value range Description
Communication / Cyclic Data Out / Cyclic Upd. Select
Communication
Flow Group ON / OFF Select the data to be output via the infrared service
HART Select the "HART" submenu. Contents: Q(%), Q(l/s), v(m/s) port. Diagnostic data is compiled in groups. Each
Cyclic Data Out Select the "Cyclic Data Out" submenu. Outputs Group ON / OFF group can be separately switched on or off, and
Contents: 20mA output thereby added to the diagnostic data set.
Service Port Select the "Service Port" submenu.
[Io(mA)], frequency at digital
PROFIBUS Select the "PROFIBUS" submenu. output DO1 [f1(Hz)],
The menu is displayed only for devices with frequency at digital output
PROFIBUS PA. DO2 [f2(Hz)]
FIELDBUS Foundation Select the "FF" submenu. Status Group ON / OFF
The menu is displayed only for devices with Contents: Alarm, Empty Pipe
FOUNDATION Fieldbus. Frequency [EPD (Hz)], TFE
Frequency [TFE (Hz)]
Communication / HART Coil Group ON / OFF
Contents: Coil current
Device Address 0 ... 15 Select the HART device address.
[Ic(mA)], Coil voltage [CV(V)],
The HART protocol has provisions for creating a bus Total coil resistance
with up to 15 devices (1 ... 15). [CR(Ohm)]
IMPORTANT (NOTE) TX Group Contents:
If an address greater than 0 is set, the device Reference voltage digits [Ref],
operates in multidrop mode. The current output is Differential signal at ADC
fixed at 4 mA. Apart from that, the current output [SP], SignalMax [SM],
is only used for HART communication. SignalMin [Sm], SignalError
Default setting: 0 from NR filter [SE], Signal DC
HART TAG 8 characters, uppercase only, Enter a HART TAG number as unique identifier for the errors [SDE], Internal
no special characters. device. amplification [Api], Signal to
noise ratio SNR
HART Descriptor 16 characters, uppercase Enter a HART descriptor.
only, no special characters. Vol. Totals Group ON / OFF
HART Message Display only. Display of the alphanumeric TAG number. Contents:
Forward totalizer [Fwd (m 3)],
HART Manf. ID Display only. Display of the HART manufacturer ID.
Reverse totalizer [Rev (m3)],
ABB = 26
Differential totalizer [Net (m 3)]
HART Device ID Display only. Display of the HART device ID.
Electrodes Group ON / OFF
FEX300 / FEX500 = 30
Contents: Electrode
Last HART Command Display only. Display of the most recently sent HART command. impedance E1 to ground [IE1
(kOhm)], Electrode
Communication / Cyclic Data Out impedance E2 to ground [IE2
(kOhm)], Deposit values of
Cyclic Upd. Rate 0,2 ... 3600 sec Set the interval for data output via the infrared service
electrode 1 [QE1] and aE1,
port
Electrode values of electrode
Default setting: 1 sec
2
IMPORTANT (NOTE) [QE2] and aE2, Gas bubble
For detailed information about how to use the value [Gasb], Conductivity
infrared service port refer to the separate [conduS], Sensor temperature
operating instructions OI/FZA100. [sensorT°C]
Cyclic Upd. Select Select the "Cyclic Upd. Select" submenu. italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Communication / Service Port Communication / PROFIBUS (continued) The menu is displayed only for devices with
Max Baud Rate 2400, 4800, 9600, 19200, Set the transmission rate (baud rate) for the infrared PROFIBUS PA.
38400 service port. AI1-Q Flowrate Display only Current flow in the selected unit from the Transducer
HART Access On / Off Activate / deactivate the infrared service port Block Flow, including status.
TOT1-Q Flowrate Display only Current totalizer status in the selected unit from the
Transducer Block Flow, including status.
Communication / PROFIBUS The menu is displayed only for devices with
PROFIBUS PA. TOT2-Q Flowrate Display only Current totalizer status in the selected unit from the
Transducer Block Flow, including status.
PA Addr. (-BUS-) 0 ... 126 The "PROFIBUS" is displayed only if this option has
AI2-Internal Tot Fwd Display only Current totalizer status of the forward totalizer in the
been ordered for the device. Displays the slave
selected unit from the Transducer Block Flow,
address.
including status.
Factory setting: 126
AI3-Internal Tot Rev Display only Current totalizer status of the reverse totalizer in the
Information about the DIP switches (transmitters with selected unit from the Transducer Block Flow,
dual-compartment housing only): including status.
• DIP switches 1 to 7 define the PROFIBUS AI4-Diagnostics Display only Current output value, including status. The channel
address, can be selected using the "AI4 Channel" parameter.
• DIP switch 8 defines the address mode:
This function block delivers active values for FEX500
• DIP switch 8 = Off = Addressing via bus or keypad
only. For this purpose, the sensor measurement or the
using the menus for the device. The message "-
conductivity measurement must be switched on. For
BUS-" is displayed.
FEX300 this function block delivers "0".
• DIP switch 8 = On = Addressing via DIP switches
1-7; the message "(HW Switch)" is displayed. AI4-Channel Sensor Temp, Selection of the channel output by AI4. The
The address switch setting is only adopted when Conductivity PV_SCALE and OUT_SCALE structure is not
the device is restarted, not during running adapted. This channel is active for FEX500 only.
operation. AO-Density Adjust Display only Current density output value from the Transducer
Factory setting for DIP switch 8: Off Block Flow, including status.
For further information read and observe chapter 7.3 DI-Alarm Info Display only Current output value, including status. The channel
“Start-up of PROFIBUS PA units”. can be selected using the "DI Channel" parameter.
Ident Nr. Selector 0x9700, 0x9740, 0x3430 Selection of the ID No. Selector. The parameter can DI-Channel Maintenance, Out of Spec, Select the channel output by "DI Alarm Info".
be changed only when cyclic communication is Function Check, Failure
stopped (Com State = OFF).
DO-Cyclic Control Display only Current function, including status. The function can be
Default setting: 0x3430 selected using the "DO Channel" parameter.
Comm State Offline, Operate, Clear, Stop Display of the communication status. DO-Channel Off, Totalizer Reset(All), Select the function for "DO Cyclic Control".
• Offline: Flowrate to Zero, System
BUS communication is deactivated. Zero Adjust, Totalizer
• Operate: Stop(All), Dual Range,
Cyclic communication is running. Start/Stop Batching
• Clear:
Device is being initialized. italics = Parameter can only be viewed at the "Advanced" password level.
• Stop: 1) Parameter / menu only available for FEP500 / FEH500.
Cyclic communication is stopped, BUS
communication remains active.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.8 Menu: Diagnostics
Menu / Parameter Value range Description
Menu / Parameter Value range Description
Communication / FF The menu is displayed only for devices with
FOUNDATION Fieldbus. Diagnostics
Show FF Address Display only Display of the FOUNDATION Fieldbus address. The Diagnosis Control Select the "Diagnosis Control" submenu.
address is set via the FOUNDATION Fieldbus Master. Diagnosis Values Select the "Diagnosis Values" submenu.
AI1-Q Flowrate Display only Current flow in the selected unit from the Transducer
Fingerprints Select the "Fingerprints" submenu.
Block Flow, including status.
INT1-Q Flowrate Display only Current output value, with status. Trend Select the "Trend" submenu.
AI2-Internal Tot Fwd Display only Current totalizer status of the forward totalizer in the Flowrate Alarm Select the "Flowrate Alarm" submenu.
selected unit from the Transducer Block Flow, Simulation Mode Off, Flow Velocity, Q [units], Q Manual simulation of measured values.
including status. [%],Iout, Freq on DO1, Freq The output values correspond to the simulated
AI3-Internal Tot Rev Display only Current totalizer status of the reverse totalizer in the on DO2, Logic DO1, Logic flowrate entered.
selected unit from the Transducer Block Flow, DO2, HART Freq, Digital in The "Configuration" information is displayed in the
including status. lower line of the display.
AI4-Diagnostics Display only Current output value, including status. The channel Restore the Simulation mode to "Off" once completed.
can be selected via the bus, only. The values in the "Value range" column can be
AO-Density Adjust Display only Current density output value from the Transducer simulated.
Block Flow, including status. Output Readings Select the "Output Readings" submenu.
DI-Alarm Info Display only Current output value, including status. The channel
can be selected via the bus, only.
Diagnostics / Diagnosis Control
DO-Cyclic Control Display only Current function, including status. The channel can be
selected via the bus, only. Empty Pipe Detector Select the "Empty Pipe Detector" submenu.
italics = Parameter can only be viewed at the "Advanced" password level. Sensor Measurements Select the "Sensor Measurements" submenu.
1) Parameter / menu only available for FEP500 / FEH500. Gas Bubble Detector 1) Select the "Gas Bubble Detector" submenu.
Coating Detector 1) Select the "Coating Detector" submenu.
Cond. Detection 1) Select the "Cond. Detection" submenu.
Grounding Check 1) Select the "Grounding Check" submenu.
TFE Detector Select the "TFE Detector" submenu.
Sil Detection Select the "Sil Detection" submenu.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Diagnostics / Diagnosis Control / Empty Pipe Detector Diagnostics / Diagnosis Control / Sensor Measurements
Empty Pipe Detector On / Off Activate the "Empty Pipe Detector" function (only for One shot Sensor Mea Start the measurement. The measured values for the
sizes ≥ DN 10 and without preamplifier). start moment are acquired.
An entirely full measuring tube is essential for an Coil Current Display only Display the coil current.
accurate measurement. The "Empty Pipe Detector" Coil Resistor Display only Display the coil resistance.
function detects an empty measuring pipe.
Coil Voltage Display only Display the coil voltage.
In the case of an alarm, the current output assumes
the status that was defined in the "Input / Output / Coil R. Max Alarm 0 ... 1000 Ω Set the maximum limit value for the coil resistance. In
Current Output / Iout at EP Alarm" menu, and the the case of overshoot an alarm is tripped.
pulse output is stopped. Default setting: 1000 Ω
Default setting: Off Coil R. Min Alarm 0 ... 1000 Ω Set the minimum limit value for the coil resistance. In
Adjust EP The Empty Pipe Detector function must be adjusted the case of undershoot an alarm is tripped.
according to the conditions on site. The switching Default setting: 0 Ω
threshold is set during the automatic adjustment. Signal-Cable length 0.01 ... 200 m Enter the signal cable length between the transmitter
Start automatic adjustment of the Empty Pipe and the flowmeter sensor. For devices with a compact
Detector function. design 0.01 m must be entered.
Manual Adjust EP F. 0 ... 255 Manually adjust the Empty Pipe Detector function. Default setting: 0 m
The value must be modified in such a way that the Sensor Temp Value 1) Display only Display the sensor temperature.
frequency for empty pipe detection (Detector EP Adj. Sensor T. Value 1) -50 ... +200 °C The sensor temperature must be adjusted according
Value) is close to 2000 Hz. to the conditions on site. The temperature measured
IMPORTANT (NOTE) with a separate thermometer can be entered here.
Prior to starting the (manual / automatic) Sensor T. Max Alarm 1) -50 ... +200 °C Set the maximum limit value for the sensor
adjustment, make sure that: temperature. In the case of overshoot an alarm is
• There is no flow through the flowmeter sensor tripped.
(close all valves, shut-off devices, etc.) Default setting: +200 °C
• The flowmeter sensor is completely filled with Sensor T. Min Alarm 1) -50 ... +200 °C Set the minimum limit value for the sensor
the fluid to be measured. temperature. In the case of undershoot an alarm is
Threshold 100 ... 60000 Hz Set the switching threshold for empty pipe detection. tripped.
The switching threshold is set automatically during Default setting: -50 °C
automatic adjustment. The switching threshold can be italics = Parameter can only be viewed at the "Advanced" password level.
changed in order to obtain manual fine adjustment.
Detector EP Value Display only Display of the frequency for empty pipe detection. If 1) Parameter / menu only available for FEP500 / FEH500.
the current value exceeds the defined switching
threshold, a message appears on the display and an
alarm is output via the digital output, if configured
accordingly.
italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Diagnostics / Diagnosis Control / Gas Bubble Detector 1) Diagnostics / Diagnosis Control / Coating Detector (continued) 1)
Gas Bubble Detector On / Off Activate the "Gas Bubble Detector" function. Coating QE Min Alarm 0 ... 100.000 Set the minimum limit value for the electrode deposit
Default setting: Off detection. When the smaller value, QE1 or QE2, is
undershot, an alarm is tripped.
IMPORTANT (NOTE)
Default setting: 0
The gas bubble detector can be used in the
nominal diameter range DN 10 ... 300. Coating QE Max Alarm 0 ... 100.000 Set the maximum limit value for the electrode deposit
detection. When the greater value, QE1 or QE2, is
For further information read and observe chapter
overshot, an alarm is tripped.
“Extended diagnostic functions”.
Default setting: 100.000
Adjust Gas Bubble The Gas Bubble Detector must be adjusted according
to the conditions on site. Start automatic adjustment of
the Gas Bubble Detector function. Diagnostics / Diagnosis Control / Cond. Detection 1)
IMPORTANT (NOTE) Cond. Detection On / Off Activate the "Cond. Detection" function.
Prior to starting the adjustment, make sure that: Default setting: Off
• There is no flow through the flowmeter sensor IMPORTANT (NOTE)
(close all valves, shut-off devices, etc.) The conductivity measurement function can be
• The flowmeter sensor is completely filled with used in the nominal diameter range DN 10 ...
the fluid to be measured and free from gas 300.
bubbles. For further information read and observe chapter
Threshold Gas Bubble Set the switching threshold. If the current value “Extended diagnostic functions”.
exceeds the defined switching threshold, a message One shot Cond. The conductivity is measured cyclically at defined
appears on the display and an alarm is output via the intervals. Here, a current measurement can be
digital output, if configured accordingly. started.
Gas Bubble Value Display only Display the current gas bubble value. Cond. Value Display the conductivity.
Adj. Cond. Value 5 ... 20,000 µS/cm The conductivity must be adjusted according to the
fluid on site. The conductivity measured with a
Diagnostics / Diagnosis Control / Coating Detector 1)
separate meter can be entered here.
Coating Detector On / Off Activate the "Electrode Deposit Detector" function. Cond. Min Alarm 5 ... 20,000 µS/cm Set the minimum limit value for the conductivity. In the
Default setting: Off case of undershoot an alarm is tripped.
IMPORTANT (NOTE) Default setting: 5 µS/cm
The electrode deposit detector can be used in the Cond. Max Alarm 5 ... 20,000 µS/cm Set the maximum limit value for the conductivity. In
nominal diameter range DN 10 ... 300. the case of overshoot an alarm is tripped.
For further information read and observe chapter Default setting: 20,000 µS/cm
“Extended diagnostic functions”. Elec. Imp. E1-GND Display only Current impedance between electrode E1 and GND
One shot Coating The electrode deposits are measured cyclically at (ground potential).
defined intervals. Here, a current measurement can Elec. Imp. E2-GND Display only Current impedance between electrode E2 and GND
be started. (ground potential).
Coating Value QE1 Display only Current deposit value for electrode 1 Elec. Imp Min Alarm 0 ... 20,000 Ω Set the minimum limit value for the impedance. In the
Coating Value QE2 Display only Current deposit value for electrode 1 case of undershoot an alarm is tripped.
italics = Parameter can only be viewed at the "Advanced" password level. Default setting: 0 Ω
Elec. Imp Max Alarm 0 ... 20,000 Ω Set the maximum limit value for the impedance. In the
1) Parameter / menu only available for FEP500 / FEH500. case of overshoot an alarm is tripped.
Default setting: 20,000 Ω
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Diagnostics / Diagnosis Control / Grounding Check 1) Diagnostics / Diagnosis Control / Sil Detection
Grounding Check Start the "Grounding Check" function. SIL Detection On / Off By switching on the detector the monitoring of safety-
relevant components is increased.
Power Spectrum Display only Current power spectrum.
With the detector switched on an SFF value of 91.6 is
Amplitude 1 Value Display only Display the four highest amplitudes in the power achieved for the FMEDA analysis (SIL2).
Amplitude 2 Value Display only spectrum. With the detector switched off an SFF value of 85.5 is
Amplitude 3 Value Display only achieved for the FMEDA analysis (SIL1).
Amplitude 4 Value Display only This is valid for all devices with HART protocol.
Default setting: Off
Diagnostics / Diagnosis Control / TFE Detector
Diagnostics / Diagnosis Values
TFE detector Activate the "Partial Filling Detector" (TFE) function.
SNR Value Display only Display the current diagnostic values for service
IMPORTANT (NOTE) purposes.
Slope Value
This function can be used only if the flowmeter
Slope Variation
sensor is provided with a measuring electrode for
the detection of partially filled tubes (option). The Reference
flowmeter sensor must be installed horizontally, Signal Ratio (signal
with the terminal box pointing upward. This difference)
function can be used for flowmeter sensors from Signal Max (Max.value of
size DN 50 without explosion protection or with pos. signal)
explosion protection for Zone 2 / Div.2. Signal Min (Max.value of
For further information read and observe chapter neg. signal)
9 “Extended diagnostic functions”.
Signal Error (signal error
Adjust TFE Full The partial filling detector must be adjusted according portion)
to the conditions on site.
NV Resets/sec
Start automatic adjustment of the Partial Filling
Detector function. Amplification Int.
IMPORTANT (NOTE)
Prior to starting the adjustment, make sure that: Diagnostics / Fingerprints 1)
• There is no flow through the flowmeter sensor Factory F.P. Select the "Factory F.P." submenu.
(close all valves, shut-off devices, etc.) Startup F.P. Select the "Startup F.P." submenu.
• The flowmeter sensor is completely filled with
the fluid to be measured. On demand F.P. Select the "On demand F.P." submenu.
TFE Threshold Manual fine adjustment of the switching italics = Parameter can only be viewed at the "Advanced" password level.
threshold. 1) Parameter / menu only available for FEP500 / FEH500.
The switching threshold is automatically set
during the automatic adjustment.
The “fingerprint” database integrated in the transmitter allows you to compare the values at the
If the current value exceeds the defined switching
time of factory calibration or commissioning with the currently recorded values.
threshold, a message appears on the display and
As a result, changes of the measuring system can be detected early, and the appropriate
an alarm is output via the digital output, if
measures can be taken.
configured accordingly.
TFE Value Display the current measuring value.
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization

Menu / Parameter Value range Description Menu / Parameter Value range Description

Diagnostics / Fingerprints / Factory F.P. 1) Diagnostics / Trend 1)


Sensor Coil R. Display only The factory fingerprint is created when the device are Conductivity The measured values are shown as a line diagram.
Elec. Coat. QE1 calibrated in the factory. Electrode Coat. QE1 When the "Trend-Logging" function is enabled, the
measured values are stored at the defined interval
Elec. Coat, QE2 Electrode Coat. QE2
(cycle time). The last 12 measured values are stored
Elec. Imp. E1-GND and indicated as a line diagram. The oldest data
Elec. Imp. E2-GND record is overwritten.
Tx check CMR Logtime Interval 1 ... 45,000 min. Interval for measured value logging.
Tx check 5 m/s Trend-Logging ON / OFF Activate the "Trend-Logging" function.
Tx check 10 m/s When the "Trend-Logging" function is enabled, the
measured values are stored at the defined interval
(cycle time).
Diagnostics / Fingerprints / Startup F.P. 1)
The data records can be read out by the
Startup F.P. Create the commissioning fingerprint for the flowmeter "ScanMaster" verification software and analyzed as
sensor. trends.
Sensor Coil R Display only The commissioning fingerprint is created on site
Elec. Coat. QE1 during commissioning. The values measured for this Diagnostics / Flowrate Alarm
Elec. Coat, QE2 fingerprint are indicated here.
Max. Flowrate Alarm 0 ... 130 % Set the maximum limit value for the flow.
Elec. Imp. E1-GND
Min. Flowrate Alarm 0 ... 130 % Set the minimum limit value for the flow.
Elec. Imp. E2-GND
Start Tx Startup F.P. Create the commissioning fingerprint for the
transmitter. Diagnostics / Output Readings
Tx check CMR Display only Current mA Display the current values and statuses of the listed
Tx check 5 m/s DO1 Frequency Hz inputs and outputs.
Tx check 10 m/s DO2 State open / closed
Digital In State open / closed
Diagnostics / Fingerprints / On demand F.P. 1) italics = Parameter can only be viewed at the "Advanced" password level.
Start On demand F.P. Creating the manual fingerprint. 1) Parameter / menu only available for FEP500 / FEH500.

Sensor Coil R Display only The manual fingerprint can be created at any time.
Elec. Coat. QE1 The values measured for this fingerprint are indicated
here.
Elec. Coat, QE2
Elec. Imp. E1-GND
Elec. Imp. E2-GND
Start Tx Startup F.P. Create the manual fingerprint for the transmitter.
Tx check CMR
Tx check 5 m/s
Tx check 10 m/s
italics = Parameter can only be viewed at the "Advanced" password level.
1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.4.9 Menu: Totalizer
Menu / parameter Value range Description
Menu / parameter Value range Description

Totalizer / ....Batching (continued) 1)


Totalizer
Batch Tot. Read only Once a fill operation has been started, the quantity
....Reset Vol. Totals Select the "....Reset Vol. Totals" submenu. already filled is shown here.
Select the "....Batching" submenu. The totalizer restarts at zero for each fill operation
....Batching 1)
initiated and then counts up to the set fill quantity.
....Edit Vol. Totals Select the "....Edit Vol. Totals" submenu. Read only Total number of fill operations.
Total Batch Counter
Reset Batch Counter Resets fill operation totalizer to zero.
Totalizer / ....Reset Vol. Totals
Start/Stop Batching Manual start / stop of the fill operation.
Edit Totalizer Fwd Resets forward totalizer to zero. Alternatively, the digital input can be configured for
Edit Totalizer Rev Resets reverse totalizer to zero. starting / stopping the fill operation.

Edit Totalizer Net Resets the difference totalizer to zero.


Totalizer / totalizer default setting.
All Vol. Totalizer Resets all totalizers to zero.
Edit Totalizer Fwd - Enter totalizer statuses (e.g. when replacing the
transmitter).
Edit Totalizer Rev -
Totalizer / ....Batching 1)
Edit Totalizer Net -
Damping ON / OFF Switches the damping on / off.
Default setting: ON italics = Parameter can only be viewed at the "Advanced" password level.
IMPORTANT (NOTE)
1) Parameter / menu only available for FEP500 / FEH500.
In order to achieve a shorter response time for
the fill function, the damping must be switched
off.
The fill time should be > 3 seconds.
Preset Batch Tot. - Setting of the fill quantity. When the defined fill
quantity is reached, the configured digital output is
activated.
Lag Corr. Mode Automatic / Manual Select the overrun correction.
Closing the fill valve takes some time and as a
consequence more liquid is added, even though the
fill quantity is reached and the contact for closing the
valve is actuated.
With "Automatic overrun correction" the set fill quantity
is corrected with the overrun quantity.
Lag Corr. Quantity -100.000 ... 100.000 Manual entry of the overrun quantity.

italics = Parameter can only be viewed at the "Advanced" password level.

1) Parameter / menu only available for FEP500 / FEH500.

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Parameterization Parameterization
8.5 Alarm Simulation 8.6 FEP500 and FEH500 during fill operation

In the "Process Alarm / Alarm Simulation" menu a variety of alarms can be simulated.

Parameter Description

Process Alarm
... / Alarm Simulation
Off Alarm Simulation switched off.
0-Sim.CurrentOut Simulate current output
1-Sim.Logic on DO1 Switch on/off contact output (terminals 51, 52)
2-Sim.Pulse on DO1 Simulate pulse output (terminal 51/52)
3-Sim.Logic on DO2 Switch on/off contact output (terminals 41, 42)
4-Sim.Pulse on DO2 Simulate pulse output (terminal 51/52)
5-Min Alarm Flowrate Simulate flowrate min. alarm
6-Max Alarm Flowrate Simulate flowrate max. alarm
7-Flowrate >103% Simulate flowrate > 103 % as alarm
8-Flow Simulation Run flowrate simulation
9-Calbration Mode Run transmitter alarm on simulator Fig. 67: Fill function (batch)
10-Flowrate to Zero Simulate external output switch-off
1 Supply tank O Valve open (filling started)
11-Totalizer Stop Simulate external totalizer stop
12-Tot.Display<1600h Simulate display value <1600 h for Qmax . 2 Start / stop contact (digital input) C Valve closed (fill quantity reached)
13-Totalizer Reset Simulate external totalizer reset 3 Sensor tv Valve closing time
14-Err.Sensor-Comms Simulate distorted communication to SensorMemory. 4 Motor valve tn Overrun time
15-HART Address <> 0 Simulate HART Multiplex mode 5 Tank to be filled
16-FRAM-Com Fail Simulate FRAM error in the transmitter DI Digital input
17-No Sensor Simulate error "No communication to SensorMemory"
18-Sim.Digital Input Simulate digital input "ON/OFF"
DO Digital output
19-ADC saturated Simulate "AD converter override" error
20-Error Coil circ Simulate error in coil loop The integrated fill function (batch) of the ProcessMaster FEP500 and HygienicMaster FEH500
21-Coil Resistor Simulate "Coil resistance out of limits" error
models allows you to control filling processes with a filling time >3 seconds.
22-Driver Err Uref=0 Simulate "Reference voltage = 0" error
23-El.Noise too High Simulate "Noise signal too high" error During this process, the fill quantity is given via an adjustable totalizer.
24-DC to High Simulate "DC too high, several NV resets" error
The fill operation is started via the digital input (DI) or via the fieldbus.
25-Empty Pipe Simulate "Empty pipe" error
27-NV Corrupt Simulate "NV Corrupt" error The valve is triggered via one of the digital outputs (DO) and closed again once the preset fill
29-Electrode Imp. Simulate "Electrode impedance out of limits" error quantity is reached.
30-Hold Last Value Simulate "Hold last good value" error
32-Digi-Pot Error Simulate "Digital potentiometer" error
The transmitter measures the overrun quantity (tn) and uses this value to calculate the overrun
33-TFE Simulate "Partial filling alarm" error quantity correction value.
34-CurrentOut Error Simulate "Loop current output interrupted" error Additionally, the low flow cut-off can be activated if required.
35-Not Calibrated Simulate "Not calibrated" error
36-SensorIncompatib. Simulate "Calibration mode incompatible" error
37-ROM Error Simulate ROM error in the transmitter
38-RAM Error Simulate RAM error in the transmitter 8.6.1 Configuration
39-Sim. HART Freq. Simulate a HART frequency
40-SIL Simulate "Self check alarm" error The fill function is configured via menus using the LCD indicator.
41-Conductivity Simulate "Conductivity alarm" error
42-Elec.Coated Simulate "Electrode deposits" error 1. If the fill operation is to be controlled via the digital input (DI), the following settings must be
43-Gas bubble Simulate "Gas bubbles" error applied in the "Input/Output" menu.
44-Pulse Cut Off Simulate "Pulse output" error
46-Sensor Temp Simulate "Sensor temperature alarm" error
Menu / parameter Selection Description

Input/Output
Digital Input Setup Start/Stop Batching Select the operating mode for the digital
1) output.
• Start / stop of the fill function (batch)
1).

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Parameterization Parameterization

2. To control the fill valve, the following settings must be applied: Menu / parameter Selection Description

Menu / parameter Selection Description Totalizer / ....Batching 1)


Lag Corr. Quantity -100.000 ... 100.000 Manual entry of the overrun quantity.
Input/Output / ....Digital Out Mode
Batch Tot. Read only Once a fill operation has been started,
DO1/DO2 Function Logic/Logic Select the functions for the digital the quantity already filled is shown here.
outputs DO1 and DO2. The totalizer restarts at zero for each fill
• Logic/Logic: operation initiated and then counts up to
- DO1 = Binary output. the set fill quantity.
- DO2 = Binary output. Total Batch Counter Read only Total number of fill operations.

Reset Batch Counter Resets fill operation totalizer to zero.


Input/Output / ....Logic Setup
Start/Stop Batching Manual start / stop of the fill operation.
DO1 Signal Batch end contact 1 The menu is displayed only if the Alternatively, the digital input can be
"Logic/Logic" function is set in the configured for starting / stopping the fill
DO2 Signal "DO1/DO2 Function" menu. This menu operation.
is not displayed in the factory setting.
• Batch end contact:
The digital output is activated when 4. To display all the data relevant to the fill operation in the process display, one of the operator
the set fill quantity is reached pages in the "Display" menu must be configured accordingly.

3. The parameters for the fill function must be configured. Menu / parameter Value range Description

Display / ....Operator Pages / ....Operator Page 1 (n)


Menu / parameter Selection Description
Display Mode 3 lines with 9 Configure each operator page.
1)
characters
Totalizer / ....Batching
1st Line Flow rate [unit] Select the measured value displayed in
Damping Off Switches the damping on / off.
each line. The following variants in the
Default setting: ON 2st Line Number of fill
value range can be selected:
IMPORTANT (NOTE) operations
In order to achieve a shorter response time for the fill function, 3st Line Batch totalizer
the damping must be switched off.
The fill time should be > 3 seconds.
Preset Batch Tot. - Setting of the fill quantity. When the
defined fill quantity is reached, the
configured digital output is activated.
Lag Corr. Mode Automatic / Manual Select the overrun correction.
Closing the fill valve takes some time and
as a consequence more liquid is added,
even though the fill quantity is reached
and the contact for closing the valve is
actuated.
With "Automatic overrun correction" the
set fill quantity is corrected with the
overrun quantity.

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Parameterization Extended diagnostic functions
8.7 Software – history 9 Extended diagnostic functions
8.7.1 Devices with HART protocol 9.1 General remarks
Software D200S062U01 IMPORTANT (NOTE)
Software Version Type of changes Operating instruction • The extended diagnostic functions are available for ProcessMaster 500 and
00.01.01 Original software OI / FEP300 / FEH300, rev. A HygienicMaster 500 only.
00.01.02 Function extension, incorporated OI / FEP300 / FEH300, rev. A • The "Partial Filling Detector" function is not available for HygienicMaster 500.
new HART commands • When using the extended diagnostic functions the external flowmeter sensor must not be
00.02.00 Optimized measured value OI / FEP300 / FEH300, rev. B provided with a preamplifier.
processing • To facilitate initial start-up, the extended diagnostic functions are deactivated (factory
00.02.01 Optimized measured value OI / FEP300 / FEH300, rev. B default).
processing
• To use the extended diagnostic functions, a "start-up fingerprint" must be created during
00.02.04 Optimized boot sequence OI / FEP300 / FEH300, rev. B
start-up of the flowmeter.
Software D200S069U01 • Each diagnostic function (e.g. Gas Bubble Detector or Electrode Deposit Detector) can be
01.01.02 Optimized access to the service OI / FEX300 / FEX500, rev. C individually activated. Once activated, the diagnostic function must be calibrated according
menu. Implemented TFE to the conditions on site and the limit values must be set.
functionality. Added diagnostic
functions and batch mode
(for 500 series, only)
9.1.1 Detection of partial filling
01.01.04 Optimized sensitivity of the keys OI / FEX300 / FEX500, rev. D
on the display Optionally, a measuring electrode (TFE electrode) is available for detecting a partially filled
01.01.06 Optimized view on the display OI / FEX300 / FEX500, rev. D flowmeter sensor. The alarm for partial filling is output via the programmable digital output.
01.02.00 Totalizer preset for ProcessMaster OI / FEX300 / FEX500, rev. E
Conditions for using the function:
300 implemented.Error with
Swedish menu navigation • Nominal diameter from DN 50 (2“) with sensor design level B
corrected. • Max. signal cable length for version with external transmitter 200 m (656 ft).
01.02.01 TFE functionality optimized for OI / FEX300 / FEX500, rev. F • Conductivity of the measuring medium: 20 μS/cm ... 20,000 μS/cm
integral mount design. • The function is only available for ProcessMaster 300 / 500 without explosion protection or
01.03.01 Software optimized for ScanMaster OI / FEX300 / FEX500, rev. F with explosion protection for Zone 2 / Div. 2.
verification tool. Additional installation conditions:
• The flowmeter sensor must be installed horizontally with the terminal box pointing upward.
8.7.2 Devices with PROFIBUS PA or FOUNDATION fieldbus
9.1.2 Detection of gas bubbles
Software D200S069U02 (PA) Software D200S069U03 (FF)
Software Version Type of changes Operating instruction Gas bubbles in the fluid are detected by using an adjustable maximum limit value. When this
limit value is exceeded, an alarm is tripped via the programmable digital output, depending on
00.01.02 Original software for OI / FEX300 / FEX500, rev. C
the configuration.
PROFIBUS PA,
FOUNDATION Fieldbus Conditions for using the function:
00.01.04 Optimized sensitivity of the keys OI / FEX300 / FEX500, rev. D • This function is available in the nominal diameter range 1) of DN 10 … 300 (3/8 “ ... 12 “).
on the display • The signal cable length of the remote transmitter must not exceed a maximum value of 50 m
00.01.05 (164 ft) .
Optimized view on the display OI / FEX300 / FEX500, rev. E
• For this function, the conductivity of the measuring medium must be in the range
00.02.00 Totalizer preset for ProcessMaster OI / FEX300 / FEX500, rev. F 20 μS/cm ... 20,000 μS/cm.
300 implemented.
Additional installation conditions:
• The flowmeter sensor can be installed either horizontally or vertically. Vertical installation is
preferred.

1) The specified nominal diameter range is valid for ProcessMaster, only. The nominal diameter range valid for
HygienicMaster is DN 10 … 100 (3/8 “ ... 4 “).

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Extended diagnostic functions Extended diagnostic functions
9.1.3 Electrode coating detection 9.1.6 Sensor measurements
This function provides the opportunity to detect coatings on the measuring electrodes by using This function includes the monitoring of the sensor temperature and the monitoring of the
an adjustable maximum limit value. resistance of the flowmeter sensor's coils.
When the set limit value is exceeded, an alarm is tripped via the programmable digital output,
depending on the configuration.
9.1.6.1 Sensor temperature monitoring
Conditions for using the function:
The temperature of the coils in the flowmeter sensor can be monitored by using adjustable
• This function is available in the nominal diameter range 2) of DN 10 … 300 (3/8 “ ... 12 “).
minimum / maximum limit values. When a set limit value is exceeded, an alarm is tripped via the
• The signal cable length of the remote transmitter must not exceed a maximum value of 50 m programmable digital output, depending on the configuration.
(164 ft) .
The coil temperature is a factor of the ambient and fluid temperatures. The measurement can,
• For this function, the conductivity of the measuring medium must be in the range e.g., be used to monitor overtemperature due to the fluid. The coil temperature is measured
20 μS/cm ... 20,000 μS/cm. indirectly via the coil DC resistance.
Additional installation conditions:
• When using plastic tubes, install a grounding plate at the front and back of the device.
9.1.6.2 Monitoring of the sensor coil resistance
The coils in the flowmeter sensor can be monitored by using adjustable minimum / maximum
9.1.4 Conductivity monitoring limit values for the coil resistance. When a set limit value is exceeded, an alarm is tripped via
the programmable digital output, depending on the configuration.
The conductivity of the fluid is monitored by using an adjustable minimum / maximum limit
value.
1) The specified nominal diameter range is valid for ProcessMaster, only. The nominal diameter range valid for
When the value falls below or exceeds the set limit value, an alarm is tripped via the HygienicMaster is DN 10 … 100 (3/8 “ ... 4 “).
programmable digital output, depending on the configuration.
Conditions for using the function:
9.1.7 Trend
• This function is available in the nominal diameter range 1) of DN 10 … 300 (3/8 “ ... 12 “).
• The signal cable length of the remote transmitter must not exceed a maximum value of 50 m The device has an internal memory where the measured value for the electrode deposits and
(164 ft) . the conductivity are cyclically stored as a data set with an adjustable time (1 min ... 45000 min).
• For this function, the conductivity of the measuring medium must be in the range A maximum of 12 data sets is stored. When the thirteenth record is stored, the oldest data set is
20 μS/cm ... 20,000 μS/cm. overwritten automatically.
Additional installation conditions: The data sets can be read out or analyzed as a trend using the external diagnostic tool
(ScanMaster).
• When using plastic tubes, install a grounding plate at the front and back of the device.
• There must not be any deposits on the measuring electrodes.
9.1.8 Fingerprint
1) The specified nominal diameter range is valid for ProcessMaster, only. The nominal diameter range valid for
HygienicMaster is DN 10 … 100 (3/8 “ ... 4 “). The “fingerprint” database integrated in the transmitter allows you to compare the values at the
time of factory calibration or commissioning with the currently recorded values.

9.1.5 Electrode impedance monitoring


9.1.9 Checking the grounding
The impedance between the electrode and ground is monitored by using a minimum / maximum
limit value. This enables the transmitter to detect an electrode fine short or leakage. This function allows you to check the electrical grounding of the device.
When the value falls below or exceeds the set limit value, an alarm is tripped via the While the check is in progress, no flow measurement can take place.
programmable digital output, depending on the configuration. Conditions for using the function:
Conditions for using the function: • The measuring tube must be completely full.
• This function is available in the nominal diameter range 1) of DN 10 … 300 (3/8 “ ... 12 “). • No flow must occur in the flowmeter sensor.
• The signal cable length of the remote transmitter must not exceed a maximum value of 50 m Additional installation conditions:
(164 ft) . • The flowmeter sensor must not be provided with a preamplifier.
• For this function, the conductivity of the measuring medium must be in the range
20 μS/cm ... 20,000 μS/cm.
Additional installation conditions:
• When using plastic tubes, install a grounding plate at the front and back of the device.
• There must not be any deposits on the measuring electrodes.
• The measuring tube must always be completely full, and the fluid must feature only minor
conductivity variations.

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Extended diagnostic functions Extended diagnostic functions
9.2 Performing the earthing check 9.3 Recommended settings for diagnostic limit values

... / Diagnostics / ....Diagnosis Control / ....Grounding Check1) In the "Diagnostics / Diagnosis Control / ..." menu, limit values for the diagnostic values can be
specified.
Grounding Check Start the "Grounding Check" function.
In order to simplify their setting, recommendations for the individual limit values are shown here.
Power Spectrum Read only Current power spectrum.
The values indicated are only intended as a rough guide and may need to be adapted in line
Amplitude 1 Value Read only Display the four highest amplitudes in the power with on-site conditions.
spectrum.
Amplitude 2 Value Read only
Read only 9.3.1 Limit values for the coil resistance
Amplitude 3 Value
Amplitude 4 Value Read only Coil resistance monitoring is switched off (factory default).
Monitoring can be switched on in the "Diagnostics / Diagnosis Control / Sensor
italics = Parameter can only be viewed at the "Advanced" password level. Measurements" menu.
1) Parameter / menu only available for FEP500 / FEH500.

Parameter Factory setting


....Grounding Check 5. Use or to select the "Grounding Check" entry.
Grounding Check Coil R. Min Alarm 0 ohms
Power Spectrum 6. Use to start the "Grounding Check" function. Coil R. Max Alarm 1000 ohms
Amplitude 1 Value
Back OK The coil resistance depends on the measuring medium temperature Tmedium and the ambient
temperature.
....Grounding Check Once the earthing check has been started, the frequency
Grounding Check 46,75 range up to 250 Hz is measured. The four most intensive
Parameter
48,65 frequencies of the spectrum are shown at the right of the
50,08 display. Tmedium R coil min alarm R coil max alarm
52,00 The corresponding amplitudes and the power spectrum
Back OK over the frequency range can be called up for display using -40 °C Factory for Fingerprint Factory for Fingerprint
the following parameters. (-40 °F) (coil resistance) x 0.71 (coil resistance) x 0.79
....Grounding Check -20 °C Factory for Fingerprint Factory for Fingerprint
7. Use or to select the "Power Spectrum" entry. (-4 °F) (coil resistance) x 0.81 (coil resistance) x 0.89
Power Spectrum 8. Use to display the parameter. 0 °C Factory for Fingerprint Factory for Fingerprint
335 (32 °F) (coil resistance) x 0.9 (coil resistance) x 1.0
Back OK
20 °C Factory for Fingerprint Factory for Fingerprint
(68 °F) (coil resistance) x 0.95 (coil resistance) x 1.05
....Grounding Check 9. Use or to select the "Amplitude 1 Value (n)" 60 °C Factory for Fingerprint Factory for Fingerprint
entry. (140 °F) (coil resistance) x 1.19 (coil resistance) x 1.31
Amplitude 1 Value (n) 90 °C Factory for Fingerprint Factory for Fingerprint
2,7 10. Use to display the parameter.
Back OK
(194 °F) (coil resistance) x 1.28 (coil resistance) x 1.42
130 °C Factory for Fingerprint Factory for Fingerprint
(266 °F) (coil resistance) x 1.43 (coil resistance) x 1.58
The measured values indicate possible disturbances to the earthing line of the device at the 180 °C Factory for Fingerprint Factory for Fingerprint
time of the test. (356 °F) (coil resistance) x 1.62 (coil resistance) x 1.79

No or minor disturbance:
• When the power spectrum is below 1000
• When the four measured amplitude values are above 10

Check the device earthing (!):


• When the power spectrum is above 1000
• When the four measured amplitude values are above 10

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Extended diagnostic functions Error messages
9.3.2 Limit values for the electrode deposits
10 Error messages
Electrode deposit monitoring is switched off (factory default). Monitoring can be switched on in
the "Diagnostics / Diagnosis Control / Coating Detector" menu. 10.1 Invoking the error description
Additional details about the error that has occurred can be called up on the information level.
Parameter Factory setting Process display
Coating QE Min Alarm 0 ohms 1. Use to go to the information level.
Coating QE Max Alarm 100.000 ohms

Recommended settings in the "Diagnostics / Diagnosis Control / Coating Detector" menu Electronic
• Coating QE Min Alarm = 0.5 x coating value QE unit
• Coating QE Max Alarm = 2.0 x coating value QE

Operator menu 2. Use or select the submenu "Diagnostics".


IMPORTANT (NOTE) Diagnostics
The deposit value QE is the mean value of Startup Fingerprint QE1 and QE2. The value is ....Operator Page 1 3. Confirm the selection with .
determined using the following formula: ....Operator Page 2
QE = (Startup Fingerprint QE1 + Startup Fingerprint QE2) / 2
Back Select

9.3.3 Limit values for the electrode impedance


Electronic unit The first line shows the area in which the error has
Electrode impedance monitoring is switched off (factory default). Monitoring can be switched on
F123.321 occurred.
in the "Diagnostics / Diagnosis Control / Cond. Detection" menu. Brief description
The second line shows the unique error number.
Information
Back Exit The next lines show a brief description of the error and
Parameter Factory setting information on how to remedy it.
Elec.Imp.Min Alarm 0 ohms
Elec.Imp.Max Alarm 20.000 ohms

The limit values for parameters "Elec.Imp.Min Alarm" and "Elec.Imp.Max Alarm" depend on
the measuring media conductivity and must be determined on site.

Recommended settings
• Elec.Imp.Min Alarm = 0.2 x average impedance value
• Elec.Imp.Max Alarm = 3.0 x average impedance value

IMPORTANT (NOTE)
The average impedance value is the value of Startup Fingerprint "Elec. Imp. E1-GND" and
"Elec. Imp. E2-GND". The value is determined using the following formula:
Average impedance value = (Startup Fingerprint "Elec. Imp. E1-GND" + Startup Fingerprint
"Elec. Imp. E2-GND") / 2

9.3.4 Recommended settings for the Trend Logger

"Diagnostics / Trend" menu


• Logtime Interval = 43,200 minutes

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Error messages Error messages
10.2 Error states and alarms
Error no. / Text on the LCD display Cause Remedy
10.2.1 Errors Range
F226.019 AD Converter Signal at the input of the AD converter If the pipeline is empty, check whether
Error no. / Text on the LCD display Cause Remedy Electronics
saturated exceeds the maximum value of 2.5 V. the empty pipe detection function is
Range Check empty pipe No further measurement is possible. activated.
unit or Galv. Voltage In the "Diagnostics" menu, activate the
F254.038 RAM Error in Transmitter Error in the transmitter electronics unit. Replace the electronics unit or contact empty pipe detection function.
Contact ABB Service.
Electronics ABB Service
Check whether the current flowrate
unit exceeds the configured flow range end
value. If yes, increase Qmax (= flow
F253.037 ROM Error in Transmitter Error in the transmitter electronics unit. Replace the electronics unit or contact range end value).
Contact ABB Service.
Electronics ABB Service
unit
F252.017 No Sensor Memory Incorrectly wired terminals D1 and D2. Check the wiring for terminals D1, D2. 10.2.2 Function check
Check wiring Short circuit or break in wires for D1, If an old flowmeter sensor (e.g., model
Sensor Check switch SW3 D2. DE41F) is connected without Error no. / Text on the LCD display Cause Remedy
Jumper SW3 is not correctly plugged SensorMemory, plug the jumper on the
Range
into the backplane. backplane in the "ON" position.
Old flowmeter sensor connected C190.045 An alarm is Simulation mode is activated. In the "Diagnostics" menu, deactivate
without SensorMemory. simulated simulation mode.
Config. Switch off
F251.040 Self Check Alarm The SIL monitoring function has Replace the transmitter or contact ABB alarm simulation
detected a transmitter error. Service.
Electronics C186.009 Tx Simulator/ The transmitter is operated on In the "Diagnostics" menu, deactivate
unit Calibrator mode simulator 55XC4000. simulation mode.
Config. Switch off
F250.016 Tx. memory fault detected Error in the transmitter electronics unit. Replace the electronics unit or contact Calibrator Mode
Contact ABB Service.
Electronics ABB Service C185.030 Hold last good The noise exceeds the bandwidth set Switch off noise reduction in the
unit known value for noise reduction for a longer period "Device Setup" menu or contact ABB
Operation Switch OFF
Incompatible snsTx+ of time. Service.
F248.036 Calibration mode is not compatible. Contact ABB Service. Noise Reduction
snr are not the same series
Sensor ABB Service
Defect digital potentiometer Internal digital potentiometer for Replace the electronics unit or contact C184.010 The Flowrate The function of the digital input (DI) is Set the digital input (DI) to low signal (0
F246.032 is set to zero
Transmitter Hardware fault common mode rejection is defective. ABB Service. set to "External output switch-off" and VDC).
Electronics Config. Check digital in
ABB Service the digital input (DI) is set to high
unit terminals 81,82 signal (+24 V DC).
F245.047 Stack NV Corrupt The internal stack memory for Replace the electronics unit or contact C182.008 Flowrate Simulation mode is activated. One of In the "Diagnostics" menu, deactivate
Contact PROFIBUS PA / ABB Service. Simulation the following functions is simulated: simulation mode.
Electronics ABB Service Config. Switch off
FOUNDATION Fieldbus is defective. Flowrate [%] or flowrate [unit] or flow
unit Simulation Mode velocity.
F244.031 Internal supply voltage error Failure of transmitter internal power Replace the electronics unit or contact These readings in simulation mode do
Contact supply. ABB Service.
Electronics ABB Service
not represent the system conditions.
unit C178.000 Simulated/ The current output is simulated and is Deactivate simulation mode in the
Fixed Current Output currently set to a specific value. "Process Alarm" menu or set the HART
F236.024 DC to High Multi-phase measuring media that Check electrical connections and Config. Simulation Mode?
Lot of NV-Resets The error message is displayed if the address to 0 in the "Communication"
produce a very high level of noise. grounding of device.
Operation Refer to instr. Manual
HART address>0? HART address is not 0 (HART menu.
Stones or solids that produce a very Activate empty pipe detector and
multidrop mode, current output is set
high level of noise. calibrate if the meter tube is empty.
permanently to 4 mA).
Galvanic voltages at the measuring Contact ABB Service.
electrodes. C177.015 HART Address <>0 HART address not 0 Set the HART address to 0 in the
Multidrop Mode (HART multidrop mode, current output "Communication" menu.
Conductivity of measuring medium is Config. Set HART
not evenly distributed (e.g., directly is set permanently to 4 mA).
Addr. = 0
after injection points).
C176.011 Totalizer Stop The function of the digital input (DI) is Set the digital input (DI) to low signal
F232.022 Driver Error Incorrect wiring (terminals M1, M2) or Check that the wiring (terminals M1, Check digital in set to "external totalizer stop" and the (0 V DC).
Uref = 0 wire break / short circuit. M2) is connected properly, check for Config.
Electronics Check wiring for
terminals 81,82 digital input (DI) is set to high signal
Defective fuse in the coil circuit or wire breaks and short circuits. (+24 V DC).
unit open circuit moisture in the terminal box. Check the coil circuit fuse.
Check fuse Check the connection box for moisture. Continued on next page.
F228.020 Error in Incorrect wiring (terminals M1, M2) or Check that the wiring (terminals M1,
Coil circuit wire break / short circuit. M2) is connected properly, check for
Electronics Check wiring for Fuse in the coil circuit is defective. wire breaks and short circuits.
unit short circuit Check the coil circuit fuse.
Continued on next page.

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Error messages Error messages
10.2.3 Operation outside of specifications (Off Spec)
Error no. / Text on the LCD display Cause Remedy Error no. / Text on the LCD display Cause Remedy
Range Range
C175.013 Totalizer Reset The function of the digital input (DI) is Set the digital input (DI) to low signal Coil resistor
S149.021 Coil resistance too high: Coil or fuse Check wiring, check fuse for coil
Check digital in set to "External totalizer reset" and the (0 V DC).
Config. terminals 81,82 Operation
out of limits for coil circuit is defective, or M1/M2 circuit, contact ABB Service.
digital input (DI) is set to high signal Check wiring wired incorrectly, or wire break, or fluid
(+24 V DC). Contact is too hot.
C174.002 Pulse Simulation Simulation mode is activated. In the "Process Alarm" menu, ABB Service Coil resistance too low: Coil is
selected on DO1 deactivate simulation mode. defective or short circuit in M1 / M2
Config. Switch off wiring.
Simulation Mode
S148.025 Empty Pipe The pipeline in the system is empty. Fill pipeline.
C172.004 Pulse Simulation Simulation mode is activated. In the "Process Alarm" menu, Check Pipe
selected on DO2 deactivate simulation mode. Operation
Config. Switch off
S146.043 Gas Bubble Alarm Gas bubbles were detected in the fluid. Check the process.
Simulation Mode The measured value is above the set
Logic Simulation Simulation mode is activated. In the "Process Alarm" menu, Operation
C168.001 switching threshold.
selected on DO1 deactivate simulation mode.
Config. Switch off S144.033 Partially Alarm tripped by Partial Filling Check process, fill pipeline.
filled pipe(TFE) Detector.
Simulation Mode Operation Check Pipe
C164.003 Logic Simulation Simulation mode is activated. In the "Process Alarm" menu, Or adjust
selected on DO2 deactivate simulation mode.
Config. Switch off
Detector
S143.042 Electrode Insulating or conductive deposits Check process, flush pipeline, clean
Simulation Mode Coating Alarm detected on measuring electrodes. The measuring electrodes.
C158.039 Simulation of Simulation mode is activated. In the "Process Alarm" menu, Operation
deposit value is above the set
HART frequency deactivate simulation mode.
Config. Switch off
switching threshold.
Simulation Mode S142.041 Conductivity Alarm The fluid conductivity is outside the Check process, adjust alarm limits if
configured limit values. required.
C154.018 Simulation Simulation mode is activated. In the "Process Alarm" menu, Operation
Digital In deactivate simulation mode.
Config. Switch off S141.046 Sensor and or Housing The flowmeter sensor temperature is Check process, adjust alarm limits if
Temperature to high outside the configured limit values. required.
Simulation Mode Operation
S140.007 Flowrate >103% The flowrate in the system exceeds the Increase the flow range end value in
Check Flowrate configured flow range end value by the "Easy Set-up - Qmax " menu.
Operation Check Range more than 3 %.
Setting
S136.006 Max Alarm The current flowrate in the pipeline is Reduce the flowrate or increase the
Flowrate greater than the max. alarm value for the max. alarm.
Operation
configured.
S132.005 Min Alarm The current flowrate in the pipeline is Increase the flowrate or increase the
Flowrate lower than the min. alarm configured. value for the min. alarm.
Operation
Continued on next page.

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Error messages Error messages
10.3 Overview of error states and alarms
Error no. / Text on the LCD display Cause Remedy
Range Error no. / Text on the LCD Current Digital output Pulse Display Error
Electr.Impedance This could be caused by insulating If the pipeline is empty, check whether Range display output behavior output maskable?
S124.029
too high deposits on the electrodes, the empty pipe detection function is behavior behavior
Operation Coating? conductivity that is too low, or an activated. RAM Error in Transmitter Iout at Alarm General Alarm 0 Hz 0% No
Conductivity? empty meter tube. In the "Diagnostics" menu, activate the
F254.038
Contact
Empty Pipe? empty pipe detection function. Electronics ABB Service
Check conductivity, check deposits on unit
the electrodes. F253.037 ROM Error in Transmitter Iout at Alarm General Alarm 0 Hz 0% No
Increase the value for "Elec. Imp. Max. Contact
Alarm" in the "Diagnostics - Alarm
Electronics ABB Service
Limits" menu. unit
Short-ciruit E1 Galvanic voltages. Increase the value in the "Diagnostics - F252.017 No Sensor Memory Iout at Alarm General Alarm 0 Hz 0% No
S122.026 Check wiring
E2 with shield. Alarm Limits - Electr. V Max Alarm" Sensor
Operation Check switch SW3
menu and decrease the value for
"Electr. V Min Alarm". F251.040 Self Check Alarm Iout at Alarm General Alarm 0 Hz 0% No
S120.023 Electrode Noise too high The noise at the measuring electrodes Check process. Electronics
Switch on is above the limit value.
Operation unit
Noise Reduction
Sensor setup F250.016 Tx. memory fault Iout at Alarm General Alarm 0 Hz 0% No
S110.035 Sensor is uncalibrated or Cal status is Contact ABB Service.
detected
Operation
Cal-Status not set to "calibrated". Electronics Contact
Set Cal-Status unit
to calibrated ABB Service
Pulse output is F248.036 Incompatible snsTx+ Iout at Alarm General Alarm 0 Hz 0% No
S108.044 Incorrect configuration. In the "Easy Set-up" menu, reduce the
snr are not the same
Operation
cutted off "Pulses per unit" value. Sensor series
Check pulse out
configuration F246.032 Defect digital Iout at Alarm General Alarm 0 Hz 0% No
potentiometer
Electronics Transmitter Hardware
unit fault
10.2.4 Maintenance ABB Service
F245.047 Stack NV Corrupt Iout at Alarm General Alarm 0 Hz 0% No
Error no. / Text on the LCD display Cause Remedy Electronics
Contact
Range ABB Service
unit
M099.027 NV Corrupt NV Memory, SensorMemory, FRAM Contact ABB Service. Internal supply voltage Iout at Alarm General Alarm 0 Hz 0% No
F244.031
defective. error
Electronics Electronics Contact
unit unit ABB Service
M094.034 Current 20 mA loop open, wire break or no Check for incorrect wiring, wire break. DC to High
out fault
F236.024 Iout at Alarm General Alarm 0 Hz 0% No
power connected during operation as Check that the jumper to the 20 mA Lot of NV-Resets
Electronics Comms. to MSP Operation
passive 20 mA output, max. active / passive switchover is Refer to instr. Manual
unit Check wiring! permissible load exceeded or connected correctly to the backplane in Driver Error
20mA passive? hardware defective.
F232.022 Iout at Alarm General Alarm 0 Hz 0% No
the transmitter housing. Uref = 0
Check BR901! Check whether the external power is
Electronics Check wiring for
connected during operation as 20 mA unit open circuit
passive. Check fuse
Errors F228.020 Error in Iout at Alarm General Alarm 0 Hz 0% No
M090.014 EMC environment or loose contact on Check for incorrect wiring (terminals
Coil circuit
Sensor Comms the D1 or D2 terminals, or incorrect D1, D2), check terminal box. Electronics
Sensor Bad EMC Check wiring for
wiring, or short circuit, or moisture in
environment the terminal box.
unit short circuit
Check wiring F226.019 AD Converter Iout at Alarm General Alarm 0 Hz 0% No
Display value is Display value <1,600 h for Qmax . Change the totalizer unit. saturated
M080.012 Electronics Check empty pipe
<1600h at Q max
Operation Change eng. unit or Galv. Voltage
Unitfor Totalizer

OI/FEX300/FEX500-EN FEX300, FEX500 149 150 FEX300, FEX500 OI/FEX300/FEX500-EN


Error messages Error messages

Error no. / Text on the LCD Current Digital output Pulse Display Error Error no. Text on the LCD Current Digital output Pulse Display Error
Range display output behavior output maskable? range display output behavior output maskable?
behavior behavior behavior behavior
An alarm is Current value No response Current value Current No Simulation Current value No response Current value Current Mask group
C190.045 C154.018 Digital In
simulated value value
Configuration Configuration Switch off
Switch off
alarm simulation Simulation Mode
Tx Simulator/ Current value Current value Current value Current Mask group Coil resistor Current value No response Current value Current Mask group
C186.009 C149.021 out of limits
Calibrator mode value value
Configuration Sensor Check wiring
Switch off
Calibrator Mode Contact
Hold last good Current value No response Current value Current Mask group ABB Service
C185.030 known value value Empty Pipe Programmed Programmed alarm 0 Hz 0% Mask single
S148.025
Operation Switch OFF Check Pipe alarm alarm
Operation
Noise Reduction
ABB Service Gas Bubble Alarm No response No response No response No Mask group
S149.021
The Flowrate 4 mA (0 % flow) No response 0 Hz 0% Mask group response
C184.010 is set to zero Operation
Configuration Check digital in Partially Current value Programmed alarm Current value Current Mask group
S146.043
terminals 81,82 filled pipe(TFE) value
Flowrate Current Value No response, Current value Current Mask group
Operation Check Pipe
C182.008 Simulation or High Alarm Min/Max or General value Or adjust
Configuration Switch off (flow > 105 %) Alarm Detector
Simulation Mode S144.033 Electrode Programmed Programmed alarm Current value Current Mask group
Coating Alarm alarm value
Simulated/ Simulated No response Current value Current Mask group
Operation
C178.000 Fixed Current Output value value S143.042 Conductivity Alarm Current value Programmed alarm Current value Current Mask group
Configuration Simulation Mode? Operation value
HART address>0?
S142.041 Sensor and or Housing Current value Programmed alarm Current value Current Mask group
HART Address <>0 4 mA Current value Current value Current Mask group
C177.015 Multidrop Mode value Operation
Temperature to high value
Configuration Set HART Flowrate >103%
S141.046 Current value Programmed alarm Current value Current Mask group
Addr. = 0 Check Flowrate value
Totalizer Stop Current value No response 0 Hz Current Mask group Operation Check Range
C176.011 Check digital in value Setting
Configuration terminals 81,82 Max Alarm
S140.007 Programmed Collective Alarm Current value Current Mask single
Totalizer Reset Current value No response Current value Current Mask group Flowrate alarm value alarm
C175.013 Check digital in value Operation
Configuration terminals 81,82 Min Alarm
S136.006 Current value Programmed alarm Current value Current Mask single
Pulse Simulation Current value No response Simulated value Current Mask group Flowrate value alarm
C174.02 selected on DO1 value Operation
Configuration Switch off Coil resistor
S132.05 Current value Programmed alarm Current value Current Mask single
Simulation Mode out of limits value alarm
Pulse Simulation Current value No response Simulated value Current Mask group Operation Check wiring
C172.04 selected on DO2 value Contact
Configuration Switch off ABB Service
Simulation Mode Electr.Impedance Current value No response Current value Current Mask group
Logic Simulation Current value Simulated value No response Current Mask group S124.029 too high
C168.01 value
selected on DO1 value Operation Coating?
Configuration Switch off Conductivity?
Simulation Mode Empty Pipe?
Logic Simulation Current value Simulated value No response Current Mask group Short-ciruit E1 Current value No response Current value Current Mask group
C164.003 selected on DO2 S122.026
value E2 with shield. value
Configuration Switch off Operation
Simulation Mode
Simulation of Current value No response Current value Current Mask group
C158.039 HART frequency value
Configuration Switch off
Simulation Mode

OI/FEX300/FEX500-EN FEX300, FEX500 151 152 FEX300, FEX500 OI/FEX300/FEX500-EN


Error messages Error messages
10.3.1 Error messages during commissioning
Error no. Text on the LCD Current Digital output Pulse Display Error
range display output behavior output maskable? 10.3.1.1 No sensor detected
behavior behavior
S120.023 Electrode Noise too high Current value No response Current value Current Mask group
Operation
Switch on value -System Startup- Once the device has been switched on, the sensor
Noise Reduction NO SENSOR DETECTED calibration data and the transmitter settings are loaded
Sensor setup Current value Current value Current value Current Group
S110.035 Cal-Status
Device Resetting from the SensorMemory into the transmitter.
value mask
Sensor Set Cal-Status If it is not possible to establish a communication with the
to calibrated Offline SensorMemory1), the shown message appears on the LCD
Pulse output is Current value No response Maximum Current Group display.
S108.044 cutted off possible value value mask
Operation Check pulse out
configuration
NV Corrupt
Possible cause Remedy
M099.027 Current value No response Current value Current Group
Elektronics value mask Terminals D1 / D2 wired incorrectly. Check wiring.
unit Short-circuit or wire-break of wires D1 / D2. Check signal cable.
Current Low Alarm No response Current value Current Single Alarm Jumper SW3 not correctly connected to the Check jumper SW3. Refer to Chapter 7.2
M94.034 out fault value mask
Electronics Comms. to MSP
backplane. "Configuring the current output".
unit Check wiring! • off: SensorMemory provided in the
20mA passive? flowmeter sensor (standard)
Check BR901!
• on: No SensorMemory in flowmeter
Errors Current value No response Current value Current Group
M90.014 Sensor Comms value mask sensor
Sensor Bad EMC Contact ABB Service
SensorMemory1) defective.
environment
Check wiring
Display value is Current value No response Current value Current Group The device will restart after the progress bar is complete until either the communication with the
M80.012 <1600h at Qmax value mask
Operation Change eng. SensorMemory1) is re-established successfully or the process is canceled by selecting "Offline".
Unitfor Totalizer In Offline mode the device can be operated or parameterized, but no measurement is
performed.
In Offline mode the error message "F252.017" is set.

1) The SensorMemory is a data memory integrated in the flowmeter sensor.

OI/FEX300/FEX500-EN FEX300, FEX500 153 154 FEX300, FEX500 OI/FEX300/FEX500-EN


Error messages Maintenance
10.3.1.2 Error message "Incompatible sensor" 11 Maintenance
IMPORTANT (NOTE) Repair and maintenance activities may only be performed by authorized customer service
When commissioning the device, make sure that the transmitter is assigned to the sensor personnel.
correctly. It is not possible to operate a flowmeter sensor of the 300 series with a transmitter of When replacing or repairing individual components, original spare parts must be used.
the 500 series.
NOTICE - Potential damage to parts!
If the transmitter is operated with a flowmeter sensor of another series, the following message The electronic components of the printed circuit board can be damaged by static electricity
appears on the transmitter display: (observe ESD guidelines).
Make sure that the static electricity in your body is discharged before touching electronic
components.
Boiler 9 In the process display, a flow of zero flow is indicated, no
Q 0.00 l/min flow measurement is performed. r

Σ+ 1403.09 m3 11.1 Flowmeter sensor


Σ- 591.74 m3 1. Use to switch to the information level.

Sensor The flowmeter sensor is largely maintenance-free. The following items should be checked
annually:
• Ambient conditions (air circulation, humidity),
-Operator Menu- 2. Use or , select the "Diagnostics" submenu. • Seal integrity of the process connections,
Diagnostics
3. Use to confirm your selection. • Cable entry points and cover screws,
Operator Page 1
• Operational reliability of the power supply feed, the lightning protection, and the station
Operator Page 2 ground.
Back Select
The flowmeter sensor electrodes must be cleaned when the flowrate information on the
transmitter changes when recording the identical flowrate volume. If the display shows a higher
flowrate, the contamination is insulating. If a lower flowrate is displayed, the contamination
Sensor results in a short-circuit.
When attempting to commission a mixed installation, the
-- F248.036-- shown error message appears. For repairs to the lining, electrodes or magnet coil, the flowmeter must be returned to the head
Incompatible sns office in Göttingen.
The device cannot measure.
Tx+snr are not
the same series The indicated value for the current flowrate is zero flow.
Back Exit IMPORTANT (NOTE)
The current output assumes its pre-configured state (Iout
for alarm). When sending the flowmeter sensor for repair to the head office of ABB Automation Products
GmbH, complete the return form in the appendix and include with device.
Make sure that the flowmeter sensor and the transmitter
are from the same series.
(e.g., flowmeter sensor ProcessMaster 300, transmitter When cleaning the exterior of meters, make sure that the cleaning agent used does not corrode
ProcessMaster 300) the housing surface and the gaskets.

11.2 Gaskets

Some device designs are shipped with special gaskets. These gaskets must be used and
installed properly to prevent leakage and ensure 3A conformity.
For all other device designs, use commercially available gaskets made from a compatible
material for the measuring medium and prevailing temperature (rubber, PDFE, lt, EPDM, silicon,
Viton, etc.) or use 3A-compliant gasket material for HygienicMaster devices.

IMPORTANT (NOTE)
A wafer type sensor is installed without gaskets directly in the pipeline.

OI/FEX300/FEX500-EN FEX300, FEX500 155 156 FEX300, FEX500 OI/FEX300/FEX500-EN


Maintenance Maintenance
11.3 Replacing the transmitter or the sensor 11.3.2 Sensor

IMPORTANT (NOTE) WARNING – danger due to electric current!


When replacing the transmitter or sensor, ensure that they are assigned correctly. It is not When the housing is open, EMC protection is impaired and there is no longer any protection
possible to operate a sensor from the 300 series with a transmitter from the 500 series. against accidental contact.
The series (e.g. ProcessMaster 300 or ProcessMaster 500) is shown on the name plate of the Before opening the housing, switch off the power supply.
transmitter or sensor.

11.3.1 Transmitter

WARNING – danger due to electric current!


When the housing is open, EMC protection is impaired and there is no longer any protection
against accidental contact.
Before opening the housing, switch off the power supply.

Transmitter with dual-compartment housing

Fig. 69

Replace the sensor as follows:


1. Switch off the power supply.
2. Open the cover safety device (3) if necessary.
3. Unscrew the housing cover (1).
4. Disconnect the signal cable (2) (if necessary, remove the potting compound).
5. Install the new sensor in accordance with the installation instructions.
6. Complete the electrical connection in accordance with the connection diagram.
7. Close the housing cover (1).
8. Download the system data (see chapter 7.5.1 "Downloading the system data" on page 70).

Transmitter with single-compartment housing


Fig. 68

Replace the transmitter plug-in as follows:


1. Switch off the power supply.
2. Unscrew the housing cover (1).
3. Loosen the screws (3) and pull out the transmitter plug-in unit (2).
4. Insert the new transmitter plug-in unit and retighten the screws (3).
5. Close the housing cover (1).
6. Download the system data (see chapter 7.5.1 "Downloading the system data" on page 70).

OI/FEX300/FEX500-EN FEX300, FEX500 157 158 FEX300, FEX500 OI/FEX300/FEX500-EN


Maintenance Spare parts list
11.3.3 Downloading the system data 12 Spare parts list
1. Switch on the power supply. After switching on the power supply, the following messages
12.1 Fuses for transmitter electronics
appear in succession on the LCD display:

System Startup System Startup System Startup


LOADING SYSTEM DATA VERIFYING SYSTEM DATA INSTALLATION CHANGED
Identify Changed Item

Transmitter Sensor

2. Download the system data as follows:

For a completely new system or initial start-up


• The calibration data of the flowmeter sensor and the transmitter settings are loaded from the
SensorMemory 1) into the transmitter.

After replacing the complete transmitter or transmitter electronic unit


• Select "Transmitter" with . The calibration data of the flowmeter sensor and the
transmitter settings are loaded from the SensorMemory 1) into the transmitter.

After replacing the sensor Fig. 70


• Select "Sensor" with . The calibration data of the flowmeter sensor are loaded from the No. Name of part Order number
SensorMemory 1) into the transmitter. The transmitter settings are stored in the
1 Fuse (1.0 A) for power supply, suitable for all devices D151B003U05
SensorMemory 1). If the new sensor is a different size, check the currently configured flow 2 Fuse (0.25 A) for the coil circuit in the field housing, suitable for D151B003U02
range. all devices

3. The flowmeter is ready for operation and will operate with factory settings or settings
12.2 Spare parts for devices with integral mount design
requested by the customer. To change the factory settings, refer to chapter 8
"Parameterization".
1) The SensorMemory is a data memory integrated in the flowmeter sensor.

IMPORTANT (NOTE)
System data must only be loaded during initial start-up. If the power supply is later switched
off, the transmitter automatically loads all data the next time the power supply is switched on
again.
A selection as described below (1-3) is not required.

Fig. 71
No. Name of part Order number
1 Housing cover for transmitter with single-compartment housing MJFA9915
with integral mount design
2 Universal backplane for transmitter with dual-compartment D685A1156U01
housing
3 Front housing cover for transmitter with dual-compartment D612A197U01
housing with integral mount design (standard, Ex Zone 2 / Div. 2)
Front housing cover for transmitter with dual-compartment D612A197U02
housing with integral mount design (Ex Zone 1 / Div. 1)

OI/FEX300/FEX500-EN FEX300, FEX500 159 160 FEX300, FEX500 OI/FEX300/FEX500-EN


Spare parts list Spare parts list
12.3 Spare parts for devices with remote mount design
12.3.3 Flowmeter sensor (Zone 2 / Div. 2)
12.3.1 field-mount housing

Fig. 74
No. Name of part Order number
for FEH model for FEP model
1 Connection board (without preamplifier) D685A1090U01 D685A1090U01
Connection board (with preamplifier) D685A1089U01 D685A1089U01

12.3.4 Flowmeter sensor (Zone 1 / Div. 1)

Fig. 72
No. Name of part Order number
1 Contact board assy for dual-compartment transmitter housing D682A016U01
2 Universal backplane for dual-compartment transmitter housing D685A1156U01
3 Housing cover for transmitter with single-compartment housing MJBX9905
with remote mount design
4 Backplane for transmitter with single-compartment housing with 3KXF002058U0100
remote mount design

12.3.2 Round field-mount housing

Fig. 75
No. Name of part Order number
1 O-ring D101A034U06
2 Cable gland for Zone 1 / Div. 1, plastic, black, M20 x 1.5 D150A004U15

Fig. 73
No. Name of part Order number
1 Front housing cover for transmitter with dual-compartment D612A197U01
housing with remote mount design (standard, Ex Zone 2 / Div. 2)
Front housing cover for transmitter with dual-compartment D612A197U02
housing with remote mount design (Ex Zone 1 / Div. 1)
2 Universal backplane for dual-compartment transmitter housing D685A1156U01

OI/FEX300/FEX500-EN FEX300, FEX500 161 162 FEX300, FEX500 OI/FEX300/FEX500-EN


Performance specifications Performance specifications

13 Performance specifications 13.2 Mechanical properties 13.3 IP rating


According to EN 60529
Ch ang e f ro m o ne to t wo co lum ns
A

13.1 General 13.1.3 Reproducibility, response time IP 65, IP 67, NEMA 4X


Integral mount Housing made of Housing made of
Reproducibility ≤ 0.11 % of measured value, design Aluminium stainless steel
13.1.1 Reference conditions tmeas = 100 s, v = 0.5 ... 10 m/s Housing Cast aluminum, Stainless steel CF3M 13.4 Vibration
Response time of As step function 0 ... 99 % painted
In accordance with EN 29104 According to EN 60068-2
current output with 5 t ³ 200 ms at 25 Hz excitation Paint Paint coat ≥ 80 µm -
Measuring medium 20 °C (68 °F) ± 2 K damping of thick, RAL 9002 - In the range 10 ... 58 Hz with max. 0.15 mm (0.006 inch)
frequency
temperature 0.02 seconds (light gray) deflection 1)
5 t ³ 400 ms at 12.5 Hz excitation
Ambient temperature 20 °C (68 °F) ± 2 K Cable gland2) Polyamide Polyamide - In the range 58 ... 150 Hz max. 2 g acceleration 1)
frequency
Power supply Nominal voltage acc. to name plate 5 t ³ 500 ms at 6.25 Hz excitation Stainless steel1) Stainless steel1) 1) Peak load
Un ± 1 %, frequency f ± 1 % frequency
Installation - Upstream > 10 x DN straight pipe
conditions section Remote mount design 13.5 Temperature data
- Downstream > 5 x DN straight pipe 13.1.4 Power supply Housing Cast aluminum, painted
section Paint Paint coat ≥ 80 µm thick, RAL 7012 (dark Ambient temperature
Warm-up phase 30 min Supply voltage 100 ... 230 V AC (-15 % / +10 %), gray), front cover / rear cover RAL 9002 -20 ... 60 °C (-4 ... 140 °F) Standard range
47 ... 64 Hz (light gray) -40 ... 60 °C (-40 ... 140 °F) Extended range
24 V AC (-30 % / +10 %), Cable gland2) Polyamide
13.1.2 Maximum measuring error 47 ... 64 Hz Stainless steel1) Storage temperature
24 V DC (-30 % / +30 %), Weight 4.5 kg (9.92 lb) -40 ... 70 °C (-40 ... 158 °F)
Pulse output
ripple: < 5 %
- Standard calibration FEP300 / FEH300:
Power consumption 1) In the case of hazardous area design for ambient temperature of -40 °C (40 °F)
± 0.4 % of measured value, ± 0.02 % QmaxDN 2) Cable Gland with M20x1,5 thread or NPT thread with plug to be specified through
AC ≤ 20 VA modelcode
(DN 3 ... 2000)
DC 12 W (switch-on current 5.6 A)
- Standard calibration FEP500 / FEH500:
Ch ang e f ro m o ne to t wo co lum ns

Screw terminals Max. 2,5 mm2 (AWG 14)


± 0.3 % of measured value, ± 0.02 % QmaxDN
(DN 1 … 600, 800)
Isolation of input / outputs
± 0.4 % of measured value, ± 0.02 % QmaxDN
The current output, digital outputs DO1 and DO2, and digital
(DN 700 … 900, 2000) input are electrically isolated from the flowmeter sensor input
- Optional calibration: (DN 10 … 600, 800) circuit and from each other. The same is valid for the signal
± 0.2 % of measured value, ± 0.02 % QmaxDN outputs of the versions with PROFIBUS PA and
- Only for FEH500: (DN 1 … 2) FOUNDATION fieldbus.
± 0.7 % of measured value, ± 0.02 % QmaxDN
Empty pipe detection
The function requires:
QmaxDN: See table in chapter 7.6 "Flowmeter sizes, flow range" on
A conductivity of the measured fluid ≥ 20 μS/cm, a signal
page 78. cable length ≤ 50 m (164 ft), a nominal diameter DN ≥ DN 10,
and the flowmeter sensor must not be provided with a
preamplifier.

Fig. 76

Y Accuracy ± of measured value in [%]


X Flow velocity v in [m/s], Q / QmaxDN [%]

Analog output effects


Same as pulse output plus ± 0.1 % of measured value ± 0.01 mA.

OI/FEX300/FEX500-EN FEX300, FEX500 163 164 FEX300, FEX500 OI/FEX300/FEX500-EN


Functional and technical properties - ProcessMaster Functional and technical properties - ProcessMaster

14 Functional and technical properties - ProcessMaster 14.5.4 Maximum ambient temperature depending on measuring medium temperature
IMPORTANT (NOTE)
Ch ang e f ro m o ne to t wo co lum ns

14.1 IP rating 14.5 Temperature data When using the device in potentially explosive areas, the additional temperature specifications in the section titled "Ex
relevant specifications" on the data sheet or in the separate Ex safety instructions (SM / FEX300 / FEX500 / ATEX /
According to EN 60529 The temperature range of the device is dependent upon a number of IECEX) or (SM / FEX300 / FEX500 / FM / CSA) must be observed.
IP 65, P 67, NEMA 4X factors which influence the specification. These factors include - fluid
IP 68 (for remote mount design only) temperature, ambient temperature, operating pressure, lining material
and hazardous area classifcation. 14.5.4.1 ProcessMaster with integral mount design (standard sensor design)

14.2 Pipeline vibration Ambient temperature Measuring medium temperature


Liner Flange material
14.5.1 Storage temperature Minimum temperature Max. temperature Minimum temperature Max. temperature
According to EN 60068-2-6, applies to aluminium transmitter -10 °C (14°F) 90 °C (194 °F)
housing only -40 ... 70 °C (-40 ... 158 °F) Hard rubber Steel -10 °C (14°F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
- In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch)
deflection -15 °C (5 °F) 90 °C (194 °F)
14.5.2 Minimum permissible pressure as a function Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
- In the 58 ... 150 Hz range with max. 2 g acceleration -5 °C (23 °F) 1) 80 °C (176 °F) 1)
of measuring medium temperature Soft rubber Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 60 °C (140 °F)
Lining Nominal POperating at TOperating 1) Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
14.3 Installation length
diameter mbar abs. 60 °C (140 °F) 90 °C (194 °F)
PTFE Steel -10 °C (14°F) -10 °C (14°F)
The flange devices comply with the installation lengths specified in Hard rubber 15 ... 2000 0 < 90 °C (194 °F) 45 °C (113 °F) 130 °C (266 °F)
VDI/VDE 2641, ISO 13359, or according to DVGW (process sheet (1/2 ... 80") < 80 °C (176 °F) 2) -20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
W420, design WP, ISO 4064 short). Soft rubber 50 ... 2000 0 < 60 °C (140 °F) PTFE Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
(2 ... 80")
60 °C (140 °F) 90 °C (194 °F)
PTFE 10 ... 600 270 < 20 °C (68 °F) PFA 1) Steel -10 °C (14°F) -10 °C (14°F)
14.4 Signal cable (3/8 ... 24") 400 < 100 °C (212 °F) 45 °C (113 °F) 130 °C (266 °F)
500 < 130 °C (266 °F) -20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
For remote mount design only PFA 1) Stainless steel -25 °C (-13 °F)
Thick PTFE, 25 … 80 0 < 180 °C (356 °F) -40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
A 5 m (16.4 ft) cable is supplied. high-temp. 100 … 250 67 < 180 °C (356 °F) 60 °C (140 °F) 90 °C (194 °F)
If you require more than 5 m (16.4 ft), a signal cable can be design 300 27 < 180 °C (356 °F) Thick PTFE 2) Steel -10 °C (14°F) -10 °C (14°F)
separately purchased (for ordering informations see the following 45 °C (113 °F) 130 °C (266 °F)
PFA 3 ... 200 0 < 180 °C (356 °F)
table or section "Accessory" in data sheet). -20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
(1/10 ... 8") Thick PTFE 2) Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
ETFE 25 ... 600 100 < 130 °C (266 °F)
Signal cable (1 ... 24") 60 °C (140 °F) 90 °C (194 °F)
ETFE 3) Steel -10 °C (14°F) -10 °C (14°F)
Application D173D031U01 D173D027U01 Linatex 2) 50 .. 600 0 < 70 °C (158 °F) 45 °C (113 °F) 130 °C (266 °F)
Non-Ex. (< DN 15) r a (2 … 24“)
ETFE 3) Stainless steel
-20 °C (-4 °F) 60 °C (140 °F)
-25 °C (-13 °F)
90 °C (194 °F)
Non-Ex. (≥ DN 15) a a Ceramic 25 ... 1000 0 < 80 °C (176 °F) -40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
Carbide (1 ... 40" Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F)
Zone 2 / Div. 2 (< DN 15) r a
1) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F)
Zone 2 / Div. 2 (≥ DN 15) a a the table titled "Maximum permissible cleaning temperature“.
60 °C (140 °F)
Zone 1 / Div. 1 2) Only China production site. Ceramic carbide Steel -10 °C (14 °F) -10 °C (14°F) 80 °C (176 °F)
r a 45 °C (113 °F)
(all nominal diameter)
60 °C (140 °F)
14.5.3 Maximum permissible cleaning temperature Ceramic carbide Stainless steel -20 °C (-4 °F) -20 °C (-4 °F) 80 °C (176 °F)
45 °C (113 °F)
r Application not permissible g Standard on delivery
a Application permissible CIP cleaning Sensor Tmax Tmax Tamb.
lining minutes
14.5.4.2 ProcessMaster with integral mount design (high-temperature sensor design) 3)
For the transmitter designed for use in zone 1, Div. 1 (model FET525), Steam cleaning PTFE, PFA 150 °C 60 25 °C
10 m (32.8 ft) of signal cable is permanently connected to the (302 °F) (77 °F) Ambient temperature Measuring medium temperature
transmitter. Fluids PTFE, PFA 140 °C 60 25 °C Liner Flange material
Minimum temperature Max. temperature Minimum temperature Max. temperature
(284 °F) (77 °F) 1)
Signal cable length and preamplifier PFA Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
A preamplifier is required for cables > 50 m (164 ft). -20 °C (-4 °F)
If the ambient temperature is > 25 °C, the difference must be PFA 1) Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
Maximum signal cable length between flowmeter sensor and subtracted from the max. cleaning temperature. Tmax - ∆ °C. -40 °C (-40 °F) 2)
transmitter: ( ∆ °C = Tamb - 25 °C) Thick PTFE 2) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
-20 °C (-4 °F)
Preamplifier Signal cable length Thick PTFE 2) Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
Without Max. 50 m (164 ft) for conductivity ≥ 5 µS/cm "Accessory" in data sheet ETFE 3) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
With Max. 200 m (656 ft) for conductivity ≥ 5 µS/cm
-20 °C (-4 °F)
ETFE 3) Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 130 °C (266 °F)
Ch ang e f ro m o ne to t wo co lum ns -40 °C (-40 °F) 2)

1) For China production site only.


2) For (optional) low-temperature version only.
3) With sensor design level "B" only.

OI/FEX300/FEX500-EN FEX300, FEX500 165 166 FEX300, FEX500 OI/FEX300/FEX500-EN


Functional and technical properties - ProcessMaster Functional and technical properties - ProcessMaster
Ch ang e f ro m o ne to t wo co lum ns

IMPORTANT (NOTE) 14.5.6 Overview sensor design level "C" ASME flange, stainless steel, up to DN 400 (16") (CL150/300) up
When using the device in potentially explosive areas, the additional temperature specifications in the section titled "Ex to DN 1000 (40") (CL150)
relevant specifications" on the data sheet or in the separate Ex safety instructions (SM / FEX300 / FEX500 / ATEX /
IECEX) or (SM / FEX300 / FEX500 / FM / CSA) must be observed.

14.5.5 ProcessMaster with remote mount design (standard sensor design)


Ambient temperature Measuring medium temperature
Liner Flange material
Minimum temperature Max. temperature Minimum temperature Max. temperature
-10 °C (14°F) 90 °C (194 °F)
Hard rubber Steel -10 °C (14°F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F)
Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 60 °C (140 °F)
DN 25 (1") X X — X X
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
DN 32 (1 1/4") X X — X X
PTFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F) DN 40 (1 1/2") X X X X X Fig. 78
-25 °C (-13 °F) DN 50 (2") X X X X X
PTFE Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F) DIN flange, steel, up to DN 600 (24")
-40 °C (-40 °F) 2) DN 65 (2 1/2") DIN PN 10, X X X X X
DN 80 (3") DIN PN 16, X X X X X
PFA 1) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
DN 100 (4") DIN PN 25, X X X X X
-25 °C (-13 °F) DIN PN 40
PFA 1) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F) DN 125 (5") X X X X X
-40 °C (-40 °F) 2) DN 150 (6") X X X X X
ASME
Thick PTFE 2) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F) DN 200 (8") CL 150, X X X X X
-25 °C (-13 °F) DN 250 (10") CL 300 X X X X X
Thick PTFE 2) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F) DN 300 (12") X X X X X
-40 °C (-40 °F) 2)
DN 350 (14") JIS 10 K X X X X X
ETFE 3) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F) DN 400 (16") X X X X X
ETFE 3) Stainless steel -25 °C (-13 °F) 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F) DN 450 (18") X X X X X
Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F) DN 500 (20") X X X X X
Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F) DN 600 (24") X X X X X
Ceramic carbide Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14°F) 80 °C (176 °F)
Ceramic carbide Stainless steel -25 °C (-13 °F) 60 °C (140 °F) -20 °C (-4 °F) 80 °C (176 °F) 14.6 Material load
Fig. 79
Limits for the permissible fluid temperature (TS) and permissible
14.5.5.1 ProcessMaster with remote mount design (high-temperature sensor) 3) pressure (PS) are calculated on the basis of the lining and flange
material used in the device (refer to the name plate on the device). ASME flange, steel, up to DN 400 (16") (CL150/300); up to
Ambient temperature Measuring medium temperature DN 1000 (40") (CL150)
Liner Flange material
Minimum temperature Max. temperature Minimum temperature Max. temperature
14.6.1 Flowmeter sensor design level “B”
PFA 1) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
-25 °C (-13 °F) DIN flange stainless steel up to DN 600 (24")
PFA 1) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
Thick PTFE 2) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 180 °C (356 °F)
-25 °C (-13 °F)
Thick PTFE 2) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
ETFE 3) Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14°F) 130 °C (266 °F)
-25 °C (-13 °F)
ETFE 3) Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)

1) For China production site only.


2) For (optional) low-temperature version only.
3) With sensor design level "B" only.

Fig. 80
JIS 10K-B2210 flange
Nominal Material PN TS PS
diameter
32 ... 400 Stainless steel 10 -25 ... 180 °C 10 bar
Fig. 77 (1 1/4 ... 16") (-13 ... 356 °F) (145 psi)
32 ... 400 Steel 10 -10 ... 180 °C 10 bar
(1 1/4 ... 16") (14 ... 356 °F) (145 psi)

OI/FEX300/FEX500-EN FEX300, FEX500 167 168 FEX300, FEX500 OI/FEX300/FEX500-EN


Functional and technical properties - ProcessMaster Functional and technical properties - ProcessMaster

DIN flange, stainless steel, DN 700 (28") up to DN 1000 (40") ASME flange, stainless steel, DN 25 ... 400 (1 ... 24“) 14.7 Materials for flowmeter sensors
14.7.3 Flowmeter sensor housing
14.7.1 Wetted parts Flowmeter sensor Design Level „B“
Part Standard Option
Lining PTFE, PFA, ETFE, Ceramic Carbide,
hard rubber, soft Linatex
rubber
Housing
Measurement and DN 3 ... 400 Dual-shell casing, cast aluminum,
grounding (1/10 ... 16") painted, paint coat, ≥ 80 µm thick,
electrode for: RAL 9002
- Hard rubber Stainless steel Hastelloy B-3 (2.4600), DN 450 ... 2000 Welded steel design, painted, paint coat,
1.4571 (AISI 316Ti) Hastelloy C-4 (18 ... 80") ≥ 80 µm thick, RAL 9002
- Soft rubber (2.4610), Titanium,
Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
Tantalum,
light gray, RAL 9002
Platinum-iridium,
1.4539 (AISI 904L), Meter tube Stainless steel 3)
Fig. 81 Tungsten carbide Cable gland 4) Polyamide
Fig. 84 - PTFE, PFA, Stainless steel Stainless steel 1.4571 CrNi steel
DIN flange, steel, DN 700 (28") up to DN 1000 (40") (in the case of hazardous area design for
ETFE 1.4539 (AISI 904L) (AISI 316Ti)
Hast. C-4 (2.4610) ambient temperature of -40 °C (40 °F))
14.6.2 Flowmeter sensor design level “C” Hast. B-3 (2.4600)
Titanium, Tantalum, Flowmeter sensor Design Level „B“
Steel casted housing, DN 25 ... 600 (1 ... 24“) Platinum-iridium
Grounding plate Stainless steel On request
Protection plate Stainless steel On request

Housing + Meter tube


14.7.2 Non-wetted parts (process connection) DN 25 ...400 (1 ... 16") Stainless steel (AISI 316, 316L)
Flowmeter sensor Design Level „B“ Cable gland 4) Polyamide

Flowmeter sensor Design Level „C“

Nominal diameter Standard Option


Fig. 82
DN 3 ... 15 Stainless steel 1) -
(1/10 ... 1/2") Housing + Meter tube
ASME flange, Steel, DN 25 ... 400 (1 ... 24“) Steel, painted, paint coat, ≥ 80 µm thick,
DN 20 ... 400 Steel (galvanized)2) Stainless steel 1) DN 25 ... 600 (1 ... 24")
(3/4 ... 16") RAL 9002
DN 450 ... 2000 Steel (painted) 2) - Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
Fig. 85 (18 ... 80") light gray, RAL 9002
Cable gland 4) Polyamide
Flowmeter sensor Design Level „B“
Welded steel housing, DN 25 ... 600 (1 ... 24“) The meter tube is made of one of the materials listed below:

3) 1.4301, 1.4307, 1.4404, 1.4435, 1.4541, 1.4571


ASTM materials:
Grade TP304, TP304L, TP316L, TP321, TP316Ti, TP317L,0Cr18Ni9, 00Cr18Ni10,
0CR17Ni14Mo2, 0Cr27Ni12Mo3, 0Cr18Ni10Ti
Nominal diameter Standard Option 4) Cable Gland with M20x1,5 thread or NPT thread with plug to be specified through
DN 25 ... 400 Stainless steel - modelcode

(1 ... 16") (AISI 316, 316L)

Flowmeter sensor Design Level „C“

Fig. 83 Nominal diameter Standard Option


DN 25 ... 600 Steel (painted) 2) -
(1 ... 24")

The process connections are made of one of the materials listed below:
Fig. 86
1) 1.4301 (AISI 304), 1.4307, 1.4404 (AISI 316L) 1.4435 (AISI 316L), 1.4541 (AISI 321)
1.4571 (AISI 316Ti), ASTM A182 F304, ASTM A182 F304L, ASTM A182 F316L, ASTM
A182 F321, ASTM A182 F316TI, ASTM A182 F316, 0Cr18Ni9, 0Cr18Ni10,
0Cr17Ni13Mo2, 0Cr27Ni12Mo3, 1Cr18Ni9Ti, 0Cr18Ni12Mo2Ti
2) 1.0038, 1.0460, 1.0570, 1.0432, ASTM A105, Q255A, 20#, 16Mn
Ch ang e f ro m o ne to t wo co lum ns

OI/FEX300/FEX500-EN FEX300, FEX500 169 170 FEX300, FEX500 OI/FEX300/FEX500-EN


Functional and technical properties - HygienicMaster Functional and technical properties - HygienicMaster
Max. ambient temperature as a function of measuring medium temperature
15 Functional and technical properties - HygienicMaster IMPORTANT (NOTE)
When using the device in explosion hazardous areas, the additional temperature specifications in the section titled "Ex
Ch ang e f ro m o ne to t wo co lum ns

Min. permissible pressure as a function of measuring relevant specifications" on the data sheet or in the the separate Ex safety instructions
15.1 Flowmeter sensor medium temperature (SM/FEX300/FEX500/ATEX/IECEX) or (SM/FEX300/FEX500/FM/CSA) must be observed.
Lining Nominal POperating at TOperating1)
15.1.1 IP rating according to EN 60529 diameter mbar abs. Standard temperature design
PFA DN 3 ... 100 0 < 180 °C (356 °F) Process Ambient temperature Measuring medium temperature
IP 65, IP 67, NEMA 4X Model
(1/10 ... 4") connection Min. temp 1) Max. temp. Min. temp. Max. temp 2)
IP 68 (for remote mount design only)
PEEK DN 1 ... 2 0 < 120 °C (248 °F)
(1/25 … 1/12") 60 °C (140 °F) 100 °C (212 °F)
Flange -20 °C (-4 °F) -25 °C (-13 °F)
FEH311 40 °C (104 °F) 130 °C (266 °F)
15.1.2 Pipeline vibration according to EN 60068-2-6 1) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to
the table titled "Maximum permissible cleaning temperature“. FEH315 Variable process 60 °C (140 °F) 100 °C (212 °F)
For devices with integral mount design the following applies: -20 °C (-4 °F) -25 °C (-13 °F)
connections 40 °C (104 °F) 130 °C (266 °F)
(transmitter mounted directly on the flowmeter sensor) Max. permissible cleaning temperature
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch) 60 °C (140 °F) 100 °C (212 °F)
CIP cleaning Flowmeter Tmax Tmax Tamb. Flange -20 °C (-4 °F) -25 °C (-13 °F)
deflection FEH321 40 °C (104 °F) 130 °C (266 °F)
sensor minutes
• In the 58 ... 150 Hz max. 2 g acceleration FEH325 Variable process 60 °C (140 °F) 100 °C (212 °F)
lining -20 °C (-4 °F) -25 °C (-13 °F)
(does not apply to DN 1…2) connections
Steam cleaning PFA 150 °C 25 °C 60 40 °C (104 °F) 130 °C (266 °F)
For devices with remote mount design the following applies: (302 °F) (77 °F)
Transmitter Fluids PFA 140 °C 60 25 °C High temperature design (from size DN 10 (3/8“))
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch) (284 °F) (77 °F) Process Ambient temperature Measuring medium temperature
deflection If the ambient temperature is > 25 °C, the difference must be Model
connection Min. temp 1) Max. temp. Min. temp. Max. temp.
• In the 58 ... 150 Hz range with max. 2 g acceleration subtracted from the max. cleaning temperature. Tmax - ∆ °C.
( ∆ °C = Tamb - 25 °C) FEH311
Flange -20 °C (-4 °F) 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
Flowmeter sensor FEH315
• In the 10 ... 58 Hz range with max. 0.15 mm (0.006 inch)
Max. permissible temperature shock FEH321
deflection Flange -20 °C (-4 °F) 60 °C (140 °F) -25 °C (-13 °F) 180 °C (356 °F)
Lining Max. temp. shock Temp. gradient FEH325
• In the 58 ... 150 Hz max. 2 g acceleration
(does not apply to DN 1…2) Temp. diff. in °C °C / min
PFA Any Any 1) The following is valid for the low temperature design (option): -40°C (-40°F).
PEEK Any Any 2) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to the table „Max. permissible cleaning temperature“ on page 171.

15.1.3 Installation length


The flange devices comply with the installation lengths specified in
VDI/VDE 2641, ISO 13359, or according to DVGW (process sheet
W420, design WP, ISO 4064 short).

15.1.4 Signal cable (for external transmitters only)


A 5 m (16.4 ft) cable is supplied.
If you require more than 5 m (16.4 ft), a cable can be purchased using
order number D173D027U01.
Alternatively, the cable with order number AD173D031U01 can be
used for transmitters without explosion protection (model FEP321,
FEH321) from DN 15 and for transmitters for use in Zone 2 (model
FEP325, FEH325) from DN 15.

Preamplifier
Maximum signal cable length between flowmeter sensor and
transmitter:
a) Without preamplifier:
• Max. 50 m (164 ft) for conductivity ≥ 5 µS/cm
A preamplifier is required for cables > 50 m (164 ft).
b) With preamplifier
• Max. 200 m (656 ft) for conductivity ≥ 5 µS/cm

15.1.5 Temperature range


Storage temperature
- 40 ... 70 °C (-40 ... 158 °F)
Ch ang e f ro m o ne to t wo co lum ns

OI/FEX300/FEX500-EN FEX300, FEX500 171 172 FEX300, FEX500 OI/FEX300/FEX500-EN


Functional and technical properties - HygienicMaster Functional and technical properties - HygienicMaster
Ch ang e f ro m o ne to t wo co lum ns

15.1.6 Material load 15.1.7 Mechanical properties


Non-wetted parts
ASME flange, stainless steel, up to DN 100 (4") (CL150 / 300)
Limits for the permissible fluid temperature (TS) and permissible Wetted parts Standard Option
pressure (PS) are calculated on the basis of the lining and flange Flange CrNi steel 1.4571 -
Part Standard Option
material used in the device (refer to the name plate on the device). (AISI 316Ti)
Lining PFA from DN 3 -
(1/10“)
Process Nominal PSmax TS
PEEK DN 1 ... 2 Flowmeter sensor housing
connection diameter bar (1/25 ... 1/12“)
(PSI) Standard
Signal and CrNi steel 1.4539 CrNi steel 1.4571
Wafer type DN 3 ... 50 40 -25 ... 130 °C grounding electrode (AISI 904L) (AISI 316Ti) Housing Deep-drawn housing
(1/10 ... 2“) (580) (-13 ... 266 °F) Hast. C-4 (2.4610) CrNi steel 1.4301 (AISI 304), 1.4308
DN 65 ... 100 16 Hast. B-3 (2.4600) Terminal box CrNi steel 1.4308 (AISI 304)
(2 1/2 ... 4“) (232) Titanium, tantalum, Meter tube Stainless steel
Welded spuds DN 3 ... 40 40 -25 ... 130 °C Platinum-iridium Cable gland Polyamide
(1/10 ... 1 1/2“) (580) (-13 ... 266 °F) Gaskets (for Weld EPDM (Ethylene- Silicone with FDA Stainless steel
DN 50, DN 80 16 stubs, threaded Propylene) with FDA approval (option, oil (in the case of hazardous area design
(232) connection, Tri- approval, silicone or grease resistant) for ambient temperature of -40 °C
(2“, 3“)
Fig. 88 Clamp, external with FDA approval PTFE with FDA (40 °F))
DN 65, DN 100 10 threads) (CIP-resistant, no oils approval (DN 3 ... 8
(2 1/2“, 4“) (145) or grease) (1/10 ... 5/16“))
For CIP / SIP cleaning, higher temperatures are permitted for limited
Threaded pipe DN 3 ... 40 40 -25 ... 130 °C Gasket for 1/8" PTFE Viton (only in
time periods; refer to the table titled "Maximum permissible cleaning
connection (1/10 ... 1 1/2“) (580) (-13 ... 266 °F) sanitary connectors combination with
temperature".
conforming to DIN PVC process
11851 connection)
JIS 10K-B2210 flange Process connection -
DN 50, DN 80 16
(232) Nominal Material PN TS PS [bar] - Welded spuds, CrNi steel 1.4404 -
(2“, 3“)
diameter Tri-Clamp, etc. (AISI 316L)
DN 65, DN 100 10 25 ... 100 Stainless steel 10 -25 ... 180 °C 10
(2 1/2“, 4“) (145) - OD tubing CrNi steel 1.4435 -
(1 ... 4") (-13 ... 356 °F) (145 psi) (AISI 316L)
Tri-Clamp DN 3 ... 50 16 -25 ... 121 °C
conforming to (1/10 ... 2“) (232) (-13 ... 250 °F) Ch ang e f ro m o ne to t wo co lum ns

DIN 32676 Wafer type design


DN 65 ... 100 10
(2 1/2 ... 4“) (145)
Tri-Clamp in acc. DN 3 ... 100 10 -25 ... 130 °C
with ASME BPE (1/10 ... 4“) (145) (-13 ... 266 °F)
External thread DN 3 ... 25 16 -25 ... 130 °C
ISO 228 / DIN 2999 (1/10 ... 1“) (232) (-13 ... 266 °F)
OD tubing DN 3 ... 50 10 -25 ... 130 °C
(1/10 ... 2“) (145) (-13 ... 266 °F)
1/8" sanitary DN 1 ... 2 10 -10 ... 120 °C
connectors (1/25 … 1/12“) (145) (-14 ... 248 °F)

DIN flange stainless steel to DN 100 (4")

Fig. 89

JIS 10K-B2210 wafer type design


Nominal Material PN TS PS [bar]
diameter
DN 32 ... 100 1.4404 10 -25 ... 130 °C 10
(1 1/4 ... 4") 1.4435 (-13 ... 266 °F) (145 psi)
1.4301

Fig. 87

OI/FEX300/FEX500-EN FEX300, FEX500 173 174 FEX300, FEX500 OI/FEX300/FEX500-EN


Appendix Appendix

16 Appendix 16.2 Overview of parameter settings (factory settings)

16.1 Return form Possible parameter settings Factory setting


Sensor TAG Alphanumeric, max. 20 characters None
Sensor Location TAG Alphanumeric, max. 20 characters None
Statement on the contamination of devices and components Qmax Depending on nominal diameter QmaxDN (see table in Section 6.6)
Repair and/or maintenance work will only be performed on devices and components if a statement form has been (see table in Section 6.6)
completed and submitted. Q (Flowrate) Unit l/s; l/min; l/h; ml/s; ml/min; m3/s; m3/min; l/min
Otherwise, the device/component returned may be rejected. This statement form may only be completed and m3/h; m3/d; hl/h; g/s; g/min; g/h; kg/s;
signed by authorized specialist personnel employed by the operator. kg/min; kg/h; kg/d; t/min; t/h; t/d
Totalizer/Pulse Unit m3; l; ml; hl; g; kg; t l
Customer details: Pulses per Unit 1
Pulse Width 0,1 ... 2,000 ms 100 ms
Company:
Damping ( 1 Tau) 0,02 ... 60 sec. 1
Address: DO1 Alarm Config Pulse F/Pulse R, Pulse F, General Alarm, Pulse F/Pulse R
Contact person: Telephone: Min. Flowrate Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE, Only available for
Fax: Email: FEP500 / FEH500 are: Gas Bubble,
Conductivity, Coating, Sensor Temp,
Signal
Device details:
Type: Serial no.:
DO1 Drive Active, Passive Passive
Reason for the return/description of the defect: DO2 Alarm Config F/R Signal, Pulse R, General Alarm, Min. F/R Signal
Flowrate Alarm, Max. Flowrate Alarm,
Empty Pipe, TFE, Only available for
FEP500 / FEH500 are:
Gas Bubble, Conductivity, Coating, Sensor
Temp, Signal
Was this device used in conjunction with substances which pose a threat or risk to health?
c Yes c No Digital Input DI No Function, Totalizer Reset(All), Flowrate Flowrate to Zero
to Zero, System Zero Adjust, Totalizer
If yes, which type of contamination (please place an X next to the applicable items)?
Stop(All), Only available for
Biological c Corrosive/irritating c Combustible (slightly/extremely FEP500 / FEH500 are:
combustible) c Switchover Dual Range, Start/Stop
Batching
Toxic c Explosive c Other Toxic substances c
Current Output 4 … 20 mA, 4 … 12 … 20 mA 4 … 20 mA
Radioactive c Iout at Alarm (in accordance with High alarm, adjustable to 21 … 23 mA or High alarm, 21.8 mA
NE43) Low alarm, adjustable to 3.5 … 3.6 mA For details refer to Section 9.2.
Which substances have come into contact with the device? Iout at Flow >103% Off (no signaling, current output remains at Off
20.5 mA), high alarm, low alarm
1.
Low Flow Cut Off 0 … 10 % 1%
2.
Empty Pipe Detector On / Off Off
3.
TFE Detector On / Off Off

We hereby state that the devices/components shipped have been cleaned and are free from any dangerous or
poisonous substances. 16.2.1 For Profibus PA version

Possible parameter settings Factory setting


PA Addr. (BUS) 0 ... 126 126
Town/city, date Signature and company stamp
Ident Nr. Selector 0 x 9700, 0 x 9740, 0 x 3430 0 x 3430

OI/FEX300/FEX500-EN FEX300, FEX500 175 176 FEX300, FEX500 OI/FEX300/FEX500-EN


Appendix Notes
Notes
16.3 Declaration of conformity

IMPORTANT (NOTE)
All documentation, declarations of conformity and certificates are available in ABB's download
area.
www.abb.com/flow

IMPORTANT (NOTE)
This is a class A device (industrial sector). This device can cause radio interferences in
residential areas. In this case, the operator may be required to take appropriate measures to
remedy the fault.

OI/FEX300/FEX500-EN FEX300, FEX500 177 178 FEX300, FEX500 OI/FEX300/FEX500-EN


Notes
Notes

ABB has Sales & Customer Support expertise in over The Company’s policy is one of continuous product
100 countries worldwide. improvement and the right is reserved to modify the
information contained herein without notice.
www.abb.com/flow
Printed in the Fed. Rep. of Germany (02.2018)

© ABB 2018

3KXF231300R4201

ABB Limited ABB Inc. ABB Automation Products GmbH ABB Engineering (Shanghai) Ltd.
Measurement & Analytics Measurement & Analytics Measurement & Analytics Measurement & Analytics
Howard Road, St. Neots 125 E. County Line Road Dransfelder Str. 2 No. 4528, Kangxin Highway, Pudong New District
Cambridgeshire, PE19 8EU Warminster, PA 18974 37079 Goettingen Shanghai, 201319,
UK USA Germany P.R. China
Tel: +44 (0) 870 600 6122 Tel: +1 215 674 6000 Tel: +49 551 905-0 Tel: +86(0) 21 6105 6666
Fax: +44 (0)1480 213 339 Fax: +1 215 674 7183 Fax: +49 551 905-777 Fax: +86(0) 21 6105 6677
Mail: [email protected] Mail: vertrieb.messtechnik- Mail: [email protected]
[email protected]
OI/FEX300/FEX500-EN FEX300, FEX500 179
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

TRO MONITORS

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 12
ִ
2.0 Routine Maintenance

2.1 Replacing or Installing the Reagents

1) The indicator reagent must be prepared and will last for up to three months when kept
in the cooling chamber. This reagent requires preparation. Locate the small liquid
bottle and remove the cap. Now locate the smaller brown bottle. Remove the cap and
add all the powder into the liquid. Recap the small bottle and agitate for 60 seconds.
Quick Instructions for CLX-XT
1.0 Orientation

1minute

2) The buffer reagent does not require preparation and will last up to one year.

3) To replace the reagents press the SERVICE button, this will empty
the cuvette and stop the flow of water.

4) Replace or install the reagents. The buffer install on the left hand side in the provided
Front View Bottom View clip. The smaller indicator is placed in cooling chamber.

5) Press the PRIME button and then the 8 button. This will draw
enough of each reagent to completely prime the tubes and replace
any old reagent.
Check Valve
Cap Assembly "A"

Flow The system will automatically return to normal operation after priming.
Tube"B"

Use caution when changing the reagents as they are caustic. These reagents
will stain clothing and anything they contact. After changing the reagents,
operators should wash their hands.

Reagent Tubing Set

CLX-XT 29149 (6/16) Page 1 CLX-XT 29149 (6/16) Page 2


Quick Instructions REV 1.3 Quick Instructions REV 1.3
2.2 Maintenance Schedule 2.3 Tube Assemblies and Cuvette

The recommended schedule is shown below. It is important to replace the reagents to get Check the condition of the cuvette and clean or replace if it appears soiled or discolored.
reliable accurate readings from the CLX-XT. The Buffer supplied can last for up to one
year. Each mixed indicator reagent will last for up to 90 days when kept in the special The cap assemblies will last for about 1 year. Discoloration is normal. Replace the caps
cooling chamber. when they leak or fail to prime. There are two different caps. The small one is used for the
indicator. Be sure to connect the center connection to check valve and the other to the
To perform any service on the instrument we recommend you press the enclosure vent.
SERVICE button. This stops the operation and drains the cuvette.

2.2.1 Pump Tubing Replacement

1) After pressing SERVICE, remove and retain the thumb screw


and washer on top of the pump assembly.

2) Pull the pump hammer and either remove or place a shown.


To replace the cuvette follow the steps below:

1) Turn the knurled top on the optics system counterclockwise (as viewed from the top),
until the cuvette “pops” out but do not remove the top.
3) Replace the pump (black) tubing between the optics and the
check valve Discard the old tubing. 2) When the cuvette is loose, move the retaining O-ring and remove
the cuvette. You may need to use a tool such as a bent paperclip.
4) Replace the hammer, retaining washer and thumb screw.
3) The removed one can usually be cleaned and should be kept as a
spare. Replace with a clean cuvette. Push firmly in place while
tightening the knurled top.

5) If no more service will be performed press PRIME to return the


instrument to operation. Return to Normal Operation
Press the SERVICE button to return sample flow to the system. Check
for leaks. If a leak occurs press SERVICE again, repair leak and try
again.

Once the system is operating correctly, return or replace reagents and


press PRIME and then one time to restart reagent flow. The system
will automatically return to normal operation

CLX-XT 29149 (6/16) Page 3 CLX-XT 29149 (6/16) Page 4


Quick Instructions REV 1.3 Quick Instructions REV 1.3
2.4 Setting the Flow Rate 2.5 T-Strainer Cleaning

The flow rate on the CLX-XT was factory adjusted and usually should not need The T-strainer is an integral part of the system and must be checked whenever performing
adjustment. Installation variances may affect the flow. The optimal flow rate through the service. When necessary it must be removed and cleaned. The element may need to be
CLX-XT may be adjusted if needed. The flow is adjusted by removing regulator vinyl cap replaced occasionally.
and turning the adjustment screw on the pressure regulator. To assist in this adjustment
follow the procedure shown below: Steps:

1) Press the SERVICE button. 1) Press SERVICE to stop the flow of sample water and drain the
cuvette.

2) Wait for the display to read HOLd, then press Mode/ Exit.

3) Display will show FLOW with the number 0. Press


either the p or q button. 2) Ensure the source water is turned off.

3) The T-strainer is clamped to the intake regulator. The removal


requires the use of a flat blade screwdriver as shown in the
photo. Once the two clamps are opened the T-strainer can be
4) CLX-XT will drain, and then pulse in water while a count is displayed on the screen. removed.

4) Disconnect the T-strainer and regulator from the tubing at the


5) The display will show one of three messages HI, LO or Good. top to clear the case.

The flow test determines if the flow rate is suitable 5) Clean the T-strainer screen and replace.
for proper operation. Loosen the locking nut then
adjust the pressure regulator using a coin or a large 6) Tighten the strainer bowl firmly
flat blade screwdriver. Press either the p or q
button while in the FLOW routine to display a new 7) Be certain the clamps are tightened fully and the pumping
flow rate. Please note that only ¼ turn incremental connections are complete.
adjustments should be made to the regulator on each
attempt. 8) Turn source water back on.

9) Return to normal operation.


If the message is LO, turn the regulator control clockwise. If the message is HI, turn the
regulator counterclockwise. If the message is Good, no adjustment is required. Tighten the
locking nut after adjustment and replace the regulator vinyl cap. To return to normal
operation, press the Ώ button.

CLX-XT 29149 (6/16) Page 5 CLX-XT 29149 (6/16) Page 6


Quick Instructions REV 1.3 Quick Instructions REV 1.3
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

DOSING PUMP(S)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 13
GRUNDFOS INSTRUCTIONS

SMART Digital XL - DDA


From 60 to 200 l/h

Installation and operating instructions

Further languages

http://net.grundfos.com/qr/i/98767821
English (GB) Installation and operating instructions
English (GB)

Original installation and operating instructions 6.4.4 Batch (pulse-based) 25


6.4.5 Dosing timer cycle 26
CONTENTS 6.4.6 Dosing timer week 27
Page 6.5 Analog output 28
6.6 SlowMode 28
1. General information 3
6.7 FlowControl 29
1.1 Symbols used in this document 3
6.8 Pressure monitoring 30
1.2 Qualification and training of personnel 3
6.8.1 Pressure setting ranges 30
1.3 Safety instructions for the operator/user 3
6.8.2 Calibration of pressure sensor 30
1.4 Safety of the system in the event of a
failure in the dosing pump 4 6.9 Flow measurement 31
1.5 Dosing chemicals 4 6.10 AutoFlowAdapt 31
1.6 Diaphragm leakage 4 6.11 Auto deaeration 31
1.6.1 Diaphragm leakage detection (optional) 4 6.12 Diaphragm leak. detect. 31
6.13 Key lock 32
2. Product introduction 5
6.13.1 Temporary deactivation 32
2.1 Applications 5
6.13.2 Deactivation 32
2.2 Improper operating methods 5
6.14 Display setup 32
2.3 Symbols on the pump 6
6.14.1 Units 32
2.4 Nameplate 6
6.14.2 Additional display 32
2.5 Type key 7 6.15 Time+date 33
2.6 Product overview 8 6.16 Bus communication 33
3. Technical data / Dimensions 9 6.16.1 GENIbus communication 33
3.1 Technical data 9 6.16.2 Possible industrial bus types 33
3.2 Dimensions 11 6.16.3 Activate communication 33
4. Assembly and installation 12 6.16.4 Setting the bus address 34
4.1 Pump assembly 12 6.16.5 Characteristics of bus communication 34
4.1.1 Requirements 12 6.16.6 Deactivate communication 34
4.1.2 Aligning and installing the mounting plate 12 6.16.7 Communication faults 34
4.1.3 Installing the pump on the mounting plate 12 6.17 Inputs/Outputs 35
4.1.4 Adjusting the control cube position 12 6.17.1 Relay outputs 35
4.2 Hydraulic connection 13 6.17.2 External stop 36
4.3 Electrical connection 14 6.17.3 Empty and Low level signals 36
6.18 Basic settings 36
5. Startup 16
5.1 Preparing the pump for startup 16 7. Service 37
5.2 Starting up the pump 16 7.1 Regular maintenance 37
5.3 Setting the menu language 17 7.2 Cleaning 37
5.4 Deaerating the pump 18 7.3 Service system 37
5.5 Calibrating the pump 18 7.4 Perform service 38
5.5.1 Calibration process - example for DDA 19 7.4.1 Dosing head overview 38
60-10 7.4.2 Dismantling the diaphragm and valves 39
6. Operation 20 7.4.3 Reassembling the diaphragm and valves 39
6.1 Control elements 20 7.5 Resetting the service system 39
6.2 Display and symbols 20 7.6 Diaphragm leakage 40
6.2.1 Navigation 20 7.6.1 Dismantling in case of diaphragm 40
leakage
6.2.2 Operating states 20
7.6.2 Dosing liquid in the pump housing 40
6.2.3 Sleep mode (energy-saving mode) 20
7.7 Repairs 41
6.2.4 Overview of display symbols 21
6.3 Main menus 22 8. Faults 41
6.3.1 Operation 22 8.1 List of faults 42
6.3.2 Info 22 8.1.1 Faults with error message 42
6.3.3 Alarm 22 8.1.2 General faults 44
6.3.4 Setup 23 9. Disposal 44
6.4 Operation modes 23
6.4.1 Manual 23
6.4.2 Pulse 24
6.4.3 Analog 0/4-20 mA 24

2
1.2 Qualification and training of personnel
Prior to installation, read this document.

English (GB)
Installation and operation must comply The personnel responsible for the installation,
with local regulations and accepted codes operation and service must be appropriately
of good practice. qualified for these tasks. Areas of responsibility,
levels of authority and the supervision of the
personnel must be precisely defined by the operator.
1. General information If necessary, the personnel must be trained
These installation and operating instructions contain appropriately.
general instructions that must be observed during
Risks of not observing the safety instructions
installation, operation and maintenance of the pump.
It must therefore be read by the installation engineer Non-observance of the safety instructions may have
and the relevant qualified operator prior to dangerous consequences for the personnel, the
installation and startup, and must be available at the environment and the pump and may result in the loss
installation location at all times. of any claims for damages.
It may lead to the following hazards:
1.1 Symbols used in this document • Personal injury from exposure to electrical,
mechanical and chemical influences.
WARNING • Damage to the environment and personal injury
Indicates a hazardous situation which, if from leakage of harmful substances.
not avoided, could result in death or
serious personal injury. 1.3 Safety instructions for the
operator/user
CAUTION The safety instructions described in these
Indicates a hazardous situation which, if instructions, existing national regulations on health
not avoided, could result in minor or protection, environmental protection and for accident
moderate personal injury. prevention and any internal working, operating and
safety regulations of the operator must be observed.
The text accompanying the three hazard symbols
DANGER, WARNING and CAUTION is structured in Information attached to the pump must be observed.
the following way: Leakages of dangerous substances must be
disposed of in a way that is not harmful to the
SIGNAL WORD personnel or the environment.
Description of hazard Damage caused by electrical energy must be
Consequence of ignoring the warning. prevented, see the regulations of the local electricity
- Action to avoid the hazard. supply company.

WARNING
A blue or grey circle with a white graphical
symbol indicates that an action must be Electric shock
taken. Death or serious personal injury
- Keep liquids away from the power
supply and electrical components.
If these instructions are not observed, it
may result in malfunction or damage to the
equipment. Before starting work on the pump, the
pump must be in the "Stop" operating state
or be disconnected from the power supply.
The system must be pressureless.
Tips and advice that make the work easier.

The mains plug is the separator separating


the pump from the mains.

Only original accessories and original spare parts


should be used.

3
1.4 Safety of the system in the event of a To avoid any danger resulting from diaphragm
failure in the dosing pump leakage, observe the following:
English (GB)

• Perform regular maintenance. See section


The dosing pump was designed according to the
7.1 Regular maintenance.
latest technologies and is carefully manufactured
and tested. • Never operate the pump with blocked or soiled
drain opening.
If it fails regardless of this, the safety of the overall
system must be ensured. Use the relevant – If the drain opening is blocked or soiled,
monitoring and control functions for this. proceed as described in section
7.6.1 Dismantling in case of diaphragm
Make sure that any chemicals that are leakage.
released from the pump or any damaged • Take suitable precautions to prevent harm to
lines do not cause damage to system parts health and damage to property from escaping
and buildings. dosing liquid.
The installation of leak monitoring • Never operate the pump with damaged or loose
solutions and drip trays is recommended. dosing head screws.

1.5 Dosing chemicals 1.6.1 Diaphragm leakage detection (optional)


Applies to DDA-AR control variant.
Before switching the supply voltage back on, the
dosing lines must be connected in such a way that Pumps with diaphragm leakage detection (DLD)
any chemicals in the dosing head cannot spray out have a special dosing head with a special diaphragm
and put people at risk. and a pressure switch. The pressure switch is fitted
and connected to the pump on delivery.
The dosing medium is pressurised and can be
harmful to health and the environment. For pumps with diaphragm leakage detection the
pressure differential between inlet and outlet side
When working with chemicals, the accident
must be at least 2 bar / 29 psi.
prevention regulations applicable at the installation
site should be applied (e.g. wearing protective
clothing and safety goggles). 4
Observe the chemical manufacturer's safety data
sheets and safety instructions when handling
chemicals! 1
A deaeration hose, which is routed into a container,

TM06 7258 3716


e.g. a drip tray, must be connected to the deaeration 2
valve.

1.6 Diaphragm leakage


3 D1 D2 D3
If the diaphragm leaks or is broken, dosing liquid
escapes from the drain opening on the dosing head. Fig. 1 Diaphragm leakage detection
See fig. 4, pos. 16. Observe section 7.6 Diaphragm
leakage.
Pos. Components
WARNING
1 Pressure switch
Danger of explosion, if dosing liquid
has entered the pump housing! 2 Dosing head
Death or serious personal injury 3 Drain opening
Operation with damaged diaphragms can
lead to dosing liquid entering the pump 4 Dosing medium
housing. D1 Working diaphragm
- In case of diaphragm leakage,
immediately separate the pump from D2 Signal diaphragm (intermediate layer)
the power supply! D3 Protective diaphragm
- Make sure the pump cannot be put back
into operation by accident!
- Dismantle the dosing head without
connecting the pump to the power
supply and make sure no dosing liquid
has entered the pump housing. Proceed
as described in section
7.6.1 Dismantling in case of diaphragm
leakage.

4
In case of a leak in the working diaphragm: Areas of application
• Dosing medium (4) penetrates between working • Drinking water treatment

English (GB)
diaphragm (D1) and protective diaphragm (D3) • Wastewater treatment
and is transferred to the pressure switch (1)
• Boiler water treatment
through the signal diaphragm (D2).
• Cooling water treatment
• On the next discharge stroke the increasing
pressure activates the pressure switch (1). • Process water treatment
• The pump indicates an alarm and stops. • CIP (Clean-In-Place)
The pump provides two relay outputs, which can be • Swimming pool water treatment
used to trigger an external alarm, for example. • Chemical industry
Replace the diaphragm as soon as possible after a • Ultrafiltration process and reverse osmosis
diaphragm leakage was detected. • Food and beverage industry
• Paper and pulp industry
Replace the pressure switch, if the
diaphragm of the pressure switch is • Irrigation
damaged.
2.2 Improper operating methods
If both the working diaphragm (D1) and the The operational safety of the pump is only
protective diaphragm (D3) are damaged, dosing guaranteed if it is used in accordance with section
liquid escapes from the drain opening (3) on the 2.1 Applications.
dosing head.
Other applications or the operation of pumps in
Immediately separate the pump from the ambient and operating conditions, which are not
power supply. Observe section approved, are considered improper and are not
1.6 Diaphragm leakage. permitted. Grundfos cannot be held liable for any
damage resulting from incorrect use.

2. Product introduction The pump is NOT approved for operation


The DDA dosing pump is a self-priming diaphragm in potentially explosive areas, automotive
pump. It consists of a housing with PMS (Permanent applications or marine applications.
Magnet Synchronous) motor and electronics, a
dosing head with double PTFE diaphragm and Frequent disengagement from the mains
valves, and the control cube. voltage, e.g. via a relay, can result in
Excellent dosing features of the pump: damage to the pump electronics and in the
breakdown of the pump. The dosing
• Optimal intake even with degassing media, as accuracy is also reduced as a result of
the pump always works at full suction stroke internal start procedures.
volume.
Do not control the pump via the mains
• Continuous dosing, as the medium is sucked up voltage for dosing purposes!
with a short suction stroke, regardless of the
current dosing flow, and dosed with the longest Only use the "External stop" function to
possible dosing stroke. start and stop the pump!

2.1 Applications
The pump is suitable for liquid, non-abrasive,
non-flammable and non-combustible media.
Observe the technical data of the product. See
section 3.1 Technical data.
Observe the freezing and boiling points of the dosing
medium.
Make sure that parts in contact with the dosing
medium are resistant to the dosing medium under
operating conditions. See data booklet:
http://net.grundfos.com/qr/i/99021865.
Should you have any questions regarding the
material resistance and suitability of the pump for
specific dosing media, please contact Grundfos.
A sunscreen is required for outdoor installation.

5
2.3 Symbols on the pump
English (GB)

Symbol Description

Indication of universally dangerous spot.

In case of emergency and prior to all maintenance work and repairs, take the mains plug out
of the power supply!

The device complies with electrical safety class I.

2.4 Nameplate

      

Type Pmax W IP 65

TM06 7046 2916


U f Imax A Q l/h gph
Model P Bar psi
99140620

Made in France 'td͕ϳϲϯϮϳWĮŶnjƚĂů͕'ĞƌŵĂŶLJ

  
Fig. 2 Nameplate

Pos. Description Pos. Description

1 Type designation 6 Enclosure class


2 Voltage 7 Marks of approval
3 Frequency 8 Country of origin
4 Power consumption 9 Max. operating pressure
5 Max. dosing flow 10 Model

6
2.5 Type key
Valve type

English (GB)
The type key is used to identify the precise pump
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
and is not used for configuration purposes.
Example: DDA 60-10 FCM-PVC/V/C-F-31U3U3FG 1 Standard
2 Spring-loaded
Type
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG Connection, inlet / outlet
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
Max. flow [l/h]
U3U3 2x Union nut G5/4
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
2x Hose connector 19/20 mm
2x Hose clamp
Max. pressure [bar]
2x Pipe connector 25 mm
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
A7A7 2x Union nut G5/4

Control variant 2x Inlay external thread 3/4" NPT

DDA 60-10 FCM-PVC/V/C-F-31U3U3FG A1A1 2x Union nut G5/4 (SS)

AR Alarm relay 2x Inlay internal thread Rp3/4" (SS)

FCM AR + FlowControl function A3A3 2x Union nut G5/4 (SS)


2x Inlay internal thread 3/4" NPT (SS)
Dosing head variant
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG Mains plug

PVC Polyvinyl chloride DDA 60-10 FCM-PVC/V/C-F-31U3U3FG

PV PVDF F EU (Schuko)

SS Stainless steel 1.4401 B USA, Canada

PVC + integrated diaphragm leakage G UK


PVC-L
detection I Australia, New Zealand, Taiwan
PV + integrated diaphragm leakage E Switzerland
PV-L
detection J Japan
SS + integrated diaphragm leakage L Argentina
SS-L
detection

Design / approval
Gasket material
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
G Grundfos red
E EPDM
A Grundfos green
V FKM
B Grundfos black
T PTFE
X Neutral / black

Valve ball material R EAC approval

DDA 60-10 FCM-PVC/V/C-F-31U3U3FG C China approval

C Ceramics
Special variant
SS Stainless steel 1.4401
DDA 60-10 FCM-PVC/V/C-F-31U3U3FGC3

Control cube Standard

DDA 60-10 FCM-PVC/V/C-F-31U3U3FG C3 Inspection certificate 3.1 (EN 10204)

Front mounted (change to left or right is


F
possible)

Supply voltage
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
3 100-240 V 50/60 Hz single phase

7
2.6 Product overview
See
English (GB)

Pos. Description
1 section
2
1 Control cube
3 2 Graphic LC display 6.2.2
8 3 Click wheel 6.1
4 [100%] key 6.1
4
5 Signal inputs/outputs 4.3
6 Mounting plate
7 Mains connection
8 [Start/stop] key 6.1
9 Dosing head
10 Valve, outlet side
5 11 Deaeration valve
12 Connection, deaeration hose
TM06 7047 2916
7 Pressure switch of diaphragm
13 leakage detection (optional for
DDA-AR)
6
FlowControl sensor plug (only
14
DDA-FCM)

Fig. 3 Front view of the pump 15 Valve, inlet side


Drain opening in case of
16
9 10 diaphragm leakage
Signal connection (FlowControl
11 17
or diaphragm leakage detection)
12

13
TM06 7048 2916

14

17 16 15

Fig. 4 Dosing head

8
3. Technical data / Dimensions

English (GB)
3.1 Technical data

Data 60-10 120-7 200-4

Turn-down ratio (setting range) [1:X] 800 800 800


[l/h] 60 120 200
Max. dosing capacity
[gph] 15.8 32 52.8
[l/h] 30 60 100
Max. dosing capacity with SlowMode 50 %
[gph] 7.9 16 26.4
[l/h] 15 30 50
Max. dosing capacity with SlowMode 25 %
[gph] 3.95 8 13.2
[l/h] 0.075 0.15 0.25
Min. dosing capacity
[gph] 0.0197 0.04 0.066
[bar] 10 7 4
Max. operating pressure (backpressure)
[psi] 145 101 58
[strokes/
Max. stroke frequency 1) 196 188 188
min]
Stroke volume [ml] 5.56 11.58 19.3
Accuracy of repeatability 5) [%] 1.5 SP + 0.1 FS 5)
Max. suction lift during operation 2) [m] 3
Max. suction lift when priming with wet
[m] 1.5
valves2)

Min. pressure difference between inlet and [bar] 1 6)


Mechanical outlet side [psi] 14.5 6)
data
[bar] 2
Max. inlet pressure, inlet side
[psi] 29
Max. viscosity in SlowMode 25 % with [mPas]
3000 3000 2000
spring-loaded valves 3) (= cP)
Max. viscosity in SlowMode 50 % with [mPas]
2000 1500 1000
spring-loaded valves 3) (= cP)
Max. viscosity without SlowMode with [mPas]
1000 1000 500
spring-loaded valves 3) (= cP)
[mPas]
Max. viscosity without spring-loaded valves 3) 100
(= cP)
Min. internal hose/pipe diameter inlet/outlet
[mm] 19
side 2), 4)
Min. internal hose/pipe diameter inlet/outlet
[mm] 19
side (high viscosity) 4)
Min. / Max. liquid temperature (PVDF, SS) [°C] 0 / 50
Min. / Max. liquid temperature (PVC) [°C] 0 / 40
Min. / Max. ambient temperature [°C] 0 / 45
Min. / Max. storage temperature (PVDF, SS) [°C] -20 / 70
Min. / Max. storage temperature (PVC) [°C] -20 / 45
Max. relative humidity (non-condensing) [%] 90
Max. altitude above sea level [m] 2000

9
Data 60-10 120-7 200-4
English (GB)

Voltage [V] 100-240 V ± 10 %, 50/60 Hz


Length of mains cable [m] 1.5
Max. inrush current for 2 ms (100 V) [A] 35

Electrical Max. inrush current for 2 ms (240 V) [A] 70


data Max. power consumption P1 [W] 62
Enclosure class IP65, Nema 4X
Electrical safety class I
Pollution degree 2
Max. load for level input 12 V, 5 mA
Max. load for pulse input 12 V, 5 mA
Max. load for External stop input 12 V, 5 mA
Min. pulse length [ms] 5
Signal input Max. pulse frequency [Hz] 100
Impedance at 0/4-20 mA analog input [Ω] 15
Accuracy of analog input (full-scale value) [%] ± 0.5
Min. resolution of analog input [mA] 0.02
Max. loop resistance in external circuit [Ω] 150
Max. resistive load on relay output [A] 0.5
Max. voltage on relay/analog output [V] 30 VDC / 30 VAC
Signal Max. loop resistance in external circuit of the
[Ω] 500
output 0/4-20 mA analog output
Accuracy of analog output (full-scale value) [%] ± 0.5
Min. resolution of analog output [mA] 0.02
Weight (PVC, PVDF) [kg] 6.7 7.9 8.9
Weight/size Weight (stainless steel) [kg] 7.2 8.3 9.1
Diaphragm diameter [mm] 74 97 117

Sound
Max. sound pressure level [dB(A)] 80
pressure

Approvals CE, CSA-US, NSF61, EAC, ACS, RCM


1)
The maximum stroke frequency varies depending on calibration
2)
Data is based on measurements with water
3)
Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
4)
Length of inlet line: 1.5 m, length of outlet line: 10 m (at max. viscosity)
5)
FS = Full-scale (maximum actual dosing flow), SP = Setpoint
6)
For FCM control variant and for pumps with diaphragm leakage detection the pressure difference must be
at least 2 bar / 29 psi.

10
3.2 Dimensions

English (GB)
29 187 4xØ9
36 140 4xØ7

105
136
180
7
10 Ø7
159
13 172.5
183.5
140.5 A
A2 A1
G 5/4"

283.5
B

25

TM06 7049 2916


D
C

194

Fig. 5 Dimensional sketch

Dosing head A A1 A2 B C D
Pump type
material [mm] [mm] [mm] [mm] [mm] [mm]

DDA 60-10 PVC/PV 410 374 26 263 112 45


DDA 60-10 SS 405 364 - 263 112 45
DDA 120-7 PVC/PV 410 374 26 276.5 97 45
DDA 120-7 SS 405 364 - 276.5 97 45
DDA 200-4 PVC/PV 410 374 26 287.5 88 45
DDA 200-4 SS 405 364 - 287.5 88 45

11
4. Assembly and installation 4.1.4 Adjusting the control cube position
The control cube is fitted to the front of the pump on
English (GB)

4.1 Pump assembly delivery. It can be turned by 90 ° so that the user can
select to operate the pump from the right or left side.
Install the pump in such a way that the
plug can easily be reached by the operator Install the control cube correctly to ensure
during operation. This will enable the the enclosure class (IP65 / Nema 4X) and
operator to separate the pump from the shock protection.
power supply quickly in case of
emergency. 1. Switch off the power supply.
2. Carefully remove both protective caps on the
4.1.1 Requirements control cube using a thin screwdriver.
• The installation location must be protected from 3. Loosen the screws.
rain, humidity, condensation, direct sunlight and 4. Carefully lift off the control cube only so far from
dust. the pump housing that no tensile stress is
• The installation location must have sufficient produced on the flat band cable.
lighting to ensure safe operation. – Make sure no liquid enters the housing.
• Observe the permissible ambient conditions. See 5. Turn the control cube by 90 ° and re-attach.
section 3.1 Technical data.
– Make sure the O-ring is placed correctly.
• The mounting surface must be stable and must
not vibrate. 6. Push down the cube and tighten the screws
using a torque wrench.
• The mounting plate must be mounted horizontally
e.g. on a tank. – Torque [Nm]: 1.3 (± 0.2)
• Dosing must flow upwards vertically. 7. Attach the protective caps observing the correct
orientation.
4.1.2 Aligning and installing the mounting plate
The mounting plate can be used as a drill template,
please see fig. 5 for drill hole distances.
1. Indicate drill holes.
2. Drill holes.
3. Secure mounting plate using four screws on a
bracket or a tank.
4.1.3 Installing the pump on the mounting plate
1. Remove the locking screws from their transport
position on the mounting plate.
2. Place the pump on the mounting plate support
clamps and slide it in as far as possible.
– The mounting plate moves into the final
position when you tighten the locking screws.
3. Carefully screw in and tighten the locking screws
using a torque wrench.
– Torque [Nm]: 2.5 (+ 0.5)
TM06 7051 2916

Fig. 7 Adjusting control cube


TM06 7050 2916

Fig. 6 Installing the pump on the mounting


plate

12
4.2 Hydraulic connection Hose connection, type U3U3
For details on connection types, see section

English (GB)
WARNING 2.5 Type key.
Chemical hazard 1. Make sure the system is pressureless.
Death or serious personal injury 2. Install hose connector (1) with union nut (2) at
- Observe the material safety data sheet inlet and outlet valve.
of the dosing medium. – Make sure the gasket at the valve is placed
- Wear protective clothing (gloves and correctly.
goggles) when working on the dosing
– Tighten union nuts manually. Do not use tools.
head, connections or lines.
3. If using PTFE gaskets, retighten union nuts after
The dosing head may contain water from the factory 2-5 operating hours.
check. When dosing media which should not come
4. Push hose clamp (3) across hose (4).
into contact with water, another medium must be
dosed beforehand. 5. Push hose (4) completely onto hose connector
(1) and tighten hose clamp (3).
Faultless function can only be guaranteed in
conjunction with lines supplied by Grundfos. 6. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
The lines used must comply with the pressure limits
suitable container or collecting tray.
as per section 3.1 Technical data.
Important information on installation 1
• Observe suction lift and line diameter, see
2
section 3.1 Technical data.

TM06 7052 2916


• Shorten hoses and pipes at right angles. 3
4
• Ensure that there are no loops or kinks in the
hoses.
• Keep inlet line as short as possible.
• Route inlet line up towards the inlet valve.
• Installing a filter in the inlet line protects the Fig. 8 Hydraulic connection
entire installation against dirt and reduces the
risk of leakage.
• Install a pressure-relief valve in the outlet line to
provide protection against impermissibly high
pressure.
• We recommend the installation of a pulsation
damper downstream the pump:
– for pipe installations.
– for hose installations where the pump is
operated with ≥ 75 % of its dosing capacity.
• Only control variant DDA-FCM:
For discharge quantities < 1 l/h we recommend
the use of an additional spring-loaded valve
(approx. 2 bar) on the outlet side for the safe
generation of the necessary differential pressure.

Pressure differential between inlet and


outlet side must be at least 1 bar / 14.5 psi.
For control variant FCM and for pumps
with diaphragm leakage detection the
pressure differential between inlet and
outlet side must be at least 2 bar / 29 psi.

13
Pipe connection, type U3U3
For details on connection types, see section
English (GB)

1
2.5 Type key. 2
1. Make sure the system is pressureless.
2. Push union nut (2) across pipe (3).

TM06 7300 3216


3
3. For PVC pipe:
Glue inlay (1) to end of pipe (3) according to pipe
manufacturer's specification.
4. For PVDF pipe:
Weld inlay (1) to end of pipe (3) according to pipe
manufacturer's specification. Fig. 10 Hydraulic connection, type A7A7
5. Install pipe with union nut (2) at inlet and outlet
valve.
1
– Make sure the gasket at the valve is placed
correctly. 2
– Tighten union nuts manually. Do not use tools.

TM06 7376 3216


6. If using PTFE gaskets, retighten union nuts after 3
2-5 operating hours.
7. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.

1 Fig. 11 Hydraulic connection, type A1A1, A3A3

2 4.3 Electrical connection


The mains plug is the separator separating the pump
TM06 7299 3216

3 from the mains.


All electrical connections must be carried out by a
qualified electrician in accordance with local
regulations.
The pump can start automatically when the power
supply is switched on.
Fig. 9 Hydraulic connection
CAUTION
Pipe connection, types A1A1, A3A3, A7A7
Automatic startup
For details on connection types, see section Minor or moderate personal injury
2.5 Type key. - Make sure the pump has been correctly
1. Make sure the system is pressureless. installed and is ready to be started
2. Push union nut (2) across pipe (3). before you switch on the power supply.
3. Apply appropriate sealing material to thread of The enclosure class (IP65 / Nema 4X) is only
inlay (1). guaranteed if plugs or protective caps are correctly
4. Screw inlay (1) into end of pipe (3). installed.
5. Install pipe with union nut (2) at inlet and outlet Do not manipulate mains plug or cable.
valve. The rated voltage of the pump must conform to local
– Make sure the gasket at the valve is placed conditions. See section 2.4 Nameplate.
correctly.
– Tighten union nuts manually. Do not use tools.
6. If using PTFE gaskets, retighten union nuts after
2-5 operating hours.
7. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.

14
Signal connections

English (GB)
WARNING
Electric shock
Death or serious personal injury
- Electric circuits of external devices
connected to the pump inputs must be
separated from dangerous voltage by
means of double or reinforced
insulation!

2 1 2 1

3 4 3 4

2 1 2 1
5 5
3 4 3 4

4 3

1 2

TM06 7054 3216


4 5 4 5 3
3 4 3 4 2
2 2 3 GND 2 2 3 GND 4
Ź GND 1
1 1 BUS BUS 1 1
GND
2
1

Fig. 12 Wiring diagram of the electrical connections

Symbol Function Pin assignment


1/brown 2/white 3/blue 4/black
Analog GND/(-) mA (+) mA
External stop GND X
Pulse GND X
1 2 3 4
Low-level signal X GND
Empty signal X GND
1/brown 2/white 3/blue 4/black 5/yellow/green
Analog output (+) mA GND/(-) mA
1 2/brown 3/blue 4 5/black
GENIbus RS-485 A RS-485 B GND

1/brown 2/white 3/blue 4/black


Relay 1 X X
Relay 2 X X

15
FlowControl signal connection (DDA-FCM) 5. Startup
English (GB)

5.1 Preparing the pump for startup

CAUTION
Chemical hazard
Minor or moderate personal injury
- Observe the material safety data sheet
of the dosing medium.
- Wear protective clothing (gloves and
goggles) when working on the dosing

TM06 7060 3716


head, connections or lines.
- Collect and dispose of all chemicals in a
way that is not harmful to persons or the
environment.
The pump can start automatically when the power
Fig. 13 FlowControl signal connection supply is switched on.

DLD signal connection (optional for DDA-AR) CAUTION


Automatic startup
Minor or moderate personal injury
- Make sure the pump has been correctly
installed and is ready to be started
before you switch on the power supply.

Tighten the dosing head screws with a


torque wrench before startup and every
time the dosing head has been opened.
After 48 operating hours, retighten the
TM06 7256 3716

dosing head screws using a torque


wrench. Torque [Nm]: 6 (+ 1).
• Make sure the pump has been connected
electrically by a qualified person.
• Make sure the power supply specified on the
Fig. 14 DLD signal connection nameplate matches the local conditions.
• Check that all pipe or hose connections have
been tightened properly and tighten them, if
necessary. See section 4.2 Hydraulic connection.

5.2 Starting up the pump


1. Read section 5.1 Preparing the pump for startup.
2. Switch on the power supply.
3. Proceed according to sections:
– 5.3 Setting the menu language
– 5.4 Deaerating the pump
– 5.5 Calibrating the pump.

16
5.3 Setting the menu language

English (GB)
For description of control elements, see section 6.

1. Turn click wheel to highlight the cog symbol.


Operation
60.0 l/h
Manual

2. Press the click wheel to open the "Setup" menu. Operation


60.0 l/h
Manual

3. Turn the click wheel to highlight the "Language"


menu.
Setup
Language English >
Operation mode Manual >
Analog output Actual flow >
SlowMode Off >
FlowControl active ❑

4. Press the click wheel to open the "Language"


menu.
Setup
Language English >
Operation mode Manual >
Analog output Actual flow >
SlowMode Off >
FlowControl active ❑

5. Turn the click wheel to highlight the desired


language.
Language
English
Deutsch ❑
Francais ❑
Espanol ❑
Italiano ❑

6. Press the click wheel to select the highlighted


language.
Language
English
Deutsch ❑
Francais ❑
Espanol ❑
Italiano ❑

7. Press the click wheel again to confirm the "Confirm


settings?" prompt and apply the setting.
Language
TM06 7061 2916

Confirm
settings?

Fig. 15 Set menu language

17
5.4 Deaerating the pump
English (GB)

1. Read section 5.1 Preparing the pump for startup.


2. Open the deaeration valve by approximately half
a turn.

WARNING
Pressurised dosing medium
Death or serious personal injury
- Do not open the deaeration valve by
more than one full turn.
3. Press the [100%] key and hold it down until liquid
flows out of the deaeration hose continuously
and without any bubbles.
4. Close the deaeration valve.

Press the [100%] key and simultaneously


turn the click wheel clockwise to increase
the duration of the process to up to 300
seconds. After setting the seconds, do not
press the key any longer.

5.5 Calibrating the pump


The pump is calibrated in the factory for media with a
viscosity similar to water at maximum pump
backpressure. See section 3.1 Technical data.
If the pump is operated with a backpressure that
deviates or if dosing a medium whose viscosity
deviates, the pump must be calibrated.
For pumps with FCM control variant, it is not
necessary to calibrate the pump if there is deviating
or fluctuating backpressure as long as the
"AutoFlowAdapt" function has been enabled. See
section 6.10 AutoFlowAdapt.

During calibration the pump performs 100


strokes/minute as a standard. If the
SlowMode function is activated, the
number of strokes is 60 at 50 % and 30 at
25 %.
Requirements
• The hydraulics and electrics of the pump are
connected. See section 4. Assembly and
installation.
• The pump is integrated into the dosing process
under operating conditions.
• The dosing head and inlet hose are filled with
dosing medium.
• The pump has been deaerated.

18
5.5.1 Calibration process - example for DDA 60-10

English (GB)
1. Fill a measuring beaker with dosing medium.
Recommended filling volumes V1:
– DDA 60-10: 2.5 l
– DDA 120-7: 5 l
– DDA 200-4: 8 l V1 = 2.5 l

2. Read off and note down the fill volume V1 (e.g.


2.5 l).
3. Place the inlet hose in the measuring beaker.

4. Start the calibration process in the "Setup >


Calibration" menu. Calibration
Strokes:
0 START

STOP
Calibrat. volume: 0.0000ml

5. The pump executes 200 dosing strokes and


displays the factory calibration value (e.g. 1.05 l). Calibration
Strokes: 200 START

STOP
Calibrat. volume: 1.05l

6. Remove the inlet hose from the measuring


beaker and check the remaining volume V2 (e.g.
1.39 l). V2 = 1.39 l

7. From V1 and V2, calculate the actual dosed


volume Vd = V1 - V2 (e.g. 2.5 l - 1.39 l = 1.11 l).
Vd = V1 - V2 = 1.11 l

8. Set and apply Vd in the calibration menu.


• The pump is calibrated. Calibration
START
Strokes:
200
TM06 7062 2916

STOP

Calibrat. volume: 1.11 l

Actual dosed volume Vd

19
6. Operation 6.2 Display and symbols
English (GB)

6.2.1 Navigation
6.1 Control elements
In the "Info", "Alarm" and "Setup" main menus, the
The pump control panel includes a display and the options and submenus are displayed in the rows
following control elements. below. Use the "Back" symbol to return to the higher
menu level. The scroll bar at the right edge of the
1 display indicates that there are further menu items
which are not shown.
Operation
The active symbol (current cursor position) flashes.
60.0 l/h Press the click wheel to confirm your selection and
Manual 60.0 l/h 3 open the next menu level. The active main menu is
2 4 displayed as text, the other main menus are

TM06 7063 3316


displayed as symbols. The position of the cursor is
highlighted in black in the submenus.
When you position the cursor on a value and press
the click wheel, a value is selected. Turning the click
wheel clockwise increases the value, turning the
click wheel counter-clockwise reduces the value.
Fig. 16 Control panel When you now press the click wheel, the cursor will
be released again.
Pos. Description 6.2.2 Operating states
The operating state of the pump is indicated by a
1 Graphical LC display
symbol and display colour.
[Start/stop] key:
2
Starting and stopping the pump. Display Fault Operating state
Click wheel:
Stop Standby
The click wheel is used to navigate through White -
the menus, select settings and confirm
them. Turning the click wheel clockwise Running
3 Green -
moves the cursor clockwise in increments
in the display. Turning the click wheel
Stop Standby Running
counter-clockwise moves the cursor Yellow Warning
counter-clockwise.
Stop Standby
[100%] key: Red Alarm
4 The pump doses at maximum flow
regardless of the operation mode. 6.2.3 Sleep mode (energy-saving mode)
If in the "Operation" main menu the pump is not
operated for 30 seconds, the header disappears.
After two minutes, the display brightness is reduced.
If in any other menu the pump is not operated for two
minutes, the display switches back to the
"Operation" main menu and the display brightness is
reduced. This state will be cancelled when the pump
is operated or a fault occurs.

20
6.2.4 Overview of display symbols
The following display symbols may appear in the menus.

English (GB)
Top row with main menus (Sect. 6.3)
Operation Back
Info
Alarm Run display
Setup Running - rotates when pump is dosing
Blocked drive - flashing symbol
Operation

59.6 l/h

Manual 59.6l/h

Activated functions Additional display (Sect. 6.14.2)


AR variant: Target flow
SlowMode (Sect. 6.6)
FCM variant: Actual flow
FlowControl (Sect. 6.7)
Remaining batch volume (Batch/Timer)
Key lock (Sect. 6.13) Input current (Analog)
Bus (Sect. 6.16)
Time until next dosing process (Timer)
Auto deaeration (Sect. 6.11)
Total dosed volume

Actual backpressure
Operation mode
Manual (Sect. 6.4.1) Signal/error display
Pulse (Sect. 6.4.2) External stop (Sect. 6.17.2)
Analog 0/4-20 mA (Sect. 6.4.3) Empty signal (Sect. 6.17.3)
Batch (Sect. 6.4.4) Low-level signal (Sect. 6.17.3)
Timer (Sect. 6.4.5, 6.4.6) Cable break (Sect. 6.4.3)

Operating state (Sect. 6.2.2) and dosing CIU (Sect. 6.16)


flow Service (Sect. 7.)
Running Diaphragm leak. (Sect. 6.12)
Standby Overheating (Sect. 8.1)
Stop Overload (Sect. 8.1)
TM06 7067 1117

100% Deaerating Disch. valve leak (Sect. 8.1)


Diaphragm position "out" (Sect. 7.)
Diaphragm position "in" (Sect. 7.)

Fig. 17 Overview of display symbols

21
6.3 Main menus Counters
The "Info > Counters" menu contains the following
English (GB)

The main menus are displayed as symbols at the top


of the display. The currently active main menu is counters:
displayed as text.
Counters Resettable
6.3.1 Operation
Status information such as the dosing flow, Volume
Yes
selected operation mode and operating state Total dosed volume [l] or US gallons
is displayed in the "Operation" main menu.
Operating hours
Accumulated operating hours (pump No
Operation switched on) [h]

TM06 7069 2916


Motor runtime
59.6 l/h
59.6l/h
Accumulated motor runtime [h]
No
Manual
Strokes
Accumulated number of dosing No
strokes
6.3.2 Info Power on/off
You can find the date, time and information Accumulated frequency of switching No
about the active dosing process, various mains voltage on
counters, product data and the service system status
in the "Info" main menu. The information can be 6.3.3 Alarm
accessed during operation. You can view errors in the "Alarm" main
The service system can also be reset from here. menu.

Info Alarm
Th 16.02.2017 12:34 1 12.02.2017 12:34
Backpressure 10.0bar Empty
Counters >
2 12.02.2017 12:34
Service -
Low level

TM06 7072 2916


ServiceKit
Reset service system
Software rev. Vx.xx
Motor Control Vx.xx Delete alarm
TM06 7071 2916

Hardware rev. Vx.xx messages ❑


Serial no.:
Product no.: Up to 10 warnings and alarms, together with their
Type Key: date, time and cause, are listed in chronological
order. If the list is full, the oldest entry will be
overwritten, see section 8. Faults.

22
6.3.4 Setup 6.4 Operation modes
The "Setup" main menu contains menus for

English (GB)
Six different operation modes can be set in the
pump configuration. These menus are "Setup > Operation mode" menu.
described in the following sections.
• Manual, see section 6.4.1
Check all pump settings after any change in the
• Pulse, see section 6.4.2
"Setup" menu.
• Analog 0-20mA, see section 6.4.3
Analog 4-20mA, see section 6.4.3
Setup Section • Batch (pulse-based), see section 6.4.4
Language English > 5.3 • Dosing timer cycle, see section 6.4.5
Operation mode Pulse > 6.4 • Dosing timer week, see section 6.4.6
Pulse memory* ❑ 6.4.2
Analog scaling > 6.4.3 6.4.1 Manual
Batch volume* 35.0 l 6.4.4 In this operation mode, the pump constantly
Dosing time[mm:ss]* 46:30 6.4.4 doses the dosing flow set with the click wheel.
Dosing timer cycle* > 6.4.5 The dosing flow is set in l/h or ml/h in the "Operation"
Dosing timer week* > 6.4.6 menu. The pump automatically switches between the
Analog output Actual flow > 6.5 units. Alternatively, the display can be reset to US
SlowMode Off > 6.6 units (gph). See section 6.14 Display setup.
FlowControl active* ❑ 6.7
FlowControl* > 6.7
Pressure monitoring* > 6.8 Operation
AutoFlowAdapt* ❑

TM06 7077 2916


6.10
Auto deaeration
Calibration

>
6.11
5.5
38.4 l/h

Diaphragm leak. detect.* ❑ 6.12 Manual 38.4l/h


Key lock Off > 6.13
Display > 6.14
TM06 7075 2916

Time+date > 6.15


Fig. 18 Manual mode
Bus > 6.16
Inputs/Outputs > 6.17 The setting range depends on the pump type:
Basic settings > 6.18
Setting range*
* These submenus are only displayed for specific Type
default settings and control variants. The [l/h] [gph]
contents of the "Setup" menu also vary
DDA 60-10 0.075 - 60 0.02 - 15
depending on the operation mode.
DDA 120-7 0.15 - 120 0.04 - 32
DDA 200-4 0.25 - 200 0.065 - 52

* When the "SlowMode" function is active, the


maximum dosing flow is reduced, see section
3.1 Technical data.

23
6.4.2 Pulse 6.4.3 Analog 0/4-20 mA
In this operation mode, the pump doses the In this operation mode, the pump doses
English (GB)

set dosing volume for each incoming (potential-free) according to the external analog signal. The
pulse, e.g. from a water meter. The pump dosing volume is proportional to the signal input
automatically calculates the optimum stroke value in mA.
frequency for dosing the set volume per pulse.
The calculation is based on: Operation Input value Dosing flow
• the frequency of external pulses mode [mA] [%]
• the set dosing volume/pulse. ≤ 4.1 0
4-20 mA
≥ 19.8 100
Operation ≤ 0.1 0
0-20 mA

TM06 7078 2916


18.4 ml/
≥ 19.8 100

Pulse 6.62l/h If the input value in operation mode 4-20 mA falls


below 2 mA, an alarm is displayed and the pump
stops. A cable break or signal transmitter error has
occurred. The "Cable break" symbol is displayed in
Fig. 19 Pulse mode the "Signal and error display" area of the display.
The dosing volume per pulse is set in ml/pulse in the
"Operation" menu using the click wheel. The setting Q [%]
range for the dosing volume depends on the pump 100
type:
80
mA
20
0-
Type Setting range [ml/pulse] 60

TM06 7079 2916


40
DDA 60-10 0.0111 - 111
mA
20 20
DDA 120-7 0.0232 - 232 4-
0
DDA 200-4 0.0386 - 386 0 4 8 12 16 20 [mA]

The frequency of incoming pulses is multiplied by the Fig. 20 Analog scaling


set dosing volume. If the pump receives more pulses
than it can process at the maximum dosing flow, it
runs at the maximum stroke frequency in continuous
operation. Excess pulses will be ignored if the
memory function is not enabled.
Operation

TM06 7080 2916


Memory function
When the "Setup > Pulse memory" function is
51.4 l/h
0-20mA 17.14mA
enabled, up to 65,000 unprocessed pulses can be
saved for subsequent processing.

Subsequent processing of saved pulses Fig. 21 Analog operation mode


can cause local increase in concentration!

The contents of the memory will be deleted by:


• Switching off the power supply
• Changing the operation mode
• Interruption (e.g. alarm, External stop).

24
Set analog scaling Set analog scaling in the "Operation" menu
Analog scaling refers to the assignment of the Analog scaling can also be modified after a security

English (GB)
current input value to the dosing flow. prompt directly in the "Operation" menu. This is how
Changes of analog scaling affect also the analog the dosing flow is directly modified for the current
output signal. See section 6.5 Analog output. flow input value. Please observe that changes also
have a direct effect on point I2/Q2 (see fig. 24).
Analog scaling passes through the two reference
points (I1/Q1) and (I2/Q2), which are set in the "Setup
> Analog scaling" menu. The dosing flow is Q [%]
(I2/Q 2) (I2/Q 2)
controlled according to this setting. 100
new
Example 1 (DDA 60-10)
Analog scaling with positive gradient:

TM06 7083 2916


Q [l/h]
(I2/Q2) (I1/Q 1)
60
0
0 4 actual mA 20 I [mA]
40
Fig. 24 Set analog scaling ("Operation" menu)

TM06 7081 3216


(I1/Q1) 6.4.4 Batch (pulse-based)
20
In this operation mode, the pump doses the
0 set batch volume in the set dosing time (t1). A
0 6 16 20 I [mA] batch is dosed with each incoming pulse.

Fig. 22 Analog scaling with pos. gradient


Batch volume
In example 1, the reference points I1 = 6 mA, Q1 = 20
l/h and I2 = 16 mA, Q2 = 60 l/h have been set.
From 0 to 6 mA analog scaling is described by a line

TM06 7085 2916


that passes through Q = 0 l/h, between 6 mA and 16 t1 t1
mA it rises proportionally from 20 l/h to 60 l/h and
from 16 mA onwards it passes through Q = 60 l/h. Time
Example 2 (DDA 60-10)
Analog scaling with negative gradient (Operation Pulse Pulse
mode 0-20 mA):
Fig. 25 Batch (pulse-based)
Q [l/h]
The setting range depends on the pump type:
(I1/Q1)
60
Setting range per batch
Type
Resolution*
TM06 7082 3216

from [ml] to [l]


[ml]
(I2/Q2)
18 DDA 60-10 5.56 999 0.694

0 DDA 120-7 11.6 999 1.45


0 2 16 20 I [mA]
DDA 200-4 19.3 999 2.41
Fig. 23 Analog scaling with neg. gradient
* Thanks to the digital motor control, dosing
In example 2, the reference points I1 = 2 mA, Q1 = 60 quantities with a resolution of up to 1/8 of the
l/h and I2 = 16 mA, Q2 = 18 l/h have been set. dosing stroke volume can be dosed.
From 0 to 2 mA analog scaling is described by a line
that passes through Q = 0 l/h, between 2 mA and 16
mA it drops proportionally from 60 l/h to 18 l/h and
from 16 mA onwards it passes through Q2 = 18 l/h.

25
The batch volume (e.g. 75.0 l) is set in the "Setup > 6.4.5 Dosing timer cycle
Batch volume" menu. The minimum dosing time In this operation mode, the pump doses the
English (GB)

required for this (e.g. 1 hour, 16 minutes) is set batch volume in regular cycles. Dosing
displayed and can be increased. starts when the pump is started after a singular start
delay. The setting range for the batch volume
corresponds to the values in section 6.4.4 Batch
Setup (pulse-based).

TM06 7086 2916


Operation mode Batch >
When time or date is changed in
Batch volume 75.0l
"Time+date" menu, timer dosing and timer
Dosing time[h:mm] 1:16
relay output functions (Relay 2) are
Analog output Input >
stopped!
SlowMode Off >
Timer dosing and timer relay output
Fig. 26 Batch mode functions must be restarted manually!
Changing time or date can cause increase
Signals received during a batch process or an or decrease in concentration!
interruption (e.g. alarm, External stop) will be
ignored. If the pump is restarted following an
interruption, the next batch volume is dosed on the Batch volume
next incoming pulse.

Operation
t1 t1
TM06 7087 2916

TM06 7089 2916


75.0 l
t2
Batch 74.5l
t3

Fig. 27 Batch mode Fig. 28 Dosing timer cycle diagram


In the "Operation" menu, the total batch volume (e.g.
75.0 l) and the remaining batch volume still to be t1 Dosing time
dosed (e.g. 74.5 l) are shown in the display. t2 Start delay
t3 Cycle time

In the event of an interruption (e.g. interruption of the


mains voltage, External stop), the dosing will be
stopped while the time continues running. After
suspending the interruption, the pump will continue
to dose according to the actual timeline position.
The following settings are required in the "Setup >
Dosing timer cycle" menu:

Timer
TM06 7090 2916

Batch volume 6.83l


Dosing time[mm:ss] 7:12
Cycle time[mm:ss] 9:00
Start delay[s] 12.0

Fig. 29 Dosing timer cycle

The batch volume to be dosed (e.g. 6.83 l) is set in


the "Setup > Dosing timer cycle" menu. The dosing
time required for this (e.g. 7:12) is displayed and can
be changed.

26
The total batch volume (e.g. 6.83 l) and the If several procedures overlap, the process with the
remaining batch volume still to be dosed are higher dosing flow has priority.

English (GB)
displayed in the "Operation" menu. During breaks in In the event of an interruption (e.g. disconnection of
dosing, the time until the next dosing process (e.g. the mains voltage, External stop), the dosing is
11 seconds) is displayed. stopped while the time continues running. After
suspending the interruption, the pump continues to
Operation dose according to the actual timeline position.
The following settings are required in the "Setup >

TM06 7091 2916


6.83 l
Dosing timer week" menu for each dosing procedure:

Timer 11.0s
Timer

TM06 7093 2916


Procedure 1
Batch volume 986ml
Fig. 30 Dosing timer cycle Dosing time[mm:ss] 1:00
Start time[hh:mm] 05:00
6.4.6 Dosing timer week
In this operation mode, up to 16 dosing M❑ T W❑ T F❑ S❑ S
procedures are defined for a week. These
Fig. 32 Setting the timer
dosing procedures may take place regularly on one
or several week days. The setting range for the The batch volume (e.g. 986 ml) is set in the "Setup >
batch volume corresponds to the values in section Dosing timer week" menu. The dosing time required
6.4.4 Batch (pulse-based). for this (e.g. 1 minute, 0 seconds) is displayed and
can be changed.
When time or date is changed in
"Time+date" menu, timer dosing and timer In the "Operation" menu, the total batch volume (e.g.
relay output functions (Relay 2) are 986 ml) and the remaining batch volume to be dosed
stopped! is displayed. During breaks in dosing, the time (e.g.
1 day, 2 hours) until the next dosing is displayed.
Timer dosing and timer relay output
functions must be restarted manually!
Changing time or date can cause increase Operation
or decrease in concentration!

TM06 7091 2916



986
Timer
ml
1:02d
   

 
Fig. 33 Weekly timer dosing (break in dosing)

TM06 7092 2916

 

      

MO TU WE TH FR SA SU

Fig. 31 Example for Dosing timer week function

27
6.5 Analog output 6.6 SlowMode
English (GB)

When the "SlowMode" function is enabled, the


Analog out pump slows down the suction stroke. The function is
enabled in the "Setup > SlowMode" menu and is

TM06 7094 2916


Output = Input used to prevent cavitation in the following cases:
Actual flow ❑ • for dosing media with a high viscosity
Backpressure ❑ • for degassing dosing media
Bus control ❑
• for long inlet lines
• for large suction lift.
Fig. 34 Configure analog output In the "Setup > SlowMode" menu, the speed of the
suction stroke can be reduced to 50 % or 25 %.
The analog output of the pump is parametrised in the
"Setup > Analog output" menu. The following Enabling the 'SlowMode' function reduces
settings are possible: the maximum dosing flow of the pump to
the set percentage value!
Variant
Description of output
Setting
signal SlowMode
FCM

AR

TM06 7094 2916


Off
Analog feedback signal SlowMode (50% max.) ❑
(not for master-slave SlowMode (25% max.) ❑
Output =
application). The analog X X
Input
input signal is mapped
1:1 to the analog output.
Current actual flow Fig. 35 SlowMode menu
• 0/4 mA = 0 %
Actual
• 20 mA = 100 % X X*
flow**
see section 6.9 Flow
measurement
Backpressure, measured
in the dosing head
• 0/4 mA = 0 bar
Backpre
• 20 mA = Max. X
ssure
operating pressure
see section 6.8 Pressure
monitoring
Enabled by command in
Bus
Bus control, see section X X
control
6.16 Bus communication

* Output signal is based on motor speed and pump


status (target flow).
** Signal has same analog scaling as the current
analog input signal. See 6.4.3 Analog 0/4-20 mA.
Wiring diagram see section 4.3 Electrical
connection.

In all operation modes, the analog output


has a range of 4-20 mA. Exception:
Operation mode 0-20 mA. Here, the
analog output range is 0-20 mA.

28
6.7 FlowControl FlowControl works with a maintenance-free sensor
in the dosing head. During the dosing process, the

English (GB)
Applies to DDA-FCM control variant.
sensor measures the current pressure and
This function is used to monitor the dosing process. continuously sends the measured value to the
Although the pump is running, various influences microprocessor in the pump. An internal indicator
e.g. air bubbles, can cause a reduced flow or even diagram is created from the current measured values
stop the dosing process. In order to guarantee and the current diaphragm position (stroke length).
optimum process safety, the enabled "FlowControl" Causes for deviations can be identified immediately
function directly detects and indicates the following by aligning the current indicator diagram with a
errors and deviations: calculated optimum indicator diagram. Air bubbles in
• Overpressure the dosing head reduce e.g. the discharge phase
• Damaged outlet line and consequently the stroke volume (see fig. 36).
• Air in the dosing chamber Requirements for a correct indicator diagram are:
• Cavitation • FlowControl function is active
• Inlet valve leakage > 70 % • pressure difference between inlet and outlet side
is > 2 bar
• Outlet valve leakage > 70 %.
• No interruption/pause in discharge stroke
The occurrence of a fault is indicated by the "eye"
symbol flashing. The faults are displayed in the • Pressure sensor and cable are functioning
"Alarm" menu. See section 8. Faults. properly
• No leakage > 50 % in inlet or outlet valve
If one of these requirements is not met, the indicator
diagram cannot be evaluated.

Pressure

Trouble-free dosing stroke


Faulty dosing stroke: Air
bubbles in the dosing
head

1
3

TM06 7097 2916


4

Stroke length

Fig. 36 Indicator diagram

Sensitivity
1 Compression phase
In "Sensitivity" the deviation in stroke volume, which
2 Discharge phase will result in an error message, is set in percent.
3 Expansion phase
Sensitivity Deviation
4 Suction phase
low approx. 70 %
Setting FlowControl
medium approx. 50 %
The "FlowControl" function is set using the two
parameters "Sensitivity" and "Delay" in the "Setup > high approx. 30 %
FlowControl" menu.

29
Delay 6.8.2 Calibration of pressure sensor
The "Delay" parameter is used to define the time The pressure sensor is calibrated in the factory. As a
English (GB)

period until an error message is generated: "short", rule, it does not need to be re-calibrated. If specific
"medium" or "long". The delay depends on the set circumstances (e.g. pressure sensor exchange,
dosing flow and therefore cannot be measured in extreme air pressure values at the location of the
strokes or time. pump) necessitate a calibration, the sensor can be
calibrated as follows:
Air bubbles
1. Set pump to "Stop" operating state.
The "FlowControl" function identifies air bubbles >
60 % of the stroke volume. After switching to "Air 2. Make system pressureless and flush.
bubble" warning status, the pump adapts the stroke 3. Dismantle inlet line and inlet valve.
frequency to approximately 30-40 % of max. stroke
frequency, and starts a special motor drive strategy. Calibrating when the inlet valve is installed
The adaptation of the stroke frequency allows the air produces incorrect calibration and can
bubbles to rise from inlet to outlet valve. Due to the cause personal injuries and damage to
special motor drive strategy the air bubbles are property!
displaced from the dosing head into the outlet line. Only carry out a calibration if this is
If the air bubbles have not been eliminated after a technically required!
maximum of 60 strokes, the pump returns to the 4. Proceed as described below to calibrate:
normal motor drive strategy.

6.8 Pressure monitoring Plug in pressure sensor plug or select "Setup >
FlowControl active" menu
Applies to DDA-FCM control variant.
A pressure sensor monitors the pressure in the
dosing head. If the pressure during the discharge
phase falls below 2 bar, a warning is generated Prompt:
(pump continues running). If in the "Setup > "Activate FlowContr.?"
Pressure monitoring" menu the function "Min.
pressure alarm" is activated, an alarm is generated FlowControl not
and the pump is stopped. activated
If the pressure exceeds the "Max. pressure" set in Prompt:
the "Setup > Pressure monitoring" menu, the pump "Sensor calibration?"
is shut down, enters the standby state and indicates
an alarm. FlowControl active,
Sensor not calibrated.
The pump restarts automatically once the Prompt:
backpressure falls below the set "Max. "Suction valve removed?"
pressure"!

6.8.1 Pressure setting ranges Sensor not calibrated.

Fixed min. Adjustable max. Calibration error


Type pressure pressure OK
[bar] [psi] [bar] [psi] Message: Message:
DDA 60-10 <2 < 29 3-11 44-165 "Sensor calib. OK!" "Sensor calib. failed!"
"Current pressure: X "Repeat?"
DDA 120-7 <2 < 29 3-8 44-115 bar"
TM06 7098 2916

DDA 200-4 <2 < 29 3-5 44-73

The pressure measured in the dosing head


is slightly higher than the actual system Sensor not calibrated.
pressure.
Therefore the "Max. pressure " should be If a calibration is not successfully possible, check
set at least 1 bar higher than the system plug connections, cable and sensor and replace
pressure. defective parts where necessary.

30
6.9 Flow measurement Example of "AutoFlowAdapt"
Pressure fluctuations

English (GB)
Applies to DDA-FCM control variant.
The pump accurately measures the actual flow and The dosing volume decreases as backpressure
displays it. Via the 0/4-20 mA analog output, the increases and conversely the dosing volume
actual flow signal can easily be integrated into an increases as the backpressure decreases.
external process control without additional The "AutoFlowAdapt" function identifies pressure
measuring equipment. See section 6.5 Analog fluctuations and responds by adjusting the stroke
output. frequency. The actual flow is thus maintained at a
The flow measurement is based on the indicator constant level.
diagram as described in section 6.7 FlowControl.
The accumulated length of the discharge phase 6.11 Auto deaeration
multiplied by the stroke frequency produces the Dosing degassing media can result in air
displayed actual flow. Faults e.g. air bubbles or pockets in the dosing head during breaks in
backpressure that is too low result in a smaller or dosing. This can result in no medium being dosed
larger actual flow. When the "AutoFlowAdapt" when restarting the pump. The "Setup > Auto
function is activated (see section deaeration" function performs pump deaeration
6.10 AutoFlowAdapt), the pump compensates for automatically at regular intervals.
these influences by correction of the stroke Software-controlled diaphragm movements
frequency. encourage any bubbles to rise and gather at the
Strokes which cannot be analysed (partial strokes, outlet valve so that they can be removed on the next
pressure differential which is too low) are dosing stroke.
provisionally calculated based on the setpoint value The function works:
and displayed. • when the pump is not in the "Stop" operating
state
6.10 AutoFlowAdapt
• during breaks in dosing (e.g. External stop, no
Applies to DDA-FCM control variant. incoming pulses, etc.).
The "AutoFlowAdapt" function is activated in the The diaphragm movements can displace small
"Setup" menu. It detects changes in various volumes into the outlet line. When dosing strongly
parameters and responds accordingly in order to degassing media, this is however virtually
keep the set target flow constant. impossible.

Dosing accuracy is increased when 6.12 Diaphragm leak. detect.


"AutoFlowAdapt" is activated. Applies to DDA-AR control variant.
This function is only available if the pump is
This function processes information from the equipped with a special dosing head for leakage
pressure sensor in the dosing head. Errors detected detection. See section 2.5 Type key.
by the sensor are processed by the software. The The "Diaphragm leak. detect." function is activated in
pump responds immediately regardless of the the "Setup" menu. It detects diaphragm leakages.
operation mode by adjusting the stroke frequency or When a leakage is detected, the pump stops and an
where necessary compensating for the deviations alarm is displayed.
with a corresponding indicator diagram.
See also sections:
If the target flow cannot be achieved by the
adjustments, a warning is issued. • 1.6.1 Diaphragm leakage detection (optional)
"AutoFlowAdapt" operates on the basis of the • 6.2.4 Overview of display symbols
following functions: • 8.1 List of faults
• FlowControl: malfunctions are identified. See
section 6.7 FlowControl.
• Pressure monitoring: pressure fluctuations are
identified. See section 6.8 Pressure monitoring.
• Flow measurement: deviations from the target
flow are identified. See section 6.9 Flow
measurement.

31
6.13 Key lock 6.14.2 Additional display
The additional display provides additional
English (GB)

The key lock is set in the "Setup > Key lock"


menu by entering a four-digit code. It protects the information about the current pump status. The value
pump by preventing changes to settings. Two levels is shown in the display with the corresponding
of key lock can be selected: symbol.
In "Manual" mode the "Actual flow" information can
Level Description be displayed with Q = 31.9 l/h (see fig. 37).

All settings can only be changed by


Settings
entering the lock code. Operation
The [Start/stop] key and the [100%]
key are not locked.
32.0 l/h

TM06 7103 2916


Settings + The [Start/stop] key and the [100%] Manual 31.9l/h
keys key and all settings are locked.

It is still possible to navigate in the "Alarm" and "Info"


main menu and reset alarms. Additional display
6.13.1 Temporary deactivation Fig. 37 Display with additional display
If the "Key lock" function is activated but settings
need to be modified, the keys can be unlocked The additional display can be set as follows:
temporarily by entering the deactivation code. If the
code is not entered within 10 seconds, the display Setting Description
automatically switches to the "Operation" main
menu. The key lock remains active. Depending on the operation mode:

6.13.2 Deactivation Actual flow (Manual/Pulse) 1), 2)


The key lock can be deactivated in the "Setup > Key Target flow (Pulse)
lock" menu via the "Off" menu point. The key lock is Default
deactivated after the general code "2583" or a display Input current (analog)
pre-defined custom code has been entered.
Remaining batch volume
6.14 Display setup (Batch, Timer)
Use the following settings in the "Setup > Display" Period until next dosing (Timer)
menu to adjust the display properties: Dosed Dosed vol. since last reset (see
• Units (metric/US) volume Counters on page 22)
• Display contrast Actual flow Current actual flow 1), 2)
• Additional display.
Current backpressure in the
Backpressure
6.14.1 Units dosing head 1)
Metric units (litres/millilitres/bar) or US units (US 1)
only control variant DDA-FCM
gallons/PSI) can be selected. According to the
operation mode and menu, the following units of 2)
only if indicator diagram can be evaluated (see
measurement are displayed: 6.7 FlowControl)

Operation mode /
Metric units US units
function

Manual control ml/h or l/h gph


Pulse control ml/ ml/
0/4-20 mA Analog
ml/h or l/h gph
control
Batch (pulse- or
ml or l gal
timer-controlled)
Calibration ml ml
Volume counter l gal
Pressure monitoring bar psi

32
6.15 Time+date 6.16.2 Possible industrial bus types
The pump can be connected to a Grundfos CIU unit

English (GB)
The time and date can be set in the "Setup >
Time+date" menu. (CIU = Communication Interface Unit) equipped with
one of the following CIM modules (CIM =
The conversion between summer and winter time
Communication Interface Module):
does not take place automatically.
• CIM150 Profibus
When time or date is changed in • CIM200 Modbus
"Time+date" menu, timer dosing and timer • CIM270 GRM
relay output functions (Relay 2) are
stopped! • CIM500 Ethernet
Timer dosing and timer relay output For internal communication between the CIU and the
functions must be restarted manually! dosing pump, GENIbus is used.
Changing time or date can cause increase The maximum cable length for GENIbus
or decrease in concentration! connection is 3 m and must not be
exceeded.
6.16 Bus communication Prior to installation and startup, read the
The bus communication enables remote documentation delivered with the CIU unit.
monitoring and setting of the pump via a
fieldbus system. 6.16.3 Activate communication
Further manuals, functional profiles and support files 1. Set the pump to operating state "Stop" with the
(e.g. GSD-files) are available on the CD delivered [Start/stop] key.
with the interface hardware and on 2. Switch off the power supply of the pump.
www.grundfos.com. 3. Install and connect the CIU as described in the
6.16.1 GENIbus communication respective separate installation and operating
instructions.
The pump is supplied with an integrated module for
GENIbus communication. The pump identifies the 4. Switch on the power supply of the pump.
bus control after connecting to the corresponding The "Activate communication?" prompt is displayed.
signal input. The "Activate communication?" prompt After confirmation, the "Bus" symbol appears in the
is displayed. After confirmation, the corresponding "Activated functions" area of the "Operation" menu,
symbol appears in the "Activated functions" area in no matter if the prompt was accepted or refused.
the "Operation" menu. If the prompt has been accepted, the bus control
In the "Setup > Bus" menu the GENIbus address can function is activated. If the prompt has been refused,
be set from 32 to 231 and bus control can be bus control function can be activated in "Setup >
deactivated. Bus" menu.

Bus Profibus
TM06 7111 2916

Bus control active

TM06 7111 2916


Bus control active
Bus address 231 Bus address 126

Fig. 38 Bus menu Fig. 39 Example of submenu for Profibus®

The maximum cable length for GENIbus


connection is 3 m and must not be
exceeded.

33
6.16.4 Setting the bus address 6.16.6 Deactivate communication
1. Enter "Setup > Bus" menu and set desired bus After deactivating the bus control function, the pump
English (GB)

address: can start automatically.

Bus type Address range CAUTION


Automatic startup
Profibus® DP 0-126
Minor or moderate personal injury
Modbus RTU 1-247 - Before deactivating the bus control
function, set the pump to operating state
2. The pump needs to be restarted to initialise the "Stop".
new bus address. Switch off the power supply of
the pump and wait for approximately 20 seconds. Bus control function can be deactivated in the "Setup
> Bus" menu. After deactivation all submenus in
3. Switch on the power supply of the pump. "Setup" menu are available.
The pump is initialised with the new bus address. The "Bus" symbol in the display disappears at next
6.16.5 Characteristics of bus communication restart of the pump, after the CIU plug was
disconnected.
To start and stop the pump via bus, it needs to be in
operating state "Running". When the pump is
remotely stopped from bus, the "External stop" After disconnecting any plug, always refit
symbol is displayed and the pump switches to protective cap.
operating state "Standby".
While bus control function is activated, the "Setup" 6.16.7 Communication faults
menu only shows the "Bus" and "Key lock"
Faults are only detected, if the respective
submenus. The other main menus, the "External
"BusWatchDog" (see functional profile on CIM/CIU
stop" function and the keys are still available.
product CD) is activated.
All operation modes (see section 6.4 Operation
After a communication fault is repaired, the pump
modes) can still be used when bus control is
can start automatically, depending on current bus
activated. This allows to use the bus control only for
control and pump settings.
monitoring and setting the pump. In this case the
respective "BusWatchDog" (see functional profile on CAUTION
CIM/CIU product CD) should be deactivated in bus
control, because otherwise faults in communication Automatic startup
can stop the pump. Minor or moderate personal injury
- Before repairing any fault, set the pump
To change any settings manually, the bus to operating state "Stop".
control function must be deactivated In case of bus communication faults (e.g.
temporarily. communication cable break), the pump stops dosing
and switches to operating state "Standby"
approximately 10 seconds after the fault was
detected. An alarm is triggered, detailing the cause
of the fault. See section 8. Faults.

34
6.17 Inputs/Outputs 6.17.1 Relay outputs
The pump can switch two external signals using

English (GB)
In the "Setup > Inputs/Outputs" menu, you can
configure the two outputs "Relay 1+Relay 2" and the installed relays. The relay outputs are potential-free.
signal inputs "External stop", "Empty signal" and The connection diagram of the relays is shown in
"Low-level signal". section 4.3 Electrical connection. Both relays can be
allocated with the following signals:

In/Output Relay 1 Relay 2


Description
signal signal

TM06 7112 2916


Relay 1 >
Relay 2 > Display red, pump
External stop NO Alarm* Alarm stopped (e.g. empty
Empty signal NO signal, etc.)
Low-level signal NO
Display yellow, pump is
Fig. 40 Inputs/Outputs menu Warning* Warning running (e.g. low-level
signal, etc.)
When time or date is changed in Stroke Stroke
Each full stroke
"Time+date" menu, timer dosing and timer signal signal
relay output functions (Relay 2) are Pump Pump
stopped! Pump running and dosing
dosing dosing*
Timer dosing and timer relay output
functions must be restarted manually! Pulse Pulse Each incoming pulse
input** input** from pulse input
Changing time or date can cause increase
or decrease in concentration! Bus Bus Activated by a command
control control in the bus communication
Timer
See following sections
Cycle
Timer
See following sections
Week

Contact type

NO* NO* Normally open contact


NC NC Normally closed contact

* Factory setting
** The correct transmission of incoming pulses can
only be guaranteed up to a pulse frequency of 5
Hz.

35
Timer Cycle (Relay 2) 6.17.3 Empty and Low level signals
For the "Relay 2 > Timer Cycle" function, set the In order to monitor the filling level in the
English (GB)

following parameters: tank, a dual-level sensor can be connected to the


• On (t1) pump. The pump responds to the signals as follows:
• Start delay (t2)
Sensor signal Pump status
• Cycle time (t3).
• Display is yellow
Low level • Flashes
• Pump continues running
• Display is red
Empty • Flashes

TM06 7113 2916


t1 t1
• Pump stops

t2
t3 When the tank is filled up again, the pump
restarts automatically.
Fig. 41 Diagram
Both signal inputs are allocated to the normally open
Timer Week (Relay 2) contact (NO) in the factory. They can be re-allocated
This function saves up to 16 relay on-times for a in the "Setup > Inputs/Outputs" menu to normally
week. The following settings can be made for each closed contact (NC).
relay switching operation in the "Relay 2 > Timer
Week" menu: 6.18 Basic settings
• Procedure (No.) All settings can be reset to the settings default upon
delivery in the "Setup > Basic settings" menu.
• On time (duration)
Selecting "Save customer settings" saves the current
• Start time
configuration to the memory. This can then be
• Weekdays. activated using "Load customer settings".
6.17.2 External stop The memory always contains the previously saved
The pump can be stopped via an external configuration. Older memory data is overwritten.
contact, e.g. from a control room. When activating
the external stop signal, the pump switches to
operating state "Standby". The corresponding
symbol appears in the "Signal/error display" area of
the display.

Frequent disengagement from the mains


voltage, e.g. via a relay, can result in
damage to the pump electronics and in the
breakdown of the pump. The dosing
accuracy is also reduced as a result of
internal start procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "External stop" function to
start and stop the pump!
The contact type is factory-set to normally open
contact (NO). In the "Setup > Inputs/Outputs >
External stop" menu, the setting can be changed to
normally closed contact (NC).

36
7. Service 7.3 Service system

English (GB)
In order to ensure a long service life and dosing According to the motor runtime or after a defined
accuracy, wearing parts such as diaphragms and period of operation, service requirements will
valves must be regularly checked for signs of wear. appear. Service requirements appear regardless of
Where necessary, replace worn parts with original the current operating state of the pump and do not
spare parts made from suitable materials. affect the dosing process.
Should you have any questions, please contact your
Grundfos service partner. Motor
Time interval
Service requirement runtime
[months]*
[h]*
Maintenance work must only be carried out
by qualified staff. Service soon! 7500 23
Service now! 8000 24
7.1 Regular maintenance
* Since the last service system reset
Interval Task

Check, if liquid leaks from the drain

TM06 7117 2916


opening on the dosing head and if the Service soon!
drain opening is blocked or soiled. Please exchange
See fig. 44-45, pos. 8. diaphragm and valves!
If so, follow the instructions given in Service kit:
section 7.6 Diaphragm leakage. 97xxxxxx
Check, if liquid leaks from the dosing
head or valves. Fig. 42 Service soon!
If necessary, tighten dosing head
Daily
screws with a torque wrench. Torque
[Nm]: 6 (+ 1).
If necessary, tighten valves and cap

TM06 7117 2916


nuts, or perform service. See section Service now!
7.4 Perform service. Please exchange
diaphragm and valves!
Check, if a service requirement is Service kit:
present at the pump display. If so, 97xxxxxx
follow the instructions given in
section 7.3 Service system. Fig. 43 Service now!
Clean all pump surfaces with a dry
Weekly For media which result in increased wear, the service
and clean cloth.
interval must be shortened.
Check dosing head screws. The service requirement signals when the
If necessary, tighten dosing head replacement of wearing parts is due and displays the
Every 3
screws with a torque wrench. Torque number of the service kit. Press the click wheel to
months
[Nm]: 6 (+ 1). Replace damaged temporarily hide the service prompt.
screws immediately.
When the "Service now!" message appears
(displayed daily), the pump must be serviced
7.2 Cleaning
immediately. The symbol appears in the
If necessary, clean all pump surfaces with a dry and "Operation" menu.
clean cloth. The number of the service kit required is also
displayed in the "Info" menu.

37
7.4 Perform service 7.4.1 Dosing head overview
English (GB)

Only spare parts and accessories from Grundfos


should be used for maintenance. The usage of 1 2a 2 2d 3 4 5 6
non-original spare parts and accessories renders
any liability for resulting damages null and void.

CAUTION

TM06 7119 3716


Chemical hazard
Minor or moderate personal injury
- Observe the material safety data sheet
of the dosing medium.
- Wear protective clothing (gloves and
10 8 9 7
goggles) when working on the dosing
head, connections or lines. Fig. 44 DDA 60-10
- Collect and dispose of all chemicals in a
way that is not harmful to persons or the
environment. 1 2 2b 2c 3 4 5 6

Before starting work on the pump, the


pump must be in the "Stop" operating state
or be disconnected from the power supply.
The system must be pressureless.

TM06 7678 3716


8 10 7
Fig. 45 DDA 120-7 / DDA 200-4

Pos. Components

1 Extension piece
2 Flange
2a O-ring
2b Screws
2c Intermediate ring
2d O-ring
3 Diaphragm
4 Valve on outlet side
5 Dosing head
6 Screws
7 Valve on inlet side
8 Drain opening
9 Alignment pin
10 Safety diaphragm

38
7.4.2 Dismantling the diaphragm and valves 7.4.3 Reassembling the diaphragm and valves
The pump must only be reassembled, if nothing

English (GB)
If the diaphragm is possibly damaged, indicates that dosing liquid has entered the pump
don't connect the pump to the power housing. Otherwise proceed as described in section
supply! Proceed as described in section 7.6.2 Dosing liquid in the pump housing.
7.6 Diaphragm leakage.
This section refers to fig. 44-45.
This section refers to fig. 44-45. 1. DDA 60-10:
1. Set pump to "Stop" operating state using the – Place new O-rings (2a, 2d) in the grooves at
[Start/stop] key. flange (2) and make sure they are seated
2. Make system pressureless. correctly.
3. Take suitable steps to ensure that the returning – Attach flange (2) observing alignment pin (9).
liquid is safely collected. 2. DDA 120-7 / DDA 200-4:
4. Empty dosing head and flush it if necessary. – Retighten screws (2b) using a torque wrench.
5. Press the [Start/stop] and [100%] keys at the Torque [Nm]: 6 (+ 1).
same time to put the diaphragm into "out" – Attach intermediate ring (2c) to flange (2)
position. observing the alignment pin.
– Symbol must be displayed (see fig. 17). 3. Screw on the new diaphragm (3) clockwise.
6. Dismantle inlet, outlet and deaeration lines. – Make sure the diaphragm is screwed on
7. Unscrew valves on inlet and outlet side (4, 7). completely and fully resting on extension piece
8. Disconnect FlowControl or DLD signal (1).
connection, if present. See fig. 13-14. 4. Press the [Start/stop] and [100%] keys at the
9. Remove screws (6). same time to put the diaphragm into "in" position.
10. Remove dosing head (5). – Symbol must be displayed (see fig. 17).
11. Unscrew diaphragm (3) counter-clockwise and 5. Attach dosing head (5).
remove it. – DDA 60-10: Observe alignment pin (9).
12. DDA 60-10: 6. Install screws (6) and cross-tighten them with a
– Remove flange (2) together with O-rings (2a, torque wrench.
2d). – Torque [Nm]: 6 (+ 1).
13. DDA 120-7 / DDA 200-4: 7. Connect FlowControl or DLD signal connection, if
– Remove intermediate ring (2c). present. See fig. 13-14.
14. Make sure the drain opening (8) is not blocked or 8. Install new valves (4, 7).
soiled. Clean if necessary. – Pay attention to the flow direction arrow.
15. Check the safety diaphragm (10) for wear and 9. Perform hydraulic connection. See section
damage. If the safety diaphragm is damaged, 4.2 Hydraulic connection.
send the pump to Grundfos for repair. See 10. Press the [Start/stop] key to leave the service
section 7.7 Repairs. mode.
If nothing indicates that dosing liquid has entered the
pump housing, go on as described in section Tighten the dosing head screws with a
7.4.3 Reassembling the diaphragm and valves. torque wrench before startup and every
Otherwise proceed as described in section time the dosing head has been opened.
7.6.2 Dosing liquid in the pump housing. After 48 operating hours, retighten the
dosing head screws using a torque
wrench. Torque [Nm]: 6 (+ 1).
11. Deaerate the dosing pump. See section
5.4 Deaerating the pump.
12. Observe the notes on commissioning in section
5. Startup.

7.5 Resetting the service system


After performing the service, the service system
must be reset using the "Info > Reset service
system" function.

39
7.6 Diaphragm leakage 7.6.1 Dismantling in case of diaphragm leakage
English (GB)

If the diaphragm leaks or is broken, dosing liquid


escapes from the drain opening on the dosing head. Do not connect the pump to the power
See fig. 4, pos. 16. supply!
In case of diaphragm leakage, the safety diaphragm
(fig. 44-45, pos. 10) protects the pump housing This section refers to fig. 44-45.
against ingress of dosing liquid. 1. Make system pressureless.
When dosing crystallising liquids the drain opening 2. Take suitable steps to ensure that the returning
can be blocked by crystallisation. If the pump is not liquid is safely collected.
taken out of operation immediately, a pressure can
3. Empty dosing head and flush it if necessary.
build up between the diaphragm (fig. 44-45, pos. 3)
and the safety diaphragm. The pressure can press 4. Dismantle inlet, outlet and deaeration lines.
dosing liquid through the safety diaphragm into the 5. Unscrew valves on inlet and outlet side (4, 7).
pump housing. 6. Disconnect FlowControl or DLD signal
Most dosing liquids don't cause any danger when connection, if present. See fig. 13-14.
entering the pump housing. However a few liquids 7. Remove screws (6).
can cause a chemical reaction with inner parts of the
8. Remove dosing head (5).
pump. In the worst case, this reaction can produce
explosive gases in the pump housing. 9. Unscrew diaphragm (3) counter-clockwise and
remove it.
WARNING 10. DDA 60-10:
Danger of explosion, if dosing liquid – Remove flange (2) together with O-rings (2a,
has entered the pump housing! 2d).
Death or serious personal injury 11. DDA 120-7 / DDA 200-4:
Operation with damaged diaphragm can – Remove intermediate ring (2c).
lead to dosing liquid entering the pump
12. Make sure the drain opening (8) is not blocked or
housing.
soiled. Clean if necessary.
- In case of diaphragm leakage,
immediately separate the pump from 13. Check the safety diaphragm (10) for wear and
the power supply! damage. If the safety diaphragm is damaged,
- Make sure the pump cannot be put back send the pump to Grundfos for repair. See
into operation by accident! section 7.7 Repairs.
- Dismantle the dosing head without If nothing indicates that dosing liquid has entered the
connecting the pump to the power pump housing, go on as described in section
supply and make sure no dosing liquid 7.4.3 Reassembling the diaphragm and valves.
has entered the pump housing. Proceed Otherwise proceed as described in section
as described in section 7.6.2 Dosing liquid in the pump housing.
7.6.1 Dismantling in case of diaphragm
leakage. 7.6.2 Dosing liquid in the pump housing

To avoid any danger resulting from diaphragm Immediately separate the pump from the
leakage, observe the following: power supply!
• Perform regular maintenance. See section Make sure the pump cannot be put back
7.1 Regular maintenance. into operation by accident!
• Never operate the pump with blocked or soiled If dosing liquid has entered the pump housing:
drain opening.
• Send the pump to Grundfos for repair, following
– If the drain opening is blocked or soiled, the instructions given in section 7.7 Repairs.
proceed as described in section
• If a repair isn't economically reasonable, dispose
7.6.1 Dismantling in case of diaphragm
of the pump observing the information in section
leakage.
9. Disposal.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
dosing liquid.
• Never operate the pump with damaged or loose
dosing head screws.

40
7.7 Repairs 8. Faults

English (GB)
In the event of faults in the dosing pump, a warning
The pump housing must only be opened
or an alarm is triggered. The corresponding fault
by personnel authorised by Grundfos!
symbol flashes in the "Operation" menu, see section
Repairs must only be carried out by 8.1 List of faults. The cursor jumps to the "Alarm"
authorised and qualified personnel! main menu symbol. Press the click wheel to open the
Switch off the pump and disconnect it from "Alarm" menu and, where necessary, faults to be
the voltage supply before carrying out acknowledged will be acknowledged.
maintenance work and repairs! A yellow display indicates a warning and the pump
After consulting Grundfos, please send the pump, continues running.
together with the safety declaration completed by a A red display indicates an alarm and the pump is
specialist, to Grundfos. The safety declaration can stopped.
be found at the end of these instructions. It must be The pump can start automatically when the cause of
copied, completed and attached to the pump. the fault has been remedied.
The pump must be cleaned prior to CAUTION
dispatch!
Automatic startup
If dosing liquid has possibly entered the Minor or moderate personal injury
pump housing, state that explicitly in the - Before remedying the cause of the fault,
safety declaration! Observe section make sure the pump has been installed
7.6 Diaphragm leakage. correctly and is ready to be started.
If the above requirements are not met, Grundfos may
refuse to accept delivery of the pump. The shipping Before starting work on the pump, the
costs will be charged to the sender. pump must be in the "Stop" operating state
or be disconnected from the power supply.
The system must be pressureless.
The last 10 faults are stored in the "Alarm" main
menu. When a new fault occurs, the oldest fault is
deleted.
The two most recent faults are shown in the display,
you can scroll through all the other faults. The time
and cause of the fault are displayed.

Alarm
1 12.02.2017 12:34
Empty
2 12.02.2017 12:34
Low level

TM06 7072 2916


Delete alarm
messages ❑

The list of faults can be deleted at the end of the list.


If there is a service requirement, this appears when
the "Alarm" menu is opened. Press the click wheel to
temporarily close the service prompt. See section
7.3 Service system.

41
8.1 List of faults
English (GB)

8.1.1 Faults with error message

Display in the
Possible cause Possible remedy
"Alarm" menu
Empty • Dosing medium tank empty • Fill tank.
(Alarm) • Check contact setting (NO/NC).
Low level • Dosing medium tank almost empty
(Warning)
• Outlet valve blocked • Replace valve if necessary. See section
7.4 Perform service.
• Isolating valve in outlet line closed • Check flow direction of valves (arrow) and
correct if necessary.
Overpressure • Open the isolating valve (on the outlet
(Alarm) side).
• Pressure peaks due to high • Enlarge diameter of outlet line.
viscosity
• Max. pressure set too low. See • Change pressure setting. See section
section 6.8 Pressure monitoring) 6.8 Pressure monitoring.
• Faulty diaphragm • Change the diaphragm. See section
7.4 Perform service.
• Broken outlet line • Check outlet line and repair if necessary.
Low
backpressure • Pressure differential between inlet • Install additional spring-loaded valve
(Warning/alarm*) and outlet side too low (approx. 2 bar) on the outlet side.
• Leakage in the pressure loading
valve at Q < 1 l/h
• Deaeration valve open • Close the deaeration valve.
• Broken/leaky inlet line • Check inlet line and repair if necessary.
• Provide positive inlet pressure (place
Air bubble dosing medium tank above the pump).
(Warning) • Strongly degassing medium • Enable "SlowMode". See section
6.6 SlowMode.
• Tank dosing medium empty • Fill tank.
• Blocked/constricted/squeezed • Enable "SlowMode". See section
inlet line 6.6 SlowMode.
Cavitation • Blocked/constricted inlet valve • Reduce suction lift.
(Warning) • Suction lift too high • Increase inlet hose diameter.
• Viscosity too high • Check inlet line and open isolating valve if
necessary.
• Leaky/dirty inlet valve • Check valve and tighten it up.
• Flush system.
• Replace valve if necessary. See section
Suct. valve leak 7.4 Perform service.
(Warning)
• Check O-ring position.
• Install filter in inlet line.
• Deaeration valve open • Close the deaeration valve.
• Considerable deviation between • Check installation.
Flow deviation target and actual flow
(Warning) • Pump not or incorrectly calibrated • Calibrate the pump. See section
5.5 Calibrating the pump.

42
Display in the
Possible cause Possible remedy

English (GB)
"Alarm" menu
• Leaky/dirty outlet valve • Check valve and tighten it up. Replace
• Leakage in the pressure loading valve if necessary. See section
valve 7.4 Perform service.
• Flush system.
Disch. valve leak • Check O-ring position.
(Warning)
• Install screen in inlet line.
• Install spring-loaded valve on the outlet
side.
• Deaeration valve open • Close the deaeration valve.
• Backpressure greater than • Reduce backpressure.
nominal pressure
• Outlet valve blocked • Replace valve if necessary. See section
• Isolating valve in outlet line closed 7.4 Perform service.
• Check flow direction of valves (arrow) and
correct if necessary.
Overload • Open the isolating valve (on the outlet
(Alarm) side).
• Pressure peaks • Enlarge diameter of outlet line.
• Install a pulsation damper in the outlet line
close to the outlet valve.
• Ambient temperature below • Adjust ambient temperature to specified
specified minimum value. See value.
section 3.1 Technical data.
• Broken "FlowControl" cable (see • Check plug connection. Replace cable if
fig. 13) necessary.
Pressure sensor • Sensor defect • Replace sensor if necessary.
(Warning) • Pressure sensor not correctly • Calibrate pressure sensor correctly. See
calibrated section 6.8.2 Calibration of pressure
sensor.
• Backpressure greater than • Reduce backpressure.
nominal pressure
Motor blocked • Incorrectly installed diaphragm • Install the diaphragm correctly.
(Alarm)
• Damage to gears • Contact your Grundfos service partner.
• Hall sensor failure
• Fieldbus communication error • Check cables for correct specification and
Bus error damage; replace if necessary.
(Alarm) • Check cable routing and shielding; correct
if necessary.
CIU • CIU connection error • Check plug connection.
(Alarm) • Faulty CIU • Replace CIU if necessary.
• Defect in analog cable 4-20 mA • Check cable/plug connections and
Cable break
(input current < 2 mA) replace, if necessary.
(Alarm)
• Check signal transmitter.
• Diaphragm leakage • Read section 7.6 Diaphragm leakage
Diaphragm leak.
• Change the diaphragm. See section
(Alarm)
7.4 Perform service.
• Leaky/dirty outlet valve • Replace valve if necessary. See section
Disch. valve leak
7.4 Perform service.
(Alarm)
• Install screen in inlet line.
Overheating • Motor is overheated • Reduce ambient temperature.
(Alarm) • Stop pump until motor cools down.
Service now • Time interval for service expired • Perform service. See section 7.4 Perform
(Warning) service.

* Depending on setting
43
8.1.2 General faults
English (GB)

Fault Possible cause Possible remedy


Install additional spring-loaded valve (approx. 2
Inlet pressure greater than bar) on the outlet side.
backpressure
Dosing flow too high Increase pressure differential.
Calibrate the pump. See section 5.5 Calibrating
Incorrect calibration
the pump.
Air in dosing head Deaerate the pump.
Change the diaphragm. See section 7.4 Perform
Faulty diaphragm
service.
Leakage/fracture in lines Check and repair lines.
Valves leaking or blocked Check and clean valves.
Check that the arrow on the valve housing is
Valves installed incorrectly pointing in the direction of flow. Check whether all
O-rings are installed correctly.
Blocked inlet line Clean inlet line/install filter.
No dosing flow or
dosing flow too low Reduce suction lift.
Suction lift too high Install priming aid.
Enable "SlowMode". See section 6.6 SlowMode .
Enable "SlowMode". See section 6.6 SlowMode .
Viscosity too high Use hose with larger diameter.
Install spring-loaded valve on the outlet side.
Calibrate the pump. See section 5.5 Calibrating
Faulty calibration
the pump.
Deaeration valve open Close the deaeration valve.
Tighten up valves, replace valves if necessary.
Valves leaking or blocked
See section 7.4 Perform service.
Irregular dosing
Keep backpressure constant.
Backpressure fluctuations
Activate "AutoFlowAdapt" (only DDA-FCM).
Immediately separate the pump from the power
Liquid escaping from
supply!
the drain opening on Faulty diaphragm
Observe section 7. Service and especially section
the dosing head
7.6 Diaphragm leakage.
Dosing head screws not Tighten up screws. See section 4.2 Hydraulic
tightened connection.
Liquid escaping
Tighten up valves/union nuts. See section
Valves not tightened
4.2 Hydraulic connection.
Reduce suction lift; if necessary, provide positive
Suction lift too high
inlet pressure.
Pump not sucking in Backpressure too high Open the deaeration valve.
Flush system, replace valves if necessary. See
Soiled valves
section 7.4 Perform service.

9. Disposal
This product or parts of it must be disposed of in an
environmentally sound way. Use appropriate waste
collection services. If this is not possible, contact the
nearest Grundfos company or service workshop.

Subject to alterations.

44
45
Argentina China Germany
Grundfos companies

Bombas GRUNDFOS de Argentina S.A. Grundfos Alldos GRUNDFOS Water Treatment GmbH
Ruta Panamericana km. 37.500 Centro Dosing & Disinfection Reetzstraße 85
Industrial Garin ALLDOS (Shanghai) Water Technology D-76327 Pfinztal (Söllingen)
1619 - Garin Pcia. de B.A. Co. Ltd. Tel.: +49 7240 61-0
Phone: +54-3327 414 444 West Unit, 1 Floor, No. 2 Building (T 4-2) Telefax: +49 7240 61-177
Telefax: +54-3327 411 111 278 Jinhu Road, Jin Qiao Export E-mail: [email protected]
Processing Zone
Australia Pudong New Area
Germany
GRUNDFOS Pumps Pty. Ltd. Shanghai, 201206 GRUNDFOS GMBH
P.O. Box 2040 Phone: +86 21 5055 1012 Schlüterstr. 33
Regency Park Telefax: +86 21 5032 0596 40699 Erkrath
South Australia 5942 E-mail: Tel.: +49-(0) 211 929 69-0
Phone: +61-8-8461-4611 [email protected] Telefax: +49-(0) 211 929 69-3799
Telefax: +61-8-8340 0155 E-mail: [email protected]
China Service in Deutschland:
Austria GRUNDFOS Pumps (Shanghai) Co. Ltd. E-mail: [email protected]
GRUNDFOS Pumpen Vertrieb 10F The Hub, No. 33 Suhong Road
Ges.m.b.H. Minhang District
Greece
Grundfosstraße 2 Shanghai 201106 GRUNDFOS Hellas A.E.B.E.
A-5082 Grödig/Salzburg PRC 20th km. Athinon-Markopoulou Av.
Tel.: +43-6246-883-0 Phone: +86-21 6122 5222 P.O. Box 71
Telefax: +43-6246-883-30 Telefax: +86-21 6122 5333 GR-19002 Peania
Phone: +0030-210-66 83 400
Belgium COLOMBIA Telefax: +0030-210-66 46 273
N.V. GRUNDFOS Bellux S.A. GRUNDFOS Colombia S.A.S.
Boomsesteenweg 81-83 Km 1.5 vía Siberia-Cota Conj. Potrero
Hong Kong
B-2630 Aartselaar Chico, GRUNDFOS Pumps (Hong Kong) Ltd.
Tél.: +32-3-870 7300 Parque Empresarial Arcos de Cota Bod. Unit 1, Ground floor
Télécopie: +32-3-870 7301 1A. Siu Wai Industrial Centre
29-33 Wing Hong Street &
Belarus Cota, Cundinamarca
68 King Lam Street, Cheung Sha Wan
Представительство ГРУНДФОС в Phone: +57(1)-2913444
Telefax: +57(1)-8764586 Kowloon
Минске Phone: +852-27861706 / 27861741
220125, Минск Croatia Telefax: +852-27858664
ул. Шафарнянская, 11, оф. 56 GRUNDFOS CROATIA d.o.o.
Тел.: +7 (375 17) 286 39 72, 286 39 73 Cebini 37, Buzin
Hungary
Факс: +7 (375 17) 286 39 71 HR-10010 Zagreb GRUNDFOS Hungária Kft.
E-mail: [email protected] Phone: +385 1 6595 400 Park u. 8
H-2045 Törökbálint,
Bosnia/Herzegovina Telefax: +385 1 6595 499
Phone: +36-23 511 110
GRUNDFOS Sarajevo www.hr.grundfos.com
Telefax: +36-23 511 111
Trg Heroja 16, GRUNDFOS Sales Czechia and
BiH-71000 Sarajevo India
Phone: +387 33 713 290
Slovakia s.r.o. GRUNDFOS Pumps India Private
Čapkovského 21
Telefax: +387 33 659 079 Limited
779 00 Olomouc
e-mail: [email protected] 118 Old Mahabalipuram Road
Phone: +420-585-716 111
Thoraipakkam
Brazil
BOMBAS GRUNDFOS DO BRASIL
Denmark Chennai 600 097
GRUNDFOS DK A/S Phone: +91-44 4596 6800
Av. Humberto de Alencar Castelo
Martin Bachs Vej 3 Indonesia
Branco, 630
DK-8850 Bjerringbro
CEP 09850 - 300 PT. GRUNDFOS POMPA
Tlf.: +45-87 50 50 50
São Bernardo do Campo - SP Graha Intirub Lt. 2 & 3
Telefax: +45-87 50 51 51
Phone: +55-11 4393 5533 Jln. Cililitan Besar No.454. Makasar,
E-mail: [email protected]
Telefax: +55-11 4343 5015 Jakarta Timur
www.grundfos.com/DK
ID-Jakarta 13650
Bulgaria
Grundfos Bulgaria EOOD
Estonia Phone: +62 21-469-51900
GRUNDFOS Pumps Eesti OÜ Telefax: +62 21-460 6910 / 460 6901
Slatina District
Peterburi tee 92G Ireland
Iztochna Tangenta street no. 100
11415 Tallinn
BG - 1592 Sofia GRUNDFOS (Ireland) Ltd.
Tel: + 372 606 1690
Tel. +359 2 49 22 200 Unit A, Merrywell Business Park
Fax: + 372 606 1691
Fax. +359 2 49 22 201 Ballymount Road Lower
email: [email protected] Finland Dublin 12
OY GRUNDFOS Pumput AB Phone: +353-1-4089 800
Canada Telefax: +353-1-4089 830
Trukkikuja 1
GRUNDFOS Canada Inc.
FI-01360 Vantaa Italy
2941 Brighton Road
Phone: +358-(0)207 889 500
Oakville, Ontario GRUNDFOS Pompe Italia S.r.l.
L6H 6C9 France Via Gran Sasso 4
Phone: +1-905 829 9533 Pompes GRUNDFOS Distribution S.A. I-20060 Truccazzano (Milano)
Telefax: +1-905 829 9512 Parc d’Activités de Chesnes Tel.: +39-02-95838112
57, rue de Malacombe Telefax: +39-02-95309290 / 95838461
F-38290 St. Quentin Fallavier (Lyon)
Tél.: +33-4 74 82 15 15
Télécopie: +33-4 74 94 10 51
Japan Portugal Switzerland

Grundfos companies
GRUNDFOS Pumps K.K. Bombas GRUNDFOS Portugal, S.A. GRUNDFOS ALLDOS International AG
1-2-3, Shin-Miyakoda, Kita-ku Rua Calvet de Magalhães, 241 Schönmattstraße 4
Hamamatsu Apartado 1079 CH-4153 Reinach
431-2103 Japan P-2770-153 Paço de Arcos Tel.: +41-61-717 5555
Phone: +81 53 428 4760 Tel.: +351-21-440 76 00 Telefax: +41-61-717 5500
Telefax: +81 53 428 5005 Telefax: +351-21-440 76 90 E-mail:
[email protected]
Korea Romania
GRUNDFOS Pumps Korea Ltd. GRUNDFOS Pompe România SRL Switzerland
6th Floor, Aju Building 679-5 Bd. Biruintei, nr 103 GRUNDFOS Pumpen AG
Yeoksam-dong, Kangnam-ku, 135-916 Pantelimon county Ilfov Bruggacherstrasse 10
Seoul, Korea Phone: +40 21 200 4100 CH-8117 Fällanden/ZH
Phone: +82-2-5317 600 Telefax: +40 21 200 4101 Tel.: +41-44-806 8111
Telefax: +82-2-5633 725 E-mail: [email protected] Telefax: +41-44-806 8115
Latvia Russia Taiwan
SIA GRUNDFOS Pumps Latvia ООО Грундфос GRUNDFOS Pumps (Taiwan) Ltd.
Deglava biznesa centrs Россия, 109544 Москва, ул. Школьная 7 Floor, 219 Min-Chuan Road
Augusta Deglava ielā 60, LV-1035, Rīga, 39 Taichung, Taiwan, R.O.C.
Tālr.: + 371 714 9640, 7 149 641 Тел. (+7) 495 737 30 00, 564 88 00 Phone: +886-4-2305 0868
Fakss: + 371 914 9646 Факс (+7) 495 737 75 36, 564 88 11 Telefax: +886-4-2305 0878
E-mail [email protected]
Lithuania Thailand
GRUNDFOS Pumps UAB Serbia GRUNDFOS (Thailand) Ltd.
Smolensko g. 6 GRUNDFOS Predstavništvo Beograd 92 Chaloem Phrakiat Rama 9 Road,
LT-03201 Vilnius Dr. Milutina Ivkovića 2a/29 Dokmai, Pravej, Bangkok 10250
Tel: + 370 52 395 430 YU-11000 Beograd Phone: +66-2-725 8999
Fax: + 370 52 395 431 Phone: +381 11 26 47 877 / 11 26 47 Telefax: +66-2-725 8998
496
Malaysia Telefax: +381 11 26 48 340
Turkey
GRUNDFOS Pumps Sdn. Bhd. GRUNDFOS POMPA San. ve Tic. Ltd.
7 Jalan Peguam U1/25 Singapore Sti.
Glenmarie Industrial Park GRUNDFOS (Singapore) Pte. Ltd. Gebze Organize Sanayi Bölgesi
40150 Shah Alam 25 Jalan Tukang Ihsan dede Caddesi,
Selangor Singapore 619264 2. yol 200. Sokak No. 204
Phone: +60-3-5569 2922 Phone: +65-6681 9688 41490 Gebze/ Kocaeli
Telefax: +60-3-5569 2866 Telefax: +65-6681 9689 Phone: +90 - 262-679 7979
Telefax: +90 - 262-679 7905
Mexico Slovakia E-mail: [email protected]
Bombas GRUNDFOS de México S.A. de GRUNDFOS s.r.o.
C.V. Prievozská 4D Ukraine
Boulevard TLC No. 15 821 09 BRATISLAVA Бізнес Центр Європа
Parque Industrial Stiva Aeropuerto Phona: +421 2 5020 1426 Столичне шосе, 103
Apodaca, N.L. 66600 sk.grundfos.com м. Київ, 03131, Україна
Phone: +52-81-8144 4000 Телефон: (+38 044) 237 04 00
Telefax: +52-81-8144 4010
Slovenia Факс.: (+38 044) 237 04 01
GRUNDFOS LJUBLJANA, d.o.o. E-mail: [email protected]
Netherlands Leskoškova 9e, 1122 Ljubljana
GRUNDFOS Netherlands Phone: +386 (0) 1 568 06 10 United Arab Emirates
Veluwezoom 35 Telefax: +386 (0)1 568 0619 GRUNDFOS Gulf Distribution
1326 AE Almere E-mail: [email protected] P.O. Box 16768
Postbus 22015 Jebel Ali Free Zone
1302 CA ALMERE
South Africa Dubai
Tel.: +31-88-478 6336 Grundfos (PTY) Ltd. Phone: +971-4- 8815 166
Telefax: +31-88-478 6332 Corner Mountjoy and George Allen Telefax: +971-4-8815 136
E-mail: [email protected] Roads
Wilbart Ext. 2 United Kingdom
New Zealand Bedfordview 2008 GRUNDFOS Pumps Ltd.
GRUNDFOS Pumps NZ Ltd. Phone: (+27) 11 579 4800 Grovebury Road
17 Beatrice Tinsley Crescent Fax: (+27) 11 455 6066 Leighton Buzzard/Beds. LU7 4TL
North Harbour Industrial Estate E-mail: [email protected] Phone: +44-1525-850000
Albany, Auckland Telefax: +44-1525-850011
Phone: +64-9-415 3240
Spain
Telefax: +64-9-415 3250 Bombas GRUNDFOS España S.A. U.S.A.
Camino de la Fuentecilla, s/n GRUNDFOS Pumps Corporation
Norway E-28110 Algete (Madrid) 17100 West 118th Terrace
GRUNDFOS Pumper A/S Tel.: +34-91-848 8800 Olathe, Kansas 66061
Strømsveien 344 Telefax: +34-91-628 0465 Phone: +1-913-227-3400
Postboks 235, Leirdal Telefax: +1-913-227-3500
N-1011 Oslo
Sweden
Tlf.: +47-22 90 47 00 GRUNDFOS AB Uzbekistan
Telefax: +47-22 32 21 50 (Box 333) Lunnagårdsgatan 6 Grundfos Tashkent, Uzbekistan The
431 24 Mölndal Representative Office of Grundfos
Poland Tel.: +46 31 332 23 000 Kazakhstan in Uzbekistan
GRUNDFOS Pompy Sp. z o.o. Telefax: +46 31-331 94 60 38a, Oybek street, Tashkent
ul. Klonowa 23 Телефон: (+998) 71 150 3290 / 71 150
Baranowo k. Poznania 3291
PL-62-081 Przeźmierowo Факс: (+998) 71 150 3292
Tel: (+48-61) 650 13 00
Fax: (+48-61) 650 13 50 Addresses revised 05.12.2016
ECM: 1205328
98767821 0317

www.grundfos.com
The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks
owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

FLOW SWITCH(ES)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 14
Flow and Temperature Sensor 52.2.
calorimetric Flex-F Flex-F.

TERMINAL ASSIGNMENT
Before the electrical installation, make sure that the supply voltage
corresponds to the data provided!

Please you use shielded cable, signal lines < 30m and
power supply lines < 10m.

MOUNTING
To achieve the greatest possible sensitivity of the sensor (especial
compact, robust flow switch/transmitter low flow speeds), the cross driven into the fastening nut must point
possible combination with temperature switch or transmitter towards the approaching flow. Seal the screw-in versions using
no movable parts in monitoring medium sealing paste (e.g. LOCTITE 577).
only a material in contact with media During mounting, make sure that the front cylinder part is immersed
easy use completely in the flowing medium.
very low pressure losses For further information, see the general description of calorimetric
various sensing element lengths and designs sensors.
fast reaction times for a calorimetric sensor
infinitely rotatable cable outlet
very low installation width; A design with a bendable gooseneck between the sensing element
pipes requiring tight laying space are possible of the sensor and the electronic housing is available to decouple the
sensing element and the electronics thermally in case of media
BENEFIT temperatures over 70°C.

The Flex-F flow sensor monitors liquid media. In a compact PROGRAMMING


design, it combines the installation sensing element and evaluation
electronics that, according to the respective version, control a limit Designs with a limit switch have a magnetic contact by means of
value output with a PNP or NPN transistor output or an analogue which the current measurement value can be assumed as a limit
output (4..20 mA or 0..10 V) or both. The limit switch can value. It is programmed by applying a magnet to the marking on the
alternatively be replaced by a frequency output. type plate for 0.5 to 2 seconds. If the contact time is too short or too
The evaluation electronics record two processing parameters: the long, no programming will take place (protection against magnetic
flow speed of the medium and its temperature. Both parameters fields). Immediately after programming, the switching output enters
can be assigned to the analogue output or the switching output. the OK state (LED on, output switched through, e.g. PNP = high or
NPN = low).

The following output combinations are available:

flow temperature
analogue switching output analogue switching output

The analogue output can be designed as a 4..20 mA output or as a


0..10 V output.

The standard design of the switching output is as a limit switch (PNP


or NPN). It can be ordered as a minimum switch or maximum switch.
Alternatively, the switch is available as a frequency output.

For further options, see page 3

HONSBERG Instruments GmbH Tenter Weg 2-8 42897 Remscheid Germany 11.03.2005
Phone +49(0)2191 9672-0 Fax +49(0)2191 9672-40 www.honsberg.com [email protected] page 1 of 3
Flow and Temperature Sensor 52.2. Flow and Temperature Sensor 52.2.
calorimetric Flex-F Flex-F. calorimetric Flex-F Flex-F.

NOMENCLATURE TECHNICAL DATA


measurement range water 20-50 cm/s (1-150) connection at locking plug M 12x1, 4-pole
Example: Flex-F 015 H K 029 I F P T R O speed oil (on request) protection class IP 67
standard values shown bold weight approx. 200 g (standard design)
A B C D E F G H I J K ±10% of final value, tested with 10xD 24 VDC ±10%
accuracy supply voltage
A sensor family: Options: for approach & exit distances with power consumption max. 100mA
Flex-F calorimetric sensor rising pipe (water medium) switching output transistor output, PNP or NPN
B connection size: special measurement range, flow: cm/s reproducibility ±1% (short circuit proof/
008 G1/4 max. 300 cm/s (standard = 150 cm/s) temperature gradient 4°C/s reverse polarity protected)
015 G1/2 measurement range 15..70°C (other temperature Iout = 100mA max.
013 system fastening Ø13.2 special measurement range, temperature: °C temperature on request) switching hysteresis flow: 4% F.S.
038 foodgrade flange, ISO 2852, Size 38 maximum 120°C (s tandard = 70°C) storage temperature -20..80°C temperature: approx. 2°C
C type of connection: materials in contact with media: 1.4571 display (only in case of yellow LED
H outer thread minimum -20°C (standard = 0°C) °C Other: 1.4305 switching output) (ON = OK /OFF = alarm)
T for insertion into system T-piece operating pressure max. 100 bar, optional: 200 bar adjustment Via magnet
L foodgrade flange special range - analogue output: operating temperature 0..70°C (electronics) analogue output 4..20 mA, max. load 500 Ohm
cm/s
D material (in contact with media): <= meas. range (standard = meas. range) °C
or 0..10V. min load 1 kOhm
K stainless steel 1.4571
T PTFE (Teflon) special range - frequency output:
cm/s
E length of sensing element: <= meas. range (standard = meas. range)
°C DIMENSIONS
028 28 mm (G1/4)
029 29.6 mm (G1/2) end frequency (max. 2000 Hz) Hz
045 45 mm (G1/2)
050 56 mm (foodgrade flange) turn-on delay (from alarm to OK) s
F analogue output:
I current output 4..20 mA turn-off delay (from OK to alarm) s
U voltage output 0..10 V
K no analogue output power-on delay s
G the analogue output is actuated by the following: (time after the supply is created; in this time
F flow the switching output is not activated)
T temperature A goose-neck (optional) between the
cm/s
H switching output: switching output with permanent setting °C
electronic head and the primary sensor
P switching output PNP provides for complete freedom of
N switching output NPN special hysteresis % movement in the alignment of the
M switching output NPN (open collector) (standard = empirical value of 4%) Puncture according to sensor.
K no switching output DIN 3852 Sheet 2
I the switching output is actuated by the following: goose-neck
F flow (recommended for application temperatures over 70°C )
T temperature
J switching signal:
L minimum switch In case of empty fields, the standard
H maximum switch setting will be selected automatically.
R frequency output System fastening with sleeve nut (width against flats of SW32)
K no switching output for system T-pieces (in brass or stainless steel)
K inversion of output: Pressure-resistant up to 25 bar
O standard output L1= 48mm, for nominal widths G3/8 through G1/2
I inverted output L2= 54mm, for nominal widths G3/4 through G2
See separate data sheet 71.1, "TS".
ACCESSORIES
Locking plug M12x1
basic type
K PU- 02 S G S specification
K assembled
KB04 self makable cable 4-pole
PU- material PUR
02 length 2 m
05 length 5 m
10 length 10 m
S moulded-on plug
G straight plug
W angled plug 90°
S shielded

All technical changes reserved

BASIC Standard BASIC Programme option VARIO Special option PLUS Accessories not recommendable

HONSBERG Instruments GmbH Tenter Weg 2-8 42897 Remscheid Germany 11.03.2005
HONSBERG Instruments GmbH Tenter Weg 2-8 42897 Remscheid Germany 11.03.2005
Phone +49(0)2191 9672-0 Fax +49(0)2191 9672-40 www.honsberg.com [email protected] page 3 of 3
Phone +49(0)2191 9672-0 Fax +49(0)2191 9672-40 www.honsberg.com [email protected] page 2 of 3
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P.1

TEMPERATURE SENSOR(S)

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 15
UTECO ABEE Headquarters UTECO ABEE Headquarters
5, M.Mavrogenous Str 5, M.Mavrogenous Str
18542 Piraeus – Greece 18542 Piraeus – Greece
Tel. : 0030 211 1206 900 Tel. : 0030 211 1206 900
Fax.: 0030 211 1206 999 Fax.: 0030 211 1206 999
Mail : [email protected] Mail : [email protected]

Datasheet UCON/30.0010 www.uteco.gr Page 1 of 4 Datasheet UCON/30.0010 www.uteco.gr Page 4 of 4

UCON Series
Temperature Probe with plug connector. UCON Series
Straight thermometer with or without extension length
Certificates

Application
The UCON temperature probes in vibration proof design allows
temperature measuring under pressure in motors, compressors,
controlling cooling water, lubrication oil, hydraulic oil, plant
engineering, in gases, fluids and refrigeration plants within general
industry and marine applications.

Technical Specifications

Element
Resistance thermometer Pt100 or Pt1000 acc. To DIN EN 60751
Recommended measuring current max 2mA

Tube
Protective sheath, stainless steel 316 or 304
Extension length stainless steel Ø 12mm, 50mm length

Sensor tip
From Ø 6mm to Ø 12mm, stainless steel 316 or 304

Plug Connection
Angular, locked, contact stable, protection class IP65 when connected

Process Connect
Thread, stainless steel AISI 316 or 304

Temperatures
Minimum Maximum
Proccess: -50°C +500°C
Connector: -40°C +125°C

Please refer to Ordering Code scheme on page 2 for combination


possibilities of Sheath, Length and Process Connection
UTECO ABEE Headquarters UTECO ABEE Headquarters
5, M.Mavrogenous Str 5, M.Mavrogenous Str
18542 Piraeus – Greece 18542 Piraeus – Greece
Tel. : 0030 211 1206 900 Tel. : 0030 211 1206 900
Fax.: 0030 211 1206 999 Fax.: 0030 211 1206 999
Mail : [email protected] Mail : [email protected]

Datasheet UCON/30.0010 www.uteco.gr Page 3 of 4 Datasheet UCON/30.0010 www.uteco.gr Page 2 of 4

UCON Series UCON Series


Connection diagram Temperature Probe with plug connector.
Straight thermometer with or without extension length
Dimensional drawing

without extension

with extension

Ordering code
DIN
Operating
Diameter Sheath Process Tolerance
Element Element Temperature in
in mm Material Connection Classes /
°C
wires
UCON1 1xPt100 ø6 316 ¼ BSP Class A 2-W from -50 to +500
UCON2 1xPt1000 ø7 304 ⅜ BSP Class A 3-W
ø8 ½ BSP Class A 4-W
ø9 ¾ BSP Class B 2-W
ø9,5 ¼ NPT Class B 3-W
ø10 ⅜ NPT Class B 4-W
ø11 Length L1 in ½ NPT ⅓ DIN B
ø12 mm ¾ NPT
from 50 to 300 16 x 1,5 M
18 x 1,5 M
20 x 1,5 M
22 x 1,5 M

UCON1 1xPt100 6 150 316 G¼ Class B 3-W 150


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P.1

PRESSURE TRANSMITTERS

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 16
A c
T
>

£ W)

³ W
£

£
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P.1

SHUTTER VALVES

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 17
GENERAL CATALOGUE GENERAL CATALOGUE
5th Edition - 1/2002 5th Edition - 1/2002

Art. “B” - BRONZE GLOBE VALVE Art. “B”


SEAL

MATERIALS
ACTUATOR
SINGLE ACTING DOUBLE ACTING 1 CYLINDER ANODIZED ALUMINIUM
A C T U ATO R A C T U ATO R 2 SPRING HARMONIC STEEL
3 * SELF-LOCKING NUT STAINLESS STEEL
4 * WASHER BRASS
CONNECTIONS 5 PISTON ALUMINIUM 11S
6 O-RING NBR
7 O-RING NBR
8 * CENTRAL BODY BRASS
10 * STEM STAINLESS STEEL
11 O-RING PTFE
ALLOWABLE TEMPERATURES 12 * GASKET-HOLDER PLATE BRASS
14 * WASHER BRASS
15 * BODY GASKET PTFE
16 * VALVE BODY BRONZE
17 FILTER (senc-seno versions) BRASS
19 * GASKET PTFE
ACTUATOR PILOT PRESSURE: S eal NBR
13 * SEAL NBR
VERSIONS AND SIZES 9 * STEM GASKET NBR
18 O-RING NBR
Seal FP M
13 * SEAL FPM
9 * STEM GASKET FPM
18 O-RING FPM
S eal E PDM
13 * SEAL EPDM
DIFFERENTIAL PRESSURE CHART 9 * STEM GASKET EPDM
18 O-RING EPDM
DOUBLE ACTING
*Parts in contact w ith the fluids intercepted
VERSION

PRESS. DeltaP
SINGLE ACTING G PILOTA bar
N.C. VERSION
1/2" 3 12
DeltaP " 4 16
G bar 3/4" 3 8
1/2" 5,5 " 4 10
3/4" 7 1" 3 13
1" 7 " 4 17
1"1/4 3 10
1"1/4 5,5
" 4 13
1"1/2 8
1"1/2 3 9 OVERALL DIMENSIONS
2" 5 " 4 11,5
2" 3 6
" 4 9
DN G A B C d E Ch KV PESO
mm mm mm mm mm mm mm m3/h gr
15 1/2" 105 85 60 17 50 27 3,4 600
MINIMUM PRESSURE REQUIRED TO OPEN
20 3/4" 113 85 75 22 50 36 7,9 700
THE VALVE IN THE S.A.N.C. VERSION
25 1" 125 95 85 28 76 46 11 1300
G 1/2" 3/4" 1" 1"1/4 1"1/2 2" 32 1"1/4 136 103 95 37 76 55 18 1700
40 1"1/2 170 130 110 43 88 60 28 2450
BAR 3 5 3 3 4 4
50 2" 180 135 120 55 88 72 44 2900

not subject
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P.1

SALINITY MEASURING DEVICE

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 18
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
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P.1

SUCTION PUMP

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 19
GARANTIA WARRANTY
CONDICIONES DE LA GARANTIA WARRANTY CONDITIONS

BOMBAS AZCUE, S . A. , garanti za l a BOMBA S A ZC UE, S . A . , w arrant i es t he


cal i dad de sus fabri cados por un perí odo de doce qual i t y of i t s product s for a peri od of t w el v e
meses a partir de la fecha de entrega del material al m ont hs, from t he dat e t he equi pm ent i s del i v e-
cliente. red t o t he cust om er.

La garantía comprende al cambio o reposición The warranty comprehends the exchange or the
sin cargo, de toda pieza o conjunto que sea reconocido replacement of any part or assembly that the technical
por los servicios técnicos de BOMBAS AZCUE, S.A., services of BOMBAS AZCUE, S .A. could find defecti-
como defectuosa por deficiencia de proyecto, fabrica- ve, due to wrong design, manufacturing of material fai-
ción o fallo de material. lure.

El desmontaje y montaje correrán a cargo del The disassembl y and assembl y shall be carried
cliente, así como el transporte en ambos sentidos, los out at the customer´s expense, as well as the transport in
cuales serán facturados al precio de coste. both directions, which will be invoiced at cost price.

La reclamación de la garantía se efectuará The warranty claims will always be done by let-
siempre por escrito, indicando el tipo y número de la ter, indicating the type and number of the pump or
bomba o grupo motobomba, fecha de entrega y agente motor-pump unit, date of delivery and the S ales Agency
de venta donde lo adquirió. La reclamación puede hacer- where it was purchased. The claim may be formulated,
se tanto a través del agente de venta como directamente either through the Agency or directly to BOMBAS
a BOMBAS AZCUE, S.A. AZCUE, S .A.

BOMBAS AZCUE, S.A., declina toda respon- BOMBAS AZCUE, S .A., does not carry any
sabilidad por los accidentes, negligencias y desgastes responsibility over the accidents, negligence or abnormal
anormales en la bomba, provocados por personal incom- wear in the pump, no matter where the origin of these
petente, por haber trabajado sin líquido, o bombeado is, such as unreliable personnel, for having it run dry or
aguas u otros productos con soluciones o materias en pumped water or other products with solutions or mate-
suspensión no detallados en oferta y pedido. ria in suspension, not specified in offer and order.

Asimismo se rechazará toda garantía por repa- All warranty on rectifications or repairs, con-
raciones o transformaciones, efectuadas sin nuestro pre- ducted without our previous consent, shall be refused as
vio consentimiento. well.

En los grupos motobombas eléctricos, nuestras In the motor-pump units, our warranty condi-
condiciones de garantía serán válidas únicamente cuan- tions will only be valid when the electrical installation
do la instalación eléctrica disponga de arrancador guar- is provided with motor protecting thermal relay, calibra-
damotor adecuado con relé térmico de regulación apro- ted fuses and discharge shut-off valve on pump outlet, in
piada, fusibles calibrados y llave de compuerta en la order to regulate the capacity and so, the motor consumed
tubería de impulsión a la salida de la bomba, para regu- amperage to the value marked on the motor plate.
lar el caudal y con ello el consumo del motor al valor en
amperios que señala la placa de características. The repairs or the replacement of the parts under
warranty, cannot in any case, extend the expire of the
La reparación o el cambio de las piezas en warranty. The pumps or motor-pump units already in
garantía no puede en ningún caso prolongar o renovar la use, are not under warranty.
fecha de la misma. No se concede garantía para las bom-
bas o grupos motobombas usados. The illustrations and data shown in this manual
or in publicity catalogues, are not binding.
Las ilustraciones y datos contenidos en este
manual o en folletos de propaganda son sin compromi- BOMBAS AZCUE, S .A., reserves the right to
so. introduce without any previous notice, and at any
moment, the eventual modifications it considers adequa-
BOMBAS AZCUE, S.A., se reserva el derecho te, this being due to market or constructive difficulties
de introducir sin previo aviso y en cualquier momento without being for that obliged to include the above chan-
las eventuales modificaciones que crea oportunas por ges or improvements is all the pumps or motor-pump
exigencias comerciales o constructivas, sin que por ello, units actually in the customer´s hands or out of the fac-
se vea obligada de incluir las modificaciones o mejoras tory.
en todas las bombas o grupos motobombas en poder del
cliente o fuera de fábrica.
! !

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! !

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ALMACENAMIENTO STORAGE
Generalmente la bomba entregada esta disponible para The delivered pump is generally suitable for immediate
la inmediata instalación: installation.

ALMACENAJE PERIODO MENOR A 3 MESES: STORAGE FOR A PERIOD OF LESS THAN 3 MONTHS:

• Almacenar la bomba en lugar seco y protegido. • Store the pump in a dry and sheltered area.
• Temperatura ambiente nuca será menor a 5ºC • Check that ambient temperature never falls below 5ºC
• Es recomendable que el eje de la bomba se gire regu- • It is recommended that the pump shaft is rotated at
larmente (cada 30 días), para prevenir daños en los regular intervals (every 30 days), this prevent damage
rodamientos y agarrotamientos en las partes rotativas. to the bearings and seizure of the rotating parts.

ALMACENAJE PERIODO MAYOR A 3 MESES: STORAGE FOR A PERIOD EXCEEDING 3 MONTHS:

• Elevar la bomba y colocar soportes de madera. • Rise the pump by means of wooden supports.
• Abrir el paquete, si lo hay, quitar las protecciones y • Open the package, if any, remove the protection from
limpiar con aire comprimido, después secar cuidadosa- the pump nozzles and clean by compressed air, then dry
mente si fuese necesario. carefully inside the pump, if necessary.
• Proteger el interior de la bomba con productos anti- • Protect the pump inside with anti-condensation pro-
condensación y tapar las bridas para evitar que entre ducts and close the flanges so that no foreign objects
nada en el interior de la bomba. can enter the pump.
• Cubrir la bomba con plástico y usar productos contra • Cover the pump with a plastic film and put inside
la condensación some products to prevent water condensation.
• Chequear las protecciones periodicamente. • Check protections periodically.
• Es recomendable que el eje de la bomba se gire regu- • It is recommended that the pump shaft is rotated at
larmente (cada 30 días), para prevenir daños en los regular intervals (every 30 days), this prevent damage
rodamientos y agarrotamientos en las partes rotativas. to the bearings and seizure of the rotating parts.
• Si los motores son almacenados más de 2 años, se • If motors are stored more than two years, bearings
debe proceder al cambio de rodamientos o a la sustitu- must be replaced or the lubrication grase must be
ción total de la grasas lubricante después de la limpie- totally removed after cleaning.
za de los mismos.

ALMACENAJE (TRAS PUESTA EN MARCHA) STORAGE (AFTER OPERATION):

• En el caso de largos periodos de almacenaje tras la • In case of long periods after operation, drain the
puesta en marcha, drenar y secar la bomba. pipings and the pump through the drain hole in the
Seguir las instrucciones mencionadas de acuerdo a las lower part of pump casing.
circunstancias. • Follow above instruction according to circumstances.
NOTAS / NOTES NOTAS / NOTES

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NOTAS / NOTES

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HYDROGEN SENSOR

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 20
Ventis™ MX4 Product Manual

Table of Contents
COPYRIGHT NOTICE ................................................................................................................................................... 3
WARNINGS AND CAUTIONARY STATEMENTS ........................................................................................................ 3
General ................................................................................................................................................................... 3
Multi-gas Monitor Personnel ............................................................................................................................................................... 3
Hazardous Conditions, Poisons, and Contaminants .............................................................................................. 3
General Usage ....................................................................................................................................................... 4
Agency-issued Conditions of Use and Warnings .................................................................................................... 4
Recommended Practices ....................................................................................................................................... 5
Product Manual
VENTIS MX4™ RESOURCES....................................................................................................................................... 6
Set-up
Operation VENTIS MX4 CAPABILITIES ........................................................................................................................................ 6
Service UNPACKING THE MONITOR ....................................................................................................................................... 7
Contents.................................................................................................................................................................. 7
Reporting a Problem .............................................................................................................................................. 7
MONITOR OVERVIEW ................................................................................................................................................. 8
Hardware Features and Functions .......................................................................................................................... 8
Display Screen ........................................................................................................................................................ 9
Alarms ................................................................................................................................................................... 11
MONITOR SET-UP ...................................................................................................................................................... 13
Battery Properties and Monitor Compatibility ....................................................................................................... 13
Charging the Lithium-ion Battery Packs ............................................................................................................... 14
Instruction ...................................................................................................................................................... 14
Power-on and –off ................................................................................................................................................. 15
Configuration......................................................................................................................................................... 16
Introduction .................................................................................................................................................... 16
Instructions .................................................................................................................................................... 16
Configuration Process.................................................................................................................................... 17
MONITOR USE AND SERVICE .................................................................................................................................. 24
Zero, Calibration, and Bump Testing .................................................................................................................... 24
Procedures .................................................................................................................................................... 24
Recommendations ......................................................................................................................................... 25
General Information .............................................................................................................................................. 25
Instructions ................................................................................................................................................... 26
Recommended Practices for In-field Air Sampling ............................................................................................... 32
Cleaning ............................................................................................................................................................... 32
Service .................................................................................................................................................................. 33
Battery Packs ................................................................................................................................................. 33
Monitor Conversion ....................................................................................................................................... 36
Sensor, Sensor Water Barrier, LCD, and Vibrating Motor Replacement ........................................................ 38
Pump Module ................................................................................................................................................. 40
Ventis MX4 Three-Dimensional View Diagrams ............................................................................................ 41
PRODUCTS, SPECIFICATIONS, AND CERTIFICATIONS ........................................................................................ 44
Ventis MX4 Accessories and Parts ....................................................................................................................... 44
Monitor Specifications ........................................................................................................................................... 46
Operating Conditions ............................................................................................................................................ 46
Storage Conditions ............................................................................................................................................... 47
Sensor Specifications ........................................................................................................................................... 47
Toxic Gas Sensor Cross-Sensitivity Table ............................................................................................................ 47
LEL and LEL Correlation Factors for Combustible Gases .................................................................................... 48
Certifications ......................................................................................................................................................... 49
WARRANTY ................................................................................................................................................................ 50
Limitation of Liability .............................................................................................................................................. 50
INDUSTRIAL SCIENTIFIC CORPORATION GLOBAL LOCATIONS ..................................................... BACK COVER

Part Number: 17152357-1


Version 12 1

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Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

►Copyright Notice
General Usage
Ventis MX4™ and Ventis™ are trademarks of Industrial Scientific Corporation.
Oxygen-deficient atmospheres may cause combustible gas readings to be lower than actual concentrations.
All trademarks and registered trademarks are the property of their respective owners.
Oxygen-enriched atmospheres may cause combustible gas readings to be higher than actual concentrations.
These help materials or any part thereof may not, without the written consent of Industrial Scientific Corporation, be
copied, reprinted, or reproduced in any material form including but not limited to photocopying, transcribing, Sudden changes in atmospheric pressure may cause temporary fluctuations in the oxygen reading.
transmitting, or storing it in any medium or translating it into any language, in any form or by any means, be it digitally,
electronic, mechanical, xerographic, optical, magnetic, or otherwise. Verify the calibration of the combustible gas sensor after any incident where the combustible gas content has
caused the monitor to display an over-range condition.
The information contained in this document is proprietary and confidential and all copyright, trademarks, trade names, Sensor openings, water barriers, and the pump inlet must be kept clean. Obstruction of the sensor openings or
patents, and other intellectual property rights in the documentation are the exclusive property of Industrial Scientific pump inlet and/or contamination of the water barriers may cause readings to be lower than actual gas
Corporation unless otherwise specified. The information (including but not limited to data, drawings, specification, concentrations.
documentation, software listings, source or object code) shall not at any time be disclosed directly or indirectly to any
third party without prior written consent. To avoid the potential of liquid being pulled into the sample tubing and pump assembly, it is recommended that
Industrial Scientific filter (P/N 17027152) be used on the sample tubing when drawing samples using the
The information contained herein is believed to be accurate and reliable. Industrial Scientific Corporation accepts no aspirated monitor.
responsibility for its use by any means or in any way whatsoever. Industrial Scientific Corporation shall not be liable WARNING: INSERT THE ALKALINE BATTERIES WITH THE CORRECT POSITIVE “+” AND NEGATIVE “-“
for any expenses, costs by damage that may result from the use of the information contained within this document. ORIENTATION. WARNING: The Ventis MX4 is only approved for use with AAA battery types Energizer EN92
Although every effort is made to ensure accuracy, the specifications of this product and the content herein are subject and Duracell MN2400. Do NOT mix battery types.
to change without notice.
WARNING: The use of leather cases can produce inaccurate readings with diffusion (non-aspirated) gas
detection instruments for specific monitoring applications. Leather cases should be used ONLY as carrying
cases, and NOT for continuous monitoring, with diffusion instruments configured to measure gases other than
►Warnings and Cautionary Statements O2, CO, CO2, H 2S, and combustible gases (LEL/CH4).

Agency-issued Conditions of Use and Warnings


General Ensure all part-use restrictions (e.g., battery) meet any agency-mandated conditions of use.
IMPORTANT
Failure to perform certain procedures or note certain conditions may impair the performance of this Ensure all instrument-configurable settings (e.g., always-on setting) meet any agency-mandated conditions of
product. For maximum safety and optimal performance, please read and understand the Ventis MX4 use. When using instrument-compatible Industrial Scientific docking stations, maintain mandated settings
Product Manual available online at the Ventis MX4 Resource Center at through the software (e.g., iNet Control or Accessory Software) or by manually configuring the instrument
www.indsci.com/ VentisMX4resources. settings after docking.
Personnel The Ventis MX4 is CSA certified according to the Canadian Electrical Code for use in Class I, Division 1 and
CAUTION: For safety reasons, this equipment must be operated and serviced by qualified personnel only. Class I, Zone 1 Hazardous Locations within an ambient temperature range of T amb: -20°C to +50°C. CSA has
Read and understand the product manual completely before operating or servicing. assessed only the %LEL combustible gas detection portion of this instrument for performance according to
CSA Standard C22.2 No. 152. This is applicable only when the monitor is used in the diffusion mode and has
been calibrated to 50% LEL CH4, and when the monitor is used in the aspirated mode with an extended range
Hazardous Conditions, Poisons, and Contaminants lithium-ion battery and has been calibrated to 50% LEL CH4.
WARNING: Servicing the unit, replacing or charging battery packs, or using the communications port must only
be done in an area known to be nonhazardous. Not for use in oxygen-enriched atmospheres. CAUTION: CSA C22.2 No. 152 requires before each day’s usage, sensitivity must be tested on a known
concentration of pentane or methane equivalent to 25% or 50% of full scale concentration. Accuracy must be
WARNING: Power-off the monitor before servicing the unit or replacing the battery. within -0% to +20% of actual concentration. Accuracy may be corrected by referring to the zero/calibration
section of the Product Manual.
WARNING: Substitution of components may impair intrinsic safety and may cause an unsafe condition.
The equipment complies with the standards IEC 60079-29-1 and EN 60079-29-1 for methane, propane, and
CAUTION: High off-scale readings may indicate explosive gas concentration(s). hexane with the following exception: as for the methane (mine) detector, the battery run time was verified to be
seven (7) hours rather than the eight (8) hours recommended by the standards, respectively.

CAUTION: Any rapid up-scale reading followed by a declining or erratic reading may indicate gas MED-certified instruments may be used only when configured and maintained to disallow power-off when the
concentration(s) beyond the upper scale limit which may be hazardous. unit is in alarm.
Silicone compound vapors or other known contaminants may affect the combustible gas sensor and cause
The Mine Safety and Health Administration (MSHA) has approved the Ventis MX4 as a Permissible Multi-Gas
readings of combustible gas to be lower than actual gas concentrations. If the monitor has been used in an
Monitor with the following warnings:
area where silicone vapors were present, always calibrate the monitor before next use to ensure accurate
measurements.
· MSHA approved for use with either the P/N 17134453-X2, 3.7 volt, lithium-ion battery or P/N 17148313-2,
3.7 volt, lithium-ion extended battery pack assembly only. The battery pack is not user-replaceable. The
monitor battery and the lithium battery on the main PCB are technician replaceable only. Charge battery
pack with an ISC battery charger designed for use with this monitor in fresh air locations only.

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· The monitor is to be calibrated according to the procedures in the instruction manual only. ►Ventis MX4 Resources
· The aspirated version of the Ventis MX4 is only approved for use with the extended battery pack.
· The monitor must display methane in the percent-by-volume mode (0-5%) for compliance determinations The Ventis MX4 Product Manual is the primary resource, within a full suite of learning tools, developed for the monitor
required by 30 CFR Part 75, subpart D. user. Its step-by-step “walk through” format covers everything from unpacking to set-up, operation, and service. All
Ventis MX4 users should read and understand the Product Manual prior to unpacking or using the monitor.
SANS 1515-certified units may be used only as follows:
· Diffusion applications A companion to the manual, the Ventis MX4 Reference Guide ships with the monitor. It serves to announce all
· Configured and maintained to disallow power-off when the unit is in alarm warnings and cautionary statements relevant to general monitor use. The guide also features process charts that
· The Methane alarms are set as follows: low alarm = 1%vol and high alarm =1.4%vol provide an overview of four fundamental tasks: operation/start-up, configuration, calibration, and functional “bump”
· With approved Lithium-ion battery packs (see Ventis MX4 Accessories and Parts in this manual). testing. These charts are tools for the user who is both familiar with the manual and proficient in the performance of
the given task.
Recommended Practices
Ventis MX4 product-specific resources are part of the organization’s broader training line-up, featuring online training
Industrial Scientific Corporation recommends the monitor be fully charged (when equipped with a rechargeable
modules and face-to-face classroom programs for technicians, operators, first responders, trainers, and distributors.
battery pack), configured, and calibrated before first time use. If the lithium-ion battery is deeply discharged, it
Courses combine theory with hands-on learning, and can be tailored to the customer’s unique requirements and gas
can take up to an hour for the instrument display to indicate that the battery is charging. Monitors used
monitoring applications.
infrequently should be fully charged every four months.
No part of the unit should be covered by any garment, part of a garment, or other item that would restrict the The organization’s customer and technical support call centers provide product and order information, how-to product
flow of air to the sensors or impair the operator's access to the audible, visual, or vibration alarms. assistance, and guidance for in-depth technical applications. Its service centers offer comprehensive factory repair
Industrial Scientific Corporation recommends a full monitor calibration be performed monthly (at a minimum), and maintenance services.
using a certified concentration(s) of Industrial Scientific calibration gas(es) to help ensure monitor accuracy.
Industrial Scientific Corporation provides a full suite of resources to aid customers in the competent and safe use of
Industrial Scientific Corporation recommends the monitor be zeroed and bump tested before each use with a its products and services. With 19 manufacturing, support, and service centers and hundreds of distributors
certified concentration(s) of Industrial Scientific calibration gas(es). worldwide, Industrial Scientific serves the globe’s gas detection needs.
Battery contacts are exposed on battery packs when they are removed from the monitor. Do not touch the
battery contacts and do not stack battery packs on top of one another.
When reassembling the instrument or installing a battery pack, maintain ingress protection by tightening each ►Ventis MX4 Capabilities
fastener to its stated torque value (see the “Ventis MX4 Monitor three-Dimensional Diagram” and its key in this
manual). The Ventis MX4 is a portable multi-gas monitor. Offered as a diffusion monitor, it detects and measures gas(es)
present in open space. To enable monitor use within confined space locations, the Ventis MX4 is also offered as an
Contact your service representative immediately if you suspect that the Ventis MX4 is working abnormally. aspirated monitor. A pump module and battery accessories enable the conversion of either monitor for dedicated use
in either confined or open spaces.
Industrial Scientific recommends the “2 & 2 Sampling Rule” when sampling with a motorized pump and tubing,
one should allow for 2 minutes plus 2 seconds per foot of tubing used, prior to noting the monitor readings. Based on the customer’s monitor order, up to four sensors are factory installed enabling the monitor to continuously
This allows time for the gas to reach the instrument and for the sensors to adequately react to any gases and simultaneously detect and measure the presence of up to four specific gases.
present. Industrial Scientific recommends that clear urethane tubing, part number 17065970, be used with the
pumped versions of the Ventis MX4 when sampling for the following gases: Nitrogen Dioxide (NO2) and Sulfur Sensor Number available per Gases Monitored
Dioxide (SO2). Category monitor
Oxygen 1 O2 (Oxygen) only
Combustible 1 Monitor can be configured for sensor to measure ONE of the following:
· LEL (Pentane)
· LEL (Methane)
· CH4 (0%-5%)
Toxic 2 Each sensor detects and measures only ONE of the following:
· CO (Carbon Monoxide)
· CO/H2 Low (Carbon Monoxide with low H2 interference)
· H2S (Hydrogen Sulfide)
· NO2 (Nitrogen Dioxide)
· SO2 (Sulfur Dioxide)

Equipped with a multi-mode (audible, visual, and vibration) and multi-level alarm system, the Ventis MX4 monitor is
capable of notifying its user of potentially hazardous gas concentrations.

The monitor performs continuous datalogging at 10 second intervals. It can store approximately 90 days of data for a
four-sensor configuration. Its date- and time-stamped event log records and stores data for the following: 60 alarm
events, 30 error events, and 250 manually performed calibrations or bump tests. The memory, when full, overwrites
the oldest data as the newest readings and events are logged.

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The Ventis MX4 monitor functions as an independent device to monitor the environment for hazardous gas ►Monitor Overview
concentrations. It is compatible with products that charge, calibrate, bump test, read and record instrument data,
protect, and otherwise enable or enhance use of the monitor and its data. For a complete list of these products,
please refer to the manual section, Ventis MX4 Accessories and Parts. HARDWARE FEATURES AND FUNCTIONS
The monitor’s case top (front of monitor) has two main sections. As shown below, the upper section contains the
sensor ports. The lower section houses the user interface features, a LCD display screen and two buttons. Each
►Unpacking the Monitor feature’s general functions are noted below. As shown, the diffusion and aspirated monitors differ with respect to the
location of the air intake mechanism and visual alarm indicators.
CONTENTS
The monitor box contains the following items including, when ordered, those marked optional. Each item ordered The instrument may be used in any orientation when clipped to the user or when used with a compatible carrying
should be accounted for in the unpacking process. case. Normal instrument orientation for measuring gas concentration is hand held with sensors and display facing the
operator.
Quantity Item Notes
1 as ordered Ventis MX4 Portable Multi-gas The monitor type is indicated on the box label.
Monitor Options:
· Ventis MX4 Diffusion
· Ventis MX4 Aspirated
· Ventis MX4 Aspirated with Conversion Kit
1 Ventis MX4 Reference Guide A companion to the Ventis MX4 Product Manual.
1 installed as ordered Battery Pack One of three battery types is factory installed as
indicated on the box label. Options:
· Rechargeable Lithium-ion
· Rechargeable Extended Range Lithium-ion
· Alkaline
1 as ordered Ventis Charger Universal power cord. AC charger products include
interchangeable plugs (US, UK, EU, and AUS).
0 or 1 Calibration Cup Diffusion – 1 included
Aspirated – 0 included
1 Calibration and Bump Test Diffusion – two feet of clear tubing
Tubing
0 or 1 In-field Sampling Tubing Diffusion – 0 included
Aspirated – Ten feet of black tubing
1 Final Inspection & Test Report Contains the following factory set* information:
· Monitor Set-up Date
· Monitor Part Number (P/N)
· Monitor Serial Number (S/N)
· For Each Sensor*:
· P/N
· S/N
· Type Number Feature Functions
· Location 1 Visual alarm indicator Signals an alarm or warning; frequency varies by alarm level. Also used as a
· Alarm level values confidence indicator.
· Span gas values 2 Pump inlet (aspirated) Air intake; calibration and bump test gas intake.
· Span reserve values Sensor ports (diffusion)
*Some factory set sensor values subject to user changes. 3 LCD display User interface; backlight flashes when monitor is in system, high, or low alarm
states.
1 Warranty Card --
4 Audible alarm ports On when monitor is in system, high, or low alarm states; frequency and tone vary
by alarm level. Also used for warnings and as confidence indicator.
5 On/Off/Mode button Used to power-on and power-off. Also used to bypass a process/step or advance
to a next screen in both gas monitoring and configuration modes. Sets values in
REPORTING A PROBLEM configuration mode.
After unpacking, if any item is missing or appears to have been damaged, contact a local distributor of Industrial
6 Enter button Used to begin a process/step in a process. Edits values in configuration mode.
Scientific products or Industrial Scientific Corporation (for contact information, please see the manual’s last page).
7 IrDA interface Indicates infrared light data exchange in-progress.
8 Charging contacts Battery charging.

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Lower Explosive Limit. Display variations:


DISPLAY SCREEN “LEL” (English)
The Ventis MX4 Boot-up Screen, as shown below, serves to introduce all icons and the alpha-numeric items (e.g., “LIE” (French)
8.8.8) that can appear on the display when the monitor is in use, docked, or charging. Each display item is stationary, “UEG” (German)
communicates unique information, and appears only when relevant to the task being performed. Oxygen (O 2)

A sample Gas Monitoring Screen is also shown below, next to the boot-up screen. This illustrates how the icons and Nitrogen Dioxide (NO2)
the alpha-numeric characters work together to communicate several points of information to the monitor user.
Hydrogen Sulfide (H2S)

COL CO H2/Low

Percentage Volume: O2 and CH4 measurement unit

Percentage unit for combustible gases; display variations:


“% LEL” (English)
Boot-Up Screen Gas Monitoring Screen “% LIE” (French)
All possible screen images. Sample screen in gas monitoring mode. “% UEG” (German)
Parts Per Million: H2S, CO, SO2 and NO2 measurement unit.
NOTE: Display screens featured throughout this manual include the “pump” icon.
Similar in appearance to a fan, it indicates an aspirated monitor is in use. For a
diffusion monitor, the pump icon does not appear on the display. Over-range: for any sensor in over-range, indicates the measured gas concentration is greater
than the measurement range of the sensor. Display variations:
It is helpful to view the boot-up screen in sections. The top and bottom rows each contain icons. The main function of “Or” (English and German)
the middle section, in gas monitoring mode, is to communicate gas concentration readings. Definitions for all icons, “Sup” (French)
gas name abbreviations, gas measurement units, and other indicators are provided below. Where applicable, display Negative Over-range: for any sensor in negative over-range indicates the measured gas
variations are noted. concentration is less than the negative measurement range of the sensor. Display variations:
“-Or” (English and German)
Top Row Icons Definition “InF” (French)
Status: indicates no monitor or sensor faults. Bottom Row Icons Definition
Battery level indicator; display variations:
Warning: indicates monitor or sensor fault.
0 black bars = low battery warning
1 black bar < 33% charge remaining
Zero: communicates zero status (e.g., zero results, zero in-progress, etc.). 2 black bars = 34% - 66% charge remaining
3 black bars = 67% – 100% charge remaining
Gas Cylinder: communicates calibration related information (calibration due, calibration apply
gas, etc.). Security Code: indicates code is set or to be entered.

Clock: indicates a process is in-progress. Pump: shown anytime an aspirated monitor is in use.

Calendar: communicates overdue warnings for service items (calibration, bump testing, etc.). Indicates IrDA communication is in-progress.

Alarm: indicates an alarm causing condition. Short Term Exposure Limit: communicates STEL values. Display variations:
“STEL” ( English and German)
Low level audio alarm is on. “VLE” (French)
Time Weighted Average: communicates TWA values. Display variations:
High level audio alarm is on. “TWA” (English and German)
“VME” (French)
Peak: displayed when peak detection values are viewed.

Alpha-numeric Definition
display values
Carbon Monoxide (CO)

Methane (CH4)

Sulfur Dioxide (SO2)

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ALARMS the up arrow icon displays.


NOTICE A low alarm condition occurs when the
® All monitor alarms and warnings should be taken seriously and responded to as stated in company safety concentration of gas sensed reaches the
standards. monitor’s low alarm value setting for a
® Once initiated, an alarm will remain on while the alarm condition is present. For gas-related alarms, once the sensor(s).
detected gas concentration changes, the alarm indicators will change to reflect any new condition such as
low-alarm gas, high-alarm gas, over-range gas, or no gas alarm.
® When the latch alarm feature is enabled and the monitor goes into alarm, it will remain in alarm until the
alarm condition no longer exists and the monitor user presses the ENTER button for one second. This Low Alarm Screen
applies only to gas-related alarms. A flashing gas concentration value* indicates which sensor(s)
reading(s) is the cause for alarm. The low level alarms turn on and
It is practical for the monitor user to be aware of the possible alarms prior to monitor set-up and use. The Ventis MX4 the down arrow icon displays.
has four alarm and warning levels. A “system level” alarm generates the highest frequency tone and highest level A TWA alarm occurs when the calculated time
visual and vibration signals. It is used to indicate such events as a pump or sensor failure. The “high” or “low” level weighted average reaches the monitor’s
audio alarms, in combination with visual and vibration indicators, turn on when gas concentration readings are over- hazardous value for the set time frame.
range, high, or low. The lowest level indicator is a warning with beep patterns to indicate service needs (e.g., low
battery or calibration due). The beep is also used as a confidence indicator when enabled.

Alarm types and their alarm generating conditions are described below.
TWA Alarm Screen
A flashing gas concentration value* indicates which sensor(s)
Display Description reading(s) is the cause for alarm. The low level alarms turn on and
An over-range condition occurs when the gas the TWA icon flashes.
concentration value sensed is above the The STEL alarm occurs when the short term
sensor’s measuring range. exposure value exceeds the acceptable limit.

After any over-range alarm, the monitor


should be calibrated.

Over-range Alarm Screen NOTES: The O2 and toxic sensor values normally
The “Or” message indicates which sensor(s) is reading an over- reset when the gas sensed reaches an acceptable STEL Alarm Screen
range condition(s). All other sensors show their current gas range. A flashing gas concentration value* indicates which sensor(s)
concentration readings on a numeric display (left) or gas names on reading(s) is the cause for alarm. The low level alarms turn on and
a text display (right). The high level alarms turn on and the alarm If the LEL reads over-range, the alarm latches and the STEL icon flashes.
icon displays. the LEL sensor is automatically turned off. Press
the enter button to turn on the LEL sensor. This will Alarm occurs when the monitor registers no
turn off the alarm indicators. After a warm-up period
sensors installed.
of approximately 30 seconds, an LEL reading will
display. If the new reading is an over-range or other
alarm condition, the alarm indicators will turn on.
A negative over-range condition occurs when
the gas concentration value sensed is less
than the sensor’s measuring range. No Sensor Installed Screen
The system level alarms turn on and the error icon displays.
After any negative over-range alarm, the Alarm occurs when any installed sensor’s
monitor should be calibrated.
data-related operations fail and the sensor is
Negative Over-range Alarm Screen not operational.
The “-Or” message indicates which sensor is reading a negative
over-range condition. All other sensors display their current gas
concentration readings*. The high level alarms turn on and the
alarm icon displays.
Sensor Data Fail Screen
A high alarm condition occurs when the A flashing “F” indicates which sensor is the cause for alarm. The
concentration of gas sensed reaches a level audio alarm turns on and the error icon displays.
greater than the monitor’s high alarm value
Error codes 4XX to 5XX (404 shown here)
setting for a sensor(s).
indicate the monitor has detected a
malfunction. The unit is not operational and
and should be examined by a qualified
High Alarm Screen technician or reported to Industrial Scientific
A flashing gas concentration value* indicates which sensor(s) for service or repair information.
reading(s) is the cause for alarm. The high level alarms turn on and Critical Error Screen

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Alarm occurs when, if attached, the pump is Properties and Compatibility Battery Pack
not operating correctly. While in alarm, every Rechargeable Rechargeable Replaceable
ten seconds the monitor attempts to restart Li-ion Extended Range Li-ion Alkaline
the pump. If unsuccessful, the monitor
remains in alarm. Ventis MX4 aspirated monitor compatible No Yes Yes
Ventis MX4 diffusion monitor compatible Yes Yes Yes
Note: The nominal flow rate is >200 cc/m (.2
Pump Fault Alarm LPM). A pump fault alarm will occur when Battery lifetime 300 charge cycles 300 charge cycles --
The system level alarms turn on and the error icon displays. the flow is less than 200 cc/m +0, -25%. Battery re-charge time 3-5 hours 3-7.5 hours N/A
Alarm occurs when the monitor’s battery Nominal run time (when fully charged and operating at room temperature)
reaches a low level of charge or is nearing its
For the aspirated monitor -- 12 hours 4 hours
end of life.
For the diffusion monitor 12 hours 20 hours 8 hours
NOTE: When a lithium-ion battery becomes deeply discharged and the instrument is docked, it can take up to an hour for the
instrument display to indicate that the battery is charging. Battery charging is suspended in temperatures below 0 °C (32 °F) and
Low Battery Warning Screen above 50 °C (122 °F).
A beep sounds every 30 seconds and the empty battery icon
flashes.
Alarm occurs when one or more sensors are
due for a bump test. If the monitor settings CHARGING THE LITHIUM-ION BATTERY PACKS
permit, an in-field bump test may be The lithium-ion battery packs are charged at the factory. As some or all of the charge may deplete before the monitor
performed in an area known to be arrives or is unpacked, it is recommended that the monitor be fully charged before first time use. The lithium-ion
nonhazardous. equipped Ventis MX4 can be charged with any of the products listed below.

Bump Overdue Screen · DS2 Docking Station™ for Ventis


A “b” indicates which sensor(s) is overdue for bump testing. Two · V-Cal™ Calibration Station
beeps sound every 30 seconds and the calendar and alarm icons · V-Cal™ 6-Unit Calibration Station
display. · Ventis Single Unit Charger
· Ventis Single Unit Charger/Datalink
Alarm occurs when one or more sensors are · Ventis 6-Unit Charger
due for calibration. If the monitor settings
· Ventis Single Unit Automotive Charger, 12 VDC
permit, an in-field calibration can be performed
· Ventis Single Unit Truck-Mount Charger, 12 VDC, with Cigarette Adapter
in an area known to be nonhazardous.
· Ventis Single Unit Truck-Mount Charger, 12 VDC, Hard Wired
NOTE: The above products are all equipped with a yellow LED “presence” indicator. This LED confirms that the monitor is properly seated
Calibration Due Alarm Screen in the cradle such that the monitor can charge; however, it is NOT intended to be used as a charging indicator.
The gas value flashes for each sensor overdue for calibration.
This LED indicator may go out intermittently during normal charging functions and will not light if the unit is fully charged when placed in the
Three beeps sound every 30 seconds and the calendar and alarm cradle. Always refer to the monitor display’s battery level indicator to confirm the battery charge level.
icons display. The gas cylinder icon flashes.
* The numeric mode display shows gas concentration values; the text mode display shows gas type names in place of gas values. The Ventis Single Unit Charger is generally shipped with the monitor. Equipped with a movable partition, which fits in
each of two dedicated slots, it charges the diffusion and aspirated monitors with their compatible lithium-ion battery
packs. Place the partition in the back slot for a diffusion or aspirated monitor with an Extended Range Li-ion battery
pack. Place the partition in the front slot to charge a diffusion monitor with a Li-ion battery pack.

►Monitor Set-up Instructions


NOTICES
Preparing the monitor for first time use is a “3-C” process: charge (if equipped with a lithium-ion battery pack), ® Charge the monitor in an area known to be nonhazardous.
configure, and calibrate. This manual section covers charging and configuration for set-up purposes and can be ® When using the charger and adjusting its partition, take care NOT to touch the battery contacts located at
consulted for ongoing instruction thereafter. Immediately following this section, calibration is covered in the manual the front of the cradle bottom.
section, Use and Service.
· The single unit charger has a universal power cord; change the plug insert, if needed, and plug into the
BATTERY PROPERTIES AND MONITOR COMPATIBILITY appropriate outlet.
Based on the customer order, the Ventis MX4 comes equipped with one of three factory installed batteries: · To properly adjust the partition, if needed, complete and observe the following.
rechargeable Lithium-ion (Li-ion), rechargeable Extended Range Lithium-ion (extended range Li-ion), or replaceable o Lift up to remove from slot.
alkaline. The factory installed battery pack type is stated on the label affixed to the monitor box. Basic battery o Push down to place in the desired slot.
properties and acceptable monitor/battery combinations are shown below. o When partition is inserted correctly, a click sounds.
Recommended Practice: To prevent the loss of the partition, it should always reside in the cradle in one of its two
dedicated slots. Choose the most used slot. Do not place the partition in the forward most compartment of the charger
where the battery contacts are located.

· To properly place the monitor in the charger, complete or observe the following.

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o The monitor’s display side faces the user. To enter gas monitoring mode:
o The charging contacts on the monitor bottom meet the contact pins inside the charger’s cradle. allow the countdown to complete and advance
o Refer to the monitor’s battery icon to confirm the battery charge level. to the Gas Monitoring Screen. Proceed to the
- If the battery is less than fully charged, the monitor displays the battery icon (flashing empty manual section, Monitor Use and Service.
to full, repeatedly).
- If the battery is fully charged, the monitor displays a full battery icon. To enter configuration mode:
Countdown Screen simultaneously press ON/OFF/MODE and
Displays the 20 second countdown, one second at a time, from 20 ENTER, hold for three seconds, and release.
POWER-ON AND -OFF to one. Options :
To power-on the Ventis MX4, press ON/OFF/MODE and hold for three to five seconds. During the first ten to15 Enter gas monitoring mode
seconds the monitor is on, its firmware completes internal tests and the user sees or hears what is described and Enter configuration mode
shown below. Following this initialization phase, a countdown screen displays. During this 20-second countdown, the Press ON/OFF/MODE, hold for the full five
monitor user can enter configuration mode to manually adjust monitor settings. second countdown to zero, and release to
power-off the monitor.
Display and Options Instructions
No user action required.

Power-Off Screen
The screen displays a five-second countdown accompanied by five
beeps and LED flashes.

Visual Test Screen CONFIGURATION


Displays for up to five seconds as the monitor completes a sensor Introduction
and alarm check. Visual, vibration, and audio alarms turn on Before first time use of the monitor, its settings should be reviewed and, if needed, be adjusted. Qualified safety
briefly, then off. personnel should complete the following tasks.
Be sure the pump inlet is not blocked. · Review the monitor settings for compliance with company policy and any applicable regulations, laws, and
observed guidelines as issued by regulatory agencies and government or industry groups.
· Determine which settings, if any, require adjustment.
· Make the adjustments or supervise other qualified personnel in the process.
· When using instrument-compatible Industrial Scientific docking station software (e.g., iNet, Docking Station
Server Administrative Console [DSSAC], or Accessory Software), maintain the mandated settings through
Pump Set-up Screen the software or by manually configuring the instrument settings after docking.
Displays for five to seven seconds for an aspirated monitor. The
monitor checks for the presence of a pump. If present, the pump is Monitor settings should be reviewed regularly and adjusted as needed. The following settings are adjustable or
started and, if needed, adjusted for optimum flow. “configurable" for the Ventis MX4.
No user action required. LEL Type Display Mode Setting Calibration In-field
Calibration Mode Setting Confidence Indicator (on/off) Calibration Due Alarm
Low Alarm Settings Confidence Indicator (type) Calibration Due Set-point
High Alarm Settings Bump Test In-field Security Code
TWA Alarm Settings Bump Test Due Warning Language Selection
TWA Interval Settings Bump Test Time Set-point Always-on Setting
Software Version Screen STEL Alarm Setting Bump Test Percentage Shutdown In Alarm Setting
The Software Version Screen message displays for five seconds. Calibration Gas Settings Bump Test Response Time Alarm on Dock Setting
Clock Settings Alarm Latch Set
No user action required. Date Settings Zero In-field

The Ventis MX4 can be configured manually as instructed below. Any changes made take effect immediately upon
exiting the configuration mode.

Calibration Days Screen Instructions


When the up arrow (▲) is featured, the number of days displayed NOTICES
for each sensor indicates when the next calibration is due. When ® The configuration mode should be accessed only by safety personnel authorized to change monitor settings
the down arrow (▼) is featured, the number of days displayed based on company policy.
indicates when the last calibration occurred. ® Read ALL requirements and instructions outlined below, including the screen-by-screen process description,
before beginning the configuration process.

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The configuration mode can be entered during the 20-second countdown of the power-on process. During the Press ON/OFF/MODE to bypass the zero and calibration processes and
countdown, simultaneously press ON/OFF/MODE and ENTER, hold for three seconds, and release to enter advance to one of two screens.
configuration mode. (While in the configuration mode, the same button presses cause the monitor to exit
configuration). Each configuration screen times out after 30 seconds and the monitor enters gas monitoring mode. To If the installed sensor set includes H2S and NO2, OR, SO2 and NO2,
re-enter the configuration mode, power-off the monitor, then power-on and repeat the entry process. the monitor is pre-set for standard calibration mode and the Low
Alarm Set-point Screen displays.
Throughout the configuration process, the main functions of the two buttons are as follows. Zero Initiate Screen
· The ENTER button is used to edit values. It is also used, where noted, to begin a process or a step in a Options For all others installed sensor combinations, the Calibration Mode
process. Bypass zero and calibration process. Selection Screen displays.
· The ON/OFF/MODE button is used to set the value. Where noted, it is also used to bypass a process or Begin zero and calibration process.
step in a process, or to advance to the next configuration screen. Press ENTER to begin the zero and calibration process. Proceed to the
manual section, Zero, Calibration, and Bump Testing
The first screen to display in configuration mode depends on three things:
The quick calibration option sets the monitor to calibrate all four sensors
· security code setting,
simultaneously. The standard calibration option sets the monitor to
· the presence or absence of the China MA feature,
calibrate each sensor independently.
· and the presence or absence of an LEL sensor.
Press ENTER to edit the value, if needed.
If the security code setting is 000, the security feature is disabled and the Enter Security Code Screen does NOT Press ON/OFF/MODE to set the value and advance to the Low Alarm
appear. If the security code is NOT 000, the security feature is enabled and the monitor displays the Enter Set Screen.
Security Code Screen. Calibration Mode Selection
Options
The monitor next checks for the presence of a China MA mining feature. If this feature is operational, the monitor 0 = Standard Calibration
displays the Zero Initiate Screen. 1 = Quick Calibration
NOTE: The user can edit the values for four alarm types in configuration mode. The monitor presents these options
If the China MA mining feature is NOT operational, the monitor then checks for an installed LEL sensor. If
in the order shown below.
installed, the monitor displays the LEL Type Screen. If no LEL sensor is installed, the monitor displays the Zero
1. Low alarm
Initiate Screen.
2. High alarm
3. TWA (if toxic sensors installed)
Configuration Process 4. STEL (if toxic sensors installed)
Display and Options Instructions For each alarm type (e.g., low alarm), the user can edit the alarm settings for each installed sensor, one sensor
at a time. The order in which the sensors are subject to change is as follows.
Press ENTER to edit the value, if needed; press repeatedly or hold down 1. Toxic sensor 1
to speed the increment pace to reach the valid security code. 2. LEL sensor
Press ON/OFF/MODE to enter configuration mode and arrive at the 3. Toxic sensor 2
next applicable screen. 4. O2 sensor
Press ON/OFF/MODE to bypass the low alarm value set process and
advance to the High Alarm Set-point Screen.
Enter Security Code Screen Press ENTER to begin the low alarm value set process.
The presence of this screen indicates an On the display, the first sensor subject to change flashes.
enabled security feature. Press ENTER to edit the value, if needed; press repeatedly or
Press ENTER to edit the value, if needed. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to the Zero Initiate Press ON/OFF/MODE to set the value.
Low Alarm Set-point Screen
Screen. Displays the existing low alarm value for The next sensor subject to change flashes. Continue to use the
each installed sensor. If any one of the ENTER and ON/OFF/MODE buttons, respectively, to edit and
NOTE: If the LEL type is changed, the sensor goes into calibration fail mode. A full calibration
is required before the monitor can be used and is accessible from the next screen in the sensors is NOT installed, its position on set each sensor’s low alarm value.
configuration process, the Zero Initiate Screen. For complete calibration instructions, proceed the display is blank.
to the manual section, Zero, Calibration, and Bump Testing.
LEL Type Set Screen After the alarm value is set for each installed sensor,
Options press ON/OFF/MODE to advance to the High Alarm Set-
LEL point Screen.
CH4

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Press ON/OFF/MODE to bypass high alarm value set process and Press ON/OFF/MODE to bypass the calibration gas set process and
advance to one of two screens as noted below. advance to the Clock Set Screen.
Press ENTER to begin the high alarm value set process. Press ENTER to begin the calibration gas value set process.
On the display, the first sensor subject to change flashes. On the display, the first sensor subject to change flashes.
Press ENTER to edit the value, if needed; press repeatedly or Press ENTER to edit the value, if needed; press repeatedly or
hold down to speed the increment pace. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value. Press ON/OFF/MODE to set the value.
High Alarm Set-point Screen Calibration Gas Set Screen
Displays the existing high alarm value The next sensor subject to change flashes. Continue to use the Displays the existing calibration gas The next sensor subject to change flashes. Continue to use the
for each installed sensor. If any one of ENTER and ON/OFF/MODE buttons, respectively, to edit and value for each installed sensor. ENTER and ON/OFF/MODE buttons, respectively, to edit and
the sensors is not installed, its position set each sensor’s high alarm value. set each sensor’s calibration gas value.
on the display is blank. If any one of the sensors is not installed,
After the alarm value is set for each installed sensor, its position on the display is blank. After calibration gas value is set for each installed sensor,
press ON/OFF/MODE and advance to one of two screens. press ON/OFF/MODE to advance to the Clock Set Screen.
If at least one toxic sensor is installed, the TWA Alarm
Press ON/OFF/MODE to bypass the clock set process and advance to
Set Screen displays.
the Date Set Screen.
Press ENTER to begin the clock set process.
If NO toxic sensors are installed, the Calibration Gas
On the display, the first time value subject to change flashes.
Set Screen displays.
Press ENTER to edit the value, if needed; press repeatedly or
Press ON/OFF/MODE to bypass the TWA alarm value set process and hold down to speed the increment pace.
advance to the TWA Interval Set-point Screen. Press ON/OFF/MODE to set the value.
Press ENTER to begin the TWA alarm value set process. Clock Set Screen
On the display, the first sensor subject to change flashes. Displays the existing time values using a The next value subject to change flashes. Use the ENTER
Press ENTER to edit the value, if needed; press repeatedly or 24-hour time format. and ON/OFF/MODE buttons, respectively, to edit the value.
hold down to speed the increment pace.
Press ON/OFF/MODE to set the value. After all values are set, press ON/OFF/MODE and
TWA Alarm Set-point Screen advance to the Date Set Screen.
Displays the existing TWA values for the The next sensor subject to change flashes. Continue to use
toxic sensors installed. No other sensor the ENTER and ON/OFF/MODE buttons, respectively, to
readings appear. Press ON/OFF/MODE to bypass the date set process and advance to
edit and set each alarm value.
the Display Mode Set Screen.
Press ENTER to begin the date set process
After the alarm value is set for each installed sensor,
On the display, the first date value subject to change flashes.
press ON/OFF/MODE to advance to the TWA Interval
Press ENTER to edit the value, if needed; press repeatedly or
Set Screen.
hold down to speed the increment pace. Press ON/OFF/MODE
Press ENTER to edit the value, if needed. to set the value.
Date Set Screen
Press ON/OFF/MODE to set the value and advance to the STEL Alarm Displays the existing date. The value
Set-point Screen. The next date value subject to change flashes. Continue to use
displayed on the far left is the month the ENTER and ON/OFF/MODE buttons, respectively, to edit
and to its right the day. The year is and set each value.
displayed beneath the day.
After all values are set, press ON/OFF/MODE and
TWA Interval Set-point Screen advance to the Display Mode Set Screen.
Displays the existing TWA interval.
The display mode selected determines whether the monitor user will see
The value can be set from one to 40
a numeric or text display (including alarm displays) when the monitor is in
hours, in increments of one.
the gas monitoring mode.
Press ON/OFF/MODE to bypass the STEL alarm value set process and
advance to the Calibration Gas Set Screen. Press ENTER to edit the value, if needed.
Press ENTER to begin the STEL alarm value set process. Press ON/OFF/MODE to set the value and advance to the Confidence
On the display, the first sensor subject to change flashes. Indicator Set Screen.
Press ENTER to edit the value, if needed; press repeatedly or Display Mode Set Screen
hold down to speed the increment pace. Options
Press ON/OFF/MODE to set the value. 0 = Numeric Mode
STEL Alarm Set-point Screen 1 = Text Mode
Displays the existing STEL values for The next sensor subject to change flashes. Continue to use the
the toxic sensors installed. No other ENTER and ON/OFF/MODE buttons, respectively, to edit and
sensor readings appear. set each sensor’s STEL alarm value.

After the alarm value is set for each installed sensor,


press ON/OFF/MODE to advance to the Calibration Gas
Set Screen.

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With an enabled confidence indicator, the monitor will emit a Sets the percentage of calibration gas the monitor expects to be
signal, every 90 seconds in gas monitoring mode, to inform the exposed to.
user it is operational.
Press ENTER to edit the value, if needed; press repeatedly or
Press ENTER to edit the value, if needed. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to one of two Press ON/OFF/MODE to set the value and advance to the Bump
screens. Test Response Time Screen.
Confidence Indicator On-Off Screen If the confidence indicator is enabled, the Confidence Bump Test Percentage Requirement Screen
Options Indicator Type Set Screen displays. Value range: 50% to 99%
0 = Disable/off Value increment: one percent
1 = Enable/on If the confidence indicator is disabled, the Bump Test In- Sets the bump test response time period.
field Option Screen displays.
Sets the type of signal that will be emitted by an enabled Press ENTER to edit the value, if needed; press repeatedly or
confidence indicator. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to the Latch
Press ENTER to edit the value, if needed. Alarm Set Screen.
Press ON/OFF/MODE to set the value and advance to the Bump Bump Test Response Time Screen
Test In-field Option Screen. Value range: 30 to 300 seconds
Value increment: five seconds
Confidence Indicator Type Set Screen
Options When enabled, if the monitor goes into any gas-related alarm, it
will remain in alarm until after the gas concentration is less than (or
1 = audible chirp
more than for oxygen) the alarm set point, and the monitor user
2 = LED flash presses the ENTER button for one second.
3 = combination audible chirp and LED flash
When enabled, permits all monitor users to bump test the monitor Press ENTER to edit the value, if needed.
from the gas monitoring mode. Latch Alarm Set Screen Press ON/OFF/MODE to set the value and advance to the Zero
Options In-field Screen.
Press ENTER to edit the value, if needed. 0 = Normal mode
Press ON/OFF/MODE to set the value and advance to one of two 1 = Latching mode
screens. When enabled, all monitor users are permitted to zero the monitor
If Bump Test In-field is enabled, the Bump Due Warning from the gas monitoring mode.
Bump Test In-field Option Screen Option Screen displays.
Options
0 = Disable/off Press ENTER to edit the value, if needed.
If the Bump Test In-field is disabled, the Alarm Latch Set Press ON/OFF/MODE to set the value and advance to one of two
1 = Enable/on Screen displays. screens.
When enabled, the monitor will sound two beeps every 30 Zero In-field Screen If Zero In-field is enabled, the Calibration In-field Option
seconds and its display icons will indicate a bump test is due. Options screen displays.
0 = Disable/off If Zero In-field is disabled, the Calibration Due Alarm screen
Press ENTER to edit the value, if needed. 1 = Enable/on displays.
Press ON/OFF/MODE to set the value and advance to the Bump
Test Time Set-point Screen. When enabled, all monitor users are permitted to calibrate the
monitor from the gas monitoring mode.
Bump Due Warning Option Screen
Options Press ENTER to edit the value, if needed.
0 = Disable/off Press ON/OFF/MODE to set the value and advance to the
1 = Enable/on Calibration Due Alarm Option.
Sets the elapsed time allowed between bump tests. Calibration In-field Option Screen
Options
Press ENTER to edit the value, if needed; press repeatedly or 0 = Disable/off
hold down to speed the increment pace. 1 = Enable/on
Press ON/OFF/MODE to set the value and advance to the Bump When enabled, the monitor will activate the calibration due alarm,
Test Percentage Requirement Screen. in gas monitoring mode, when any sensor is due for calibration. A
flashing gas cylinder and gas type will appear on the display and
Bump Test Time Set-point Screen
three beeps will sound every 30 seconds.
Value range: .5 days to 7.0 days
Value increment: .5 days
Press ENTER to edit the value, if needed.
Calibration Due Alarm Option Screen Press ON/OFF/MODE to set the value and advance to the
Options Calibration Due Set-point screen.
0 = Disable/off
1 = Enable/on

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Sets the elapsed time allowed between calibrations. Disallow or allow operator-activated shutdown when the unit is in
alarm.
Press ENTER to edit the value, if needed.
Press ON/OFF/MODE to set the value and advance to the Press ENTER to edit the value, if needed.
Calibration Days Set Screen. Press ON/OFF/MODE to set the value and advance to the next
configuration mode screen.
Shutdown In Alarm Screen
Calibration Due Set-point Screen
Options
Value range: one to 365 days
0 = Disallows shutdown
Value increment: one day
1 = Allows shutdown
Sets how the Calibration Days Screen will display in operation
Disable or enable alarm indicators when the unit is docked.
mode.
NOTE: The up arrow ( ▲) will be featured on-screen when the Press ENTER to edit the value, if needed.
unit is set to display the number of days before a sensor’s Press ON/OFF/MODE to set the value and advance to the next
next calibration is due. The down arrow (▼) will be featured configuration mode screen.
Calibration Days Set Screen when the unit is set to display the number of days since the
Options last calibration was performed. A value will be displayed for Alarm on Dock Screen
0 = display days since last calibration each installed sensor. Options
1 = display days until next calibration 0 = Disable/off
Press ENTER to edit the value, if needed. 1 = Enable/on
Press ON/OFF/MODE to set the value and advance to the
Security Code Set Screen
A security code value of 000 permits all monitor users to enter ►Monitor Use and Service
configuration mode and gain access to change the monitor’s
settings. A value other than 000 will restrict access to the
Proper monitor use and service includes everything from bump testing and calibration to keeping the monitor clean,
configuration mode; it will also restrict access to the shutdown
proper air sampling, and the replacement of parts and components. Beginning with calibration and bump testing, the
process for an instrument that is configured for “always on”.
following sections provide information and instruction on all use and service tasks.
Press ENTER to edit the value, if needed; press repeatedly or
Security Code Set Screen hold down to speed the increment pace.
Valid values: 000 to 999.
ZERO, CALIBRATION, AND BUMP TESTING
Press ON/OFF/MODE to set the value and advance to the
Increment value: one Language Selection Screen. Gas detection instruments are potentially life-saving devices. When completed regularly, the procedures defined
Allows the choice of display languages as applied to select below help to maintain proper instrument functionality and enhance operator safety.
screens.
Procedures
Press ENTER to edit the value, if needed.
Press ON/OFF/MODE to set the value and return to the LEL Type Configuration. The configuration process allows qualified personnel to review and adjust a unit's settings.
Set Screen.
Bump Test (or "functional test"). Bump testing checks for sensor and alarm functionality. The installed sensors are
Language Selection Screen briefly exposed to expected concentrations of calibration gases that are greater than the sensors’ low alarm set
Options points. When one or more sensors “pass” the test, they are “functional” and the unit will alarm. Each sensor’s “pass”
E = English
F = French or “fail” result is indicated on the unit’s display.
d = German Note: a bump test does not measure for sensor accuracy (see “Calibration”).
When enabled, the shutdown process is security-code protected Zero. Zeroing sets each installed sensor to recognize the ambient air as clean air. If the ambient air is not truly clean
only if the security code is not equal to 000. If the code is set to air, any gasses that are present and relevant to the installed sensor types will be measured and displayed as zero.
anything other than 000, the user will be prompted to enter the
unit's security code to complete the shutdown process.
Readings will be inaccurate until the unit is correctly zeroed in truly fresh air or with a zero air cylinder.
Calibration. All sensors gradually degrade over time. This diminishes a sensor's ability to measure gas
Press ENTER to edit the value, if needed. concentrations accurately; however, regular calibrations adjust the instrument to compensate for this decline in
Always-on Set Screen
Press ON/OFF/MODE to set the value and advance to the next
Options sensitivity. During calibration, the installed sensors are exposed to expected concentrations of calibration gases and,
configuration mode screen.
0 = Disable/off when needed, the instrument will self-adjust to ensure the accurate measurement and display of gas concentration
1 = Enable/on
values.
Note: when a sensor has degraded beyond an acceptable level, no further adjustment is possible and the sensor will no longer pass
calibration.
Peak Readings. The instrument stores the highest detected gas readings, the "peak readings" or "peaks". Bump
testing and calibration will often register new peak readings. Therefore, the clearing of the peak readings should
follow each calibration. The instrument operator may also wish to clear the peak readings after a bump test, before a
change in location, or after an alarm is addressed and cleared.

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Note: The peak readings and the data log readings are stored independently of one another; therefore, clearing the peak reading does not Instructions
affect the data log. Powering the instrument off or changing its battery does not affect the peak reading. These checks and balances help Calibration and Bump Testing with Calibration Cup and/or Tubing
promote operator safety, and serve to contain the peak readings in a "black-box" manner. In the event of a gas-related incident, this black-box Read all instructions before beginning: notices, supply check-list, gas cylinder preparation, and the complete screen-
record can be useful to the safety team or a prospective investigator. by-screen walk-through of the zero, calibrate, and bump test processes. Each process is presented in the order in
which it is accessible from gas monitoring mode.
Recommendations NOTICES
Industrial Scientific Corporation (ISC) minimum frequency recommendations for each procedure are summarized in ® Industrial Scientific recommends that full monitor calibration be performed, using a known certified
the table below. These recommendations are based on field data, safe work procedures, industry best practices, and concentration(s) of Industrial Scientific calibration gas(es), to prepare the monitor for first time use, and
regulatory standards to help ensure worker safety. Industrial Scientific is not responsible for setting safety practices monthly (at a minimum) thereafter, to help ensure monitor accuracy.
® Industrial Scientific also recommends that each monitor be zeroed and bump tested before each use with a
and policies. These policies may be affected by the directives and recommendations of regulatory groups,
known certified concentration(s) of Industrial Scientific calibration gas(es).
environmental conditions, operating conditions, instrument use patterns and exposure to gas, and other factors.
® Read ALL requirements and instructions outlined below, including the screen-by-screen process description,
before beginning the zero, calibration, or bump testing processes.
Procedure ISC Recommended minimum frequency ® Only qualified personnel should zero, calibrate, or bump test a monitor.
® Zero, calibration, and bump testing functions should be performed in a fresh air environment known to be
Configuration Before first use and as needed thereafter.
nonhazardous.
Calibrationa Before first use and monthly thereafter. ® After calibration or bump testing, or after terminating either process, stop the flow of gas.
Bump testb Prior to each day’s use.
aBetween regular calibrations, ISC also recommends a calibration be performed immediately following each of these incidences: the unit falls, Supplies
is dropped, or experiences another significant impact; is exposed to water; fails a bump test; or has been repeatedly exposed to an over-range Item Monitor/Regulator**
(positive or negative) gas concentration. A calibration is also recommended after the installation of a new (or replacement) sensor.
bIf conditions do not permit daily testing, bump tests may be done less frequently based on company safety policy. Aspirated monitor Aspirated monitor Diffusion monitor
with Demand Flow with Positive Flow with Positive Flow
Note: The use of calibration gases not provided by ISC may void product warranties and limit potential liability claims. Regulator** Regulator** Regulator**
Calibration cup* No No Yes
General information Calibration tubing 2 feet in length* Yes No Yes
The zero, calibration, and bump testing tasks are in-field enabled or in-field disabled in the configuration process.
This permits or denies access to these functions from the gas monitoring mode. When any of these options is Calibration tubing 2 feet in length with No Yes No
enabled, it is accessible to all monitor users. In gas monitoring mode, a series of presses on the ON/OFF/MODE integrated “t” fitting
button gives the user access to the following screens and processes in the order shown. Calibration gas cylinder Yes Yes Yes

· Gas Monitoring Screen *Shipped with monitor.


· Days Since Calibration **Industrial Scientific recommends 1) the use of positive flow regulators with a flow rate of .5 LPM, and 2) the diffusion monitor be calibrated or bump
tested using a positive flow regulator, NOT a demand flow regulator.
· Zero Initiate (if in-field enabled)
o Calibration Apply Gas Screen (if in-field enabled)
· Bump Test Initiate (if in-field enabled)
· Peak Readings
· TWA Readings
· STEL Readings

The monitor is capable of performing two types of calibration, and this option is set in configuration mode. The
calibration type selected also determines the monitor’s bump test type. With a “quick” calibration, the monitor is set to
calibrate and bump test all installed sensors simultaneously. With a “standard” calibration setting, these tasks are
completed independently for each installed sensor in the order shown below.
1. Oxygen sensor*
2. Toxic sensor 1
3. LEL sensor
4. Toxic sensor 2
*If set to the default value of 20.9% or 21%, the Oxygen sensor calibrates during the zero process and toxic 1 is the first to calibrate in the
calibration process.

The Ventis MX4 monitor can be calibrated with any of the accessories listed.
· Calibration cup and/or tubing shipped with the monitor (see instructions below)
· V-Cal Calibration Station (consult the calibration station manual for instruction)
· DS2 Docking Station for Ventis MX4 (consult the docking station manual for instruction)

Diffusion monitor with positive flow regulator. Aspirated monitor with demand flow regulator.

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Prepare the gas cylinder for use Press ENTER to begin the zero process and advance to
· According to the supply chart above, attach the correct regulator to the gas cylinder and turn clockwise to tighten. the Zero In-process Screen.
· Next, choose instruction A., B., or C. based on the monitor/regulator combination in use. Press ON/OFF/MODE to bypass zero and calibration
and advance to one of two screens.
A. Aspirated with demand flow regulator
Attach either end of the tubing to the cylinder’s nipple. If bump test in-field is enabled, the user advances to
the Bump Test Initiate Screen.
Zero Initiate Screen
DO NOT ATTACH THE OTHER END OF THE TUBING TO THE MONITOR BEFORE REACHING THE Options:
“APPLY GAS SCREEN”. Completing the connection of the tubing will cause gas to flow. If gas is If bump test in-field is disabled, the user advances to
Enter Zero the Peak Readings Screen.
applied before reaching the appropriate screen, the monitor will go into alarm and a failure will be Bypass Zero
logged.
Allow the zero process to complete and advance to the
B. Aspirated with positive flow regulator Zero Results (Pass or Fail) Screen.
The calibration tubing with the t-fitting (not included) has two different sized openings, a narrow opening
at one end and a wider opening at the other end. After the zero process, press ON/OFF/MODE to
Attach the wider opening to the nipple on the cylinder’s regulator. bypass calibration of the installed toxic and combustible
Attach the smaller opening to the pump inlet. sensors. The user returns to the mode from which the
calibration process was entered (configuration or gas
Zero In-process Screen monitoring).
DO NOT APPLY THE GAS BEFORE REACHING THE “APPLY GAS SCREEN”. If gas is applied before Each sensor’s numerical value becomes zero except
that point, the monitor will go into alarm and a failure will be logged. O2. An updated O2 span value displays. The clock icon NOTE: during the zero process, the O2 sensor is calibrated (when set to
flashes and the zero icon displays. default gas volume of 20.9%)
C. Diffusion with positive flow regulator
Attach either end of the tubing to the cylinder’s nipple. NOTE: The “span reserve” of a sensor measures its sensitivity. The
Attach the other end of the tubing to the calibration cup’s nipple. displayed span value divided by the calibration gas value equals the
span reserve percentage. A span reserve percentage of greater than
70% indicates a “good” sensor; 50%-70% indicates “marginal”
DO NOT ATTACH THE CALIBRATION CUP TO THE MONITOR OR APPLY THE GAS BEFORE sensitivity. When the span reserve percentage is less than 50%, the
REACHING THE “APPLY GAS SCREEN”. If gas is applied before that point, the monitor will go into sensor will not pass calibration.
alarm and a failure will be logged.
Within Ten Seconds
Press ENTER to repeat the zero process.
Zero and Quick Calibration Process Press ON/OFF/MODE to advance to one of two screens.
Display and Options Instructions
If zero was entered from…
Press ON/OFF/MODE to advance to the Days since
Calibration Screen. …configuration mode, the user advances to the
Zero Results (Pass) Screen Calibration Apply Gas Screen.
The check mark displays to indicate a successful zero
and a short beep sounds. Each sensor’s numerical … gas monitoring mode and the calibration in-field
values display at zero except O2. option is enabled, the user advances to the
Gas Monitoring Screen Calibration Apply Gas Screen.
Numeric mode display (left) Options:
Text mode display (right) Repeat zero …gas monitoring mode and the calibration in-field
Displays the gas concentration readings (or gas names Begin calibration option is disabled, the user advances to the Gas
in text mode) for all installed sensors. If a sensor is NOT Enter gas monitoring mode Monitoring Screen in the gas monitoring mode.
installed, its position on the LCD is blank.
Press ON/OFF/MODE to advance to one of three If neither ENTER nor ON/OFF/MODE is pressed, within
screens. ten seconds, the user advances to the Gas Monitoring
Screen in the gas monitoring mode.
If zero in-field is enabled, the user advances to the Press ON/OFF/MODE (or wait ten seconds) to return to
Zero Initiate Screen. the Zero Initiate Screen and repeat the zero process.
If zero in-field is disabled and bump test in-field is
Days Since Calibration Screen enabled, the user advances to the Bump Test Initiate
Displays the number of days since the last successful Screen.
calibration for each installed sensor. Each value can be If zero in-field and bump test in-field are both
different. disabled, the user advances to the Peak Readings Zero Results (Fail) Screen
Screen. Displays an “F” or “P”, respectively, for each failed or
NOTE: When zero, calibration, and bump test are ALL in-field enabled, and the user has entered zero from the gas passed sensor. For O 2, if the sensor passed its
monitoring mode, the monitor expects to be calibrated following a successful zero. calibration, the sensor reading displays.

If the desired task, after zero, is bump testing (or clearing the peaks) and NOT calibration, follow the instructions at
the Calibration Apply Gas Screen to terminate calibration.

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To Terminate Any failed sensor stays in alarm until it passes a


Press ON/OFF/MODE while the gas cylinder icon flashes calibration or is replaced.
to terminate the quick calibration process (or to skip a
sensor’s calibration in standard calibration) and return to Press ON/OFF/MODE to repeat calibration.
the gas monitoring mode.

To Calibrate
Calibration Apply Gas Screen* From the already prepared gas cylinder, start the flow of Calibration Failed Screen*
The gas cylinder icon flashes. Each sensor’s display gas as noted below for the monitor/regulator combination Gas readings display for all successfully calibrated
shows the calibration gas concentration to be applied. in use. sensors and an “F” displays for any failed sensors. A
(The O2 display is blank as the sensor was calibrated system level alarm turns on. The warning icon and gas
during zeroing.) The monitor waits up to five minutes to For an aspirated monitor with a demand flow cylinder display to indicate a sensor calibration failure.
successfully sense the gas. regulator, complete the tubing connection from the * During the standard calibration or standard bump test process, a series of apply gas, in-progress, and results screens show for EACH sensor as it
regulator to the pump inlet. is calibrated or tested.
Calibration In-progress Screen*
If gas is sensed, the gas values for the LEL and For an aspirated monitor with a positive flow Bump Test Process
toxic sensors increase and the O2 value decreases. regulator, turn (counterclockwise) the regulator’s
knob.
If gas is NOT sensed, a failed calibration registers Display and Options Instructions
and the Calibration Failed Screen displays. For a diffusion monitor with a positive flow Press ON/OFF/MODE to bypass the bump test process
regulator: and advance to the Peak Readings Screen.
· Place the calibration cup over the upper portion Press ENTER to begin the bump test process.
of the monitor’s case top (front of monitor). To
attach properly, complete or observe the
following.
o The cup fully covers the sensor ports.
o The monitor’s display and buttons are NOT Bump Test Initiate Screen
covered. Options
o The cup’s side arms fit securely in the Begin process
grooves on the sides of the monitor. Bypass process
o The Ventis name on the calibration cup is To Terminate
upright and readable. Press ON/OFF/MODE while the gas cylinder icon flashes
o The cup’s nipple points up and away from to terminate the quick bump test process (or to skip a
the monitor. sensor’s testing in standard bump testing). The user
· Turn (counterclockwise) the regulator’s returns to the Gas Monitoring Screen.
knob.
STOP THE FLOW OF GAS. To Bump Test
Bump Test Apply Gas Screen From the already prepared gas cylinder, start the flow of
After calibration, or if calibration is terminated at anytime Displays the bump test gas concentrations the monitor
during the process, stop the flow of gas as follows. gas as noted below for the monitor/regulator combination
is expecting to receive. The monitor waits up to five in use.
minutes to successfully sense the gas.
For an aspirated monitor with a demand flow
regulator, disconnect the tubing from the pump inlet. For an aspirated monitor with a demand flow
If gas is sensed, the user advances to the Bump regulator, complete the tubing connection from the
Test In-progress Screen. regulator to the pump inlet.
For an aspirated or diffusion monitor with a
positive flow regulator, turn (clockwise) the If gas is NOT sensed, a failed bump test occurs
regulator’s knob. For an aspirated monitor with a positive flow
and the user advances to the Bump Test Results regulator, turn (counterclockwise) the regulator’s
Screen displays. knob.
All Sensors Pass
The user returns to the mode from which the calibration For a diffusion monitor with a positive flow
Sensor Results Screen*
process was entered (configuration or gas monitoring). regulator:
Pass (top) or Fail (bottom) Screen
· Place the calibration cup over the upper portion
The display alternately shows a “P” for pass (or “F” for
Sensor Fail of the monitor’s case top (front of monitor). To
fail) and the final span value reading for each sensor. A
If one or more sensors fail calibration, the Calibration Fail attach properly, complete or observe the
check mark displays and a single beep sounds.
Screen displays and a system level alarm turns on. following.
NOTE: The “span reserve” of a sensor measures its sensitivity. The o The cup fully covers the sensor ports.
displayed span value divided by the calibration gas value equals the o The monitor’s display and buttons are not
span reserve percentage. A span reserve percentage of greater than covered.
70% indicates a “good” sensor; 50%-70% indicates “marginal”
sensitivity. When the span reserve percentage is less than 50%, the
o The cup’s side arms fit securely in the
sensor will not pass calibration. grooves on the sides of the monitor.
o The Ventis name on the calibration cup is

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Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

upright and readable. Press and release ENTER to clear the displayed TWA
o The cup’s nipple points up and away from reading(s), if desired.
the monitor. Press ON/OFF/MODE to advance to the STEL Readings
· Turn (counterclockwise) the regulator’s knob. Screen.

As the bump test progresses, observe the display


activity (left). TWA Readings Screen
Displays the TWA (time weighted average) icon and
After the bump test, the Bump Test Results Screen calculated readings for each toxic sensor installed; all
displays. other sensor values are blank.
Press and release ENTER to clear the reading(s), if
STOP THE FLOW OF GAS.
Bump Test In-progress Screen desired.
After bump testing, or if bump testing is terminated at
Displays when gas is sensed within five minutes. The Press ON/OFF/MODE to advance to the Gas Monitoring
anytime during the process, stop the flow of gas
clock icon flashes to indicate the test is in-progress. The Screen.
from the cylinder as follows.
sensor reading(s) display. The LEL and toxic sensor
readings increase and the O2 reading decreases. For an aspirated monitor with a demand flow
regulator, disconnect the tubing from the pump inlet. STEL Readings Screen
Displays the STEL (short term exposure limit) icon and
For an aspirated or diffusion monitor with a STEL values for each toxic sensor installed; all other
positive flow regulator, turn (clockwise) the sensor values are blank. The STEL value is the running
regulator’s knob. average over the last 15 minutes.
* During the standard calibration process, a series of apply gas, in-progress, and results screens show for EACH sensor as it is calibrated or tested.

No User Action Required


After a passed bump test, the monitor goes into gas
monitoring mode. RECOMMENDED PRACTICES FOR IN-FIELD AIR SAMPLING
Diffusion monitor
When worn, the diffusion monitor should be fastened securely and attached to ensure the sensor portals are exposed
to the air. The monitor should be in full view. No part of the monitor should be covered by any garment or part of a
garment.
Bump Test Results (Pass) Screen
The above displays an all sensor pass result. If one or Aspirated monitor
more sensors fail, the “F” shows in place of the “P”. The Before using an aspirated monitor, force a pump fault to ensure the pump and air-sample accessories (sample
pass/fail screen (left) and the final sensor reading tubing, probe, or sample tubing and probe) are working as intended:
screen (right) display alternately three times. A single 1 Power on the monitor.
beep sounds to indicate the bump test is completed. 2 Attach the air-sample accessory(ies) to the pump inlet.
3 Using a finger, cover the opening at the other end of the air-sample tubing (or probe) to block the flow of air.
After a failed bump test, the Bump Test Fail Screen This should result in a pump fault alarm.
4 After a pump fault occurs, remove the finger from the tubing (or probe). If the unit resumes normal
displays and a low level audio alarm turns on.
operation, the pump and air-sampling accessories are working as intended.
The monitor should be fully calibrated after a failed bump
test. Note: If no pump fault occurs or if the unit stays in pump fault, check for debris at these locations: the pump nipple,
inside the inlet barrel, at the water barrier, and inside the pump cradle; attempt to clear any blockage. Check the air-
NOTE: After a full calibration, the O2 sensor must pass a bump test to sample accessories, too, for debris and for possible crack or leaks.
Bump Test Results (Fail) Screen clear the bump test fail status.
The “bF” displays under each gas type to indicate a The Ventis MX4 aspirated monitor is rated to sustain a continuous sample draw for up to 100 feet (30.48 m) with
bump test failure. The system level alarm turns on and 0.125 inch (0.3175 cm) inside diameter sample tubing. In confined space, an air sample should be taken in four foot
the gas cylinder icon flashes. (1.2192 m) intervals. With each sample, the minimum time required to successfully draw air and read the gas
concentrations should include two minutes plus two seconds for every 12 inches (30.48 cm) of tubing.
Press and release ENTER to clear the peak values, if
desired.
Press ON/OFF/MODE to advance to one of two screens. CLEANING
· NEVER use solvents or cleaning solutions of any type.
If toxic sensors are installed, the user advances to · When necessary, wipe the outside of the Ventis MX4 with a soft, clean cloth.
the TWA Readings Screen. · Make sure the sensor diffusion membrane, inside and out, is free of debris; wipe gently with a cloth or brush that
is soft, clean, and dry.
Peak Readings Screen If no toxic sensors are installed, the user advances · Make sure the aspirated monitor’s inlet is free of debris.
Displays the peak icon and peak gas concentrations for to the Gas Monitoring Screen.
each installed sensor since the last time the peak
readings were cleared. (For O2, the lowest reading is
shown.)

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Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

SERVICE Reassembling the Aspirated Monitor.


Instructions are provided for battery service; monitor conversion (diffusion to aspirated and vice versa); sensor,
1 Re-place the monitor inside the pump module. The monitor is display side up and its logo readable.
sensor barrier and LCD service; and pump assembly service. Refer to the three-dimensional view diagrams to
Its lower exposed bottom portion covers the battery.
identify the parts referenced in the instruction sets, and for screw torque values.
2 Tighten the four screws on the pump module bottom to secure the module to the monitor.
Read all instructions before beginning any monitor service. 3 Lower and close the pump door; slide up to click in place.
NOTICES 4 Tighten the pump door screw to secure the door in place.
® Before beginning any service tasks, power-off the monitor. 5 Dispose of any spent batteries according to company policy.
® Only qualified staff should perform monitor service and should take the following precautions.
® Take care not to touch battery contacts on the monitor or the battery itself. Diffusion Monitor Battery Replacement or Changeover
® Perform work in a clean air environment that is known to be nonhazardous. The diffusion monitor can be used with all three Ventis battery packs.
® Perform work on a nonconductive work surface. · The Li-ion battery kit is a single part consisting of the monitor’s lower case bottom and the battery. It is
® Wear grounding straps. removed from and attached to the diffusion monitor as a single item.
· The Extended Range Li-ion battery pack and its cover are two distinct items.
· The Alkaline battery pack consists of three items: the batteries, the battery pack, and a battery pack cover
BATTERY PACKS (the same cover that holds the Extended Range Li-ion battery).
NOTICES NOTE: When an Extended Range Li-ion (or Alkaline) battery pack is attached to a diffusion monitor, the monitor’s lower portion becomes
® WARNING: INSERT THE ALKALINE BATTERIES WITH THE CORRECT POSITIVE “ + ” AND NEGATIVE deeper than its upper portion. The Conversion Kit’s suspender clip components are used to make the upper and lower portions depth-
“-“ ORIENTATION. FAILURE TO FOLLOW PROPER BATTERY ORIENTATION WILL RESULT IN compatible. The Conversion Kit provides a battery cover (battery not included), a suspender clip and spacer, and a screw and washer.
DAMAGE TO THE MONITOR.
® WARNING: The Ventis MX4 is only approved for use with AAA battery types Energizer EN92 and Duracell
MN2400. Do NOT mix battery types. ATTACHING THE LI-ION BATTERY TO A DIFFUSION MONITOR.
Battery Replacement.
Battery service instruction sets are provided below for each allowable monitor/battery pack combination. Please
choose, read, and then follow the appropriate instruction set. 1 Power-off the monitor.
2 Loosen the four captive screws on the lower portion of the case bottom (or the battery cover if the
Aspirated Monitor Battery Replacement Extended Range Li-ion or Alkaline battery pack is attached).
For an aspirated monitor, two of the three Ventis battery packs can be used. The Extended Range Li-ion battery
is replaced as a single part. The Alkaline battery unit consists of batteries and a pack for the batteries. 3 Lift and remove the Li-ion kit (or Extended Range Li-ion battery Alkaline battery pack and cover); set
aside.
ASPIRATED MONITOR BATTERY REPLACEMENT. 4 To properly attach the new Li-ion battery kit to the monitor, align its exterior charging contacts with
the monitor’s bottom.
Removing the Battery Pack.
5 Tighten the four captive screws to secure the battery pack to the monitor.
1 Power-off the monitor.
6 Dispose of any spent batteries according to company policy, or properly store any battery packs that
2 Loosen the four captive screws on the lower portion of the pump module bottom (back of the have a remaining life.
module).
To changeover from an Extended Range Li-ion (or Alkaline) battery pack to a Li-ion battery continue with
3 Loosen the single captive screw on the pump door. the following suspender clip instruction sets.
4 Slide the pump door down; lift to reveal and access the monitor.
5 Lift and remove the monitor from the pump module; set aside the monitor. Removal of the Suspender Clip and Spacer.
6 Lift and remove the battery pack from inside the lower portion of the pump module. 1 On the monitor’s case bottom, open the suspender clip.
Replacing the Battery Pack. 2 Using a Phillips head screwdriver, remove the screw and washer that attach the suspender clip and
If inserting the Alkaline battery pack, follow steps 1-5. spacer to the monitor.
If inserting the Extended Range Li-ion battery pack, follow step 5 ONLY.
3 Set aside and store the removed items for future use with the Extended Range Li-ion (or Alkaline)
1 To prepare the alkaline battery pack, unlatch and lift the hinged portion of the battery pack. battery pack on a diffusion monitor.
2 If needed, remove and set aside the spent batteries from within the pack. Attachment of the Suspender Clip.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. 1 Open the suspender clip.
DO NOT MIX BATTERY TYPES.
2 Place the washer on the screw (P/N 17139262).
4 Close the latch. A click sounds.
3 Insert the screw with washer through the clip’s center hole and into the screw hole on the monitor.
5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the pump module,
4 Tighten the screw to secure the suspender clip to the monitor.
complete or observe the following:
· the battery circuitry is exposed and faces the user;
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump
module bottom.

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Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

ATTACHING THE EXTENDED RANGE LI-ION (OR ALKALINE) BATTERY PACK TO A DIFFUSION MONITOR CONVERSION
MONITOR. To convert a diffusion monitor to an aspirated monitor, only the Extended Range Li-ion or Alkaline battery packs are
approved for use.
Battery Removal.
1 Power-off the monitor. To convert an aspirated monitor to a diffusion monitor, a suspender clip, washer, and screw are recommended for
use with the Li-ion battery pack. If attaching the Extended Range Li-ion or Alkaline battery packs, the conversion kit is
2 Loosen the four captive screws on the lower portion of the Case Bottom (back of the monitor. required.
3 Lift the battery unit to remove; set it aside.
NOTE: When an Extended Range Li-ion (or Alkaline) battery pack is attached to a diffusion monitor, the monitor’s lower portion becomes
deeper than its upper portion. The Conversion Kit’s suspender clip components are used to make the upper and lower portions depth-
compatible. The Conversion Kit provides a battery cover (battery not included), a suspender clip and spacer, and a screw and washer.
Battery Attachment.
If inserting the Alkaline battery, follow steps 1-7.
If inserting the Extended Range Li-ion battery, follow steps 5-7 ONLY. CONVERTING A DIFFUSION MONITOR TO AN ASPIRATED MONITOR.
Removing the Suspender Clip and Battery Pack.
1 To prepare the Alkaline battery pack, unlatch and lift the hinged lid of the battery housing.
1 Power-off the monitor.
2 If needed, remove and set aside the spent batteries from within the housing.
2 On the monitor’s case bottom (back of the monitor), open the suspender clip.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the housing.
DO NOT MIX BATTERY TYPES. 3 Using a Phillips head screwdriver, remove the screw and washer that attach the suspender clip (and
spacer, if applicable) to the monitor. Set aside and store any removed, unused items for future use with
4 Close and latch the lid. A click sounds.
a diffusion monitor.
5 To properly place the Extended Range (or Alkaline) battery pack inside the battery cover ensure:
4 Loosen the four captive screws on the lower portion of the case bottom. Lift and remove the battery
· the battery circuitry is exposed and faces the user;
pack (and cover, if applicable). Set aside and store any removed, unused items for future use with a
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump diffusion monitor.
module bottom.
Assembling the Aspirated Monitor (including battery insertion).
6 To properly attach the cover (and its enclosed battery) to the monitor, ensure the battery contacts are
If inserting the Alkaline battery pack, follow steps 1-10.
showing at the bottom of the monitor. If inserting the Extended Range Li-ion battery pack, follow steps 5-10 ONLY.
NOTE: each of the above battery packs easily fits within the battery cover. If the battery does not easily insert, stop to ensure 1 To prepare the Alkaline battery pack, unlatch and lift the hinged portion of the battery pack.
proper placement as noted above.
2 If needed, remove and set aside any spent batteries from within the pack.
7 Tighten the four captive screws to secure the battery cover to the monitor.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. DO
To changeover from a Li-ion battery kit to an Extended Range Li-ion (or Alkaline) battery pack, continue with
NOT MIX BATTERY TYPES.
the following suspender clip instruction sets.
4 Close the latch. A click sounds.
Removal of the Suspender Clip.
5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the pump module,
1 Open the suspender clip.
complete or observe the following:
2 Using a Phillips head screwdriver, remove the screw and washer that attach the clip to the monitor · the battery circuitry is exposed and faces the user;
3 Set aside and store the removed clip, washer, and screw for future use with a diffusion monitor and · a small groove at the back of the battery bottom fits over the small rib at the back of the pump
Li-ion battery pack. module bottom.

Attachment of the Suspender Clip and Spacer (from the Conversion Kit). 6 Loosen the captive screw on the front of the pump module. Slide the module’s door down and lift to
open.
1 Place the monitor face down.
7 Place the monitor inside the pump module. The monitor is display side up and its logo readable. Its
2 The spacer has one flat end. Place the spacer on the monitor’s case back so its flat end meets top lower exposed bottom portion covers the battery.
edge of the battery cover; the hole in the spacer aligns with the screw hole on the monitor.
8 Tighten the four screws on the pump module bottom to secure the module to the monitor.
3 Place the washer on the screw.
9 Close the pump door; slide up to click in place.
4 Insert the screw with washer through the clip’s hole and through the center hole on the clip back.
10 Tighten the pump door screw.
5 Place the clip on top of the spacer, inserting its screw into the spacer’s hole. Be sure the clip’s ring is
at the top of the monitor.
6 Grasp the clip and spacer with one hand. With the other hand, tighten the screw with the Phillips
screwdriver. CONVERTING AN ASPIRATED MONITOR TO A DIFFUSION MONITOR.
Removing the Pump Module.
1 Power-off the monitor.
2 Loosen the four captive screws on the lower portion of the pump module bottom (back of the module).
3 Loosen the single captive screw on the pump module door.
4 Slide the pump door down; lift to reveal and access the monitor.
5 Lift and remove the monitor from the pump module; set aside and store for future use.

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Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

Choose OPTION 1 or OPTION 2 below depending on the battery pack to be attached. SENSOR, SENSOR BARRIER, LCD, AND VIBRATING MOTOR REPLACEMENT
Service instruction sets are provided below for each monitor type. Please choose, read, and then follow the
OPTION 1: Attaching the Li-ion Battery Kit and its Compatible Suspender Clip Components. appropriate instruction set . Within each set of instructions, follow those relevant to the desired task(s) and note the
1 To properly place the Li-ion battery kit, align its contacts with the monitor’s contacts, at the monitor following.
bottom. · The monitor has a two-part circuit board assembly, the main board and a smaller sensor board. They are
attached to one another with a connecter at the center of the sensor board.
2 To secure the battery kit to the monitor, tighten the four captive screws on the kit bottom. · The sensor barrier can be replaced as an assembly that fits in the monitor’s case top, or the full case top can be
3 Open the suspender clip. replaced. NOTE: When a sensor is replaced, it is recommended that the sensor barrier/case top also be replaced. After reassembling the
monitor, a full calibration should be completed.
4 Place the washer on the screw. · The LCD is removed and attached as a single component.
5 Insert the screw with washer through the clip’s center hole and into the screw hole on the monitor. Be
sure the clip’s ring is at the top of the monitor. ASPIRATED
6 Tighten the screw. Disassembling the Monitor.

OPTION 2: Attaching the Extended Range Li-ion (or Alkaline) Battery Pack and its Compatible 1 Power-off the monitor.
Suspender Clip Components. 2 Loosen the four captive screws on the lower portion of the pump case module bottom (back of the
If inserting the Alkaline battery pack, follow steps 1-14. module).
If inserting the Extended Range Li-ion battery pack, follow steps 5-14 ONLY.
3 Loosen the single captive screw on the pump case module top.
1 To prepare the Alkaline battery pack, unlatch and lift the hinged portion of the battery pack.
4 Slide the case door down; lift the hinged door to reveal and access the monitor.
2 If needed, remove and set aside any spent batteries from within the pack.
5 Lift and remove the monitor from the pump module; set aside the module.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. DO
NOT MIX BATTERY TYPES. 6 Place the monitor display side down.

4 Close the latch. A click sounds. 7 Loosen the two captive screws on the upper portion of the case bottom.

5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the battery cover, ensure: 8 Lift to separate the monitor case top from the monitor case bottom to reveal the circuit board
assembly.
· the battery circuitry is exposed and faces the user;
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump 9 Remove the circuit board assembly and set aside the monitor case top and bottom.
module bottom. 10 Separate the main circuit board from the sensor board.
NOTE: each of these two battery packs easily fits within the battery case. If the battery does not easily insert, stop to
ensure proper placement as noted above. Replacing the LCD (if needed).
6 To properly attach the cover containing the Extended Range Li-ion or Alkaline battery pack, ensure the 1 Grasp the sides of the LCD and lift straight up to remove from the main circuit board.
battery contacts are showing at the bottom of the monitor.
2 To properly place the new LCD, align the pins on the LCD with their receptacles on the main circuit
7 To secure the battery cover (and its enclosed battery pack) to the monitor, tighten the four captive board.
screws on the battery cover.
3 Gently press straight down and into place.
8 Place the monitor face down.
Replacing the Sensor(s) (if needed).
9 The spacer for the suspender clip has one flat end. Place the spacer on the monitor’s case back so its
flat end meets top edge of the battery cover; the hole in the spacer aligns with the screw hole on the 1 Identify the sensor to be removed.
monitor. 2 Gently lift and remove the sensor.
10 Open the suspender clip. 3 To add the new sensor, align its pins or connector(s), with the respective receptacles on the sensor
11 Place the washer on the screw. board.
12 Insert the screw with washer through the clip’s hole and through the center hole on the clip back. 4 Press down. A slight click indicates the sensor is securely in place.
13 Place the clip on top of the spacer, inserting its screw into the spacer’s hole and ensuring the clip’s ring Reassembling the Circuit Board Assembly.
is at the top of the case back. 1 Re-attach the main circuit board to the sensor board, aligning their connectors.
14 Grasp the clip and spacer with one hand. With the other hand, tighten the screw with the Phillips 2 Press. A slight click indicates the boards are securely attached.
screwdriver.
Replacing the Sensor Barrier or Case Top (if needed).
To replace the sensor barrier on the inside of the case top, follow steps 1-5 below.
To replace the entire case top, skip to the instruction set, “Reassembling the Monitor”.
1 Observe the placement of the existing sensor barrier. Note that each cut-out is shaped to match the
sensor it protects.
2 Lift and remove the sensor barrier and gasket from inside the monitor case top. Ensure the entire
case top is free of adhesive; gently scrape, if needed. Wipe with a clean, dry, soft cloth or brush.
3 Lift the backing from the new sensor barrier assembly to reveal the adhesive.
4 Carefully position the new barrier. Each shaped opening matches the shape of the sensor it
protects. Press to attach to the inside of the case top.

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Replacing the Vibrating Motor (if needed). 2 Lift and remove the sensor barrier and gasket from the inside the monitor case top. Ensure the
entire case top is free of adhesive; gently scrape, if needed. Wipe with a clean, dry, soft cloth or
1 Place the monitor’s case top face down.
brush.
2 Lift the vibrating motor from its partition. The partition has two sections divided by a ridge. Discard
3 Lift the backing from the new sensor barrier to reveal the adhesive.
the used motor.
4 Carefully position the new barrier. Each shaped opening matches the shape of the sensor it
3 To properly place the new vibrating motor, its contact pins face the user and align with the left edge
protects. Press to attach to the inside of the case top.
of the partition. (The motor’s movable component fits within the small section of the partition.)
Replacing the Vibrating Motor (if needed).
4 Press into place.
1 Place the monitor’s case top face down.
Reassembling the Monitor.
2 Lift the vibrating motor from its partition. The partition has two sections divided by a ridge. Discard
1 Re-place the board assembly into the monitor’s case bottom. The LCD faces the user.
the used motor.
2 Re-place the monitor’s case top (or place its new case top).
3 To properly place the new vibrating motor, its contact pins face the user and align with the left edge
3 Tighten the two captive screws on the upper portion of the monitor case bottom. of the partition. (The motor’s movable component fits within the small section of the partition.)
4 Re-place the monitor inside the pump module. The monitor is display side up and its logo readable. 4 Press into place.
Its lower exposed bottom portion covers the battery.
Reassembling the Circuit Board Assembly and Monitor.
5 Tighten the four screws on the pump module bottom to secure the module to the monitor.
1 Re-attach the main board to the sensor board, aligning their connectors.
6 Close the pump module door; slide up to click in place.
2 Press. A slight click indicates the boards are securely attached.
7 Tighten the pump door screw to secure.
3 Re-place the circuit board assembly into the monitor’s case bottom.
8 Dispose of the used sensor(s) according to company policy.
4 Re-place the monitor’s case top (or its new case top).
9 Perform a full calibration following the addition or replacement of any sensor, or the replacement of
5 Tighten the two captive screws on the upper portion of the case bottom.
the sensor water barrier or monitor case top.
6 Re-place the battery pack and tighten the four captive screws on the case bottom.
7 Dispose of the used sensor(s) according to company policy.
8 Perform a full calibration following the addition or replacement of any sensor, or the replacement of
DIFFUSION the sensor water barrier or the monitor case top.
Disassembling the Monitor.
1 Power-off the monitor.
2 Loosen the four captive screws on the lower portion of the case bottom (back of the monitor) to PUMP MODULE
remove the battery pack. Set aside the battery kit (or pack and cover if applicable). There are two field replaceable parts on the aspirated case: the water barrier and case top door. As needed, choose,
read, and follow the appropriate instruction set(s).
3 Loosen the two captive screws on the upper portion of the case bottom.
pump module
4 Lift to separate the case top from the case bottom.
Pump Inlet Filter Cap and/or Water Barrier Replacement (if needed).
5 Remove the circuit board assembly.
1 Power off the monitor.
6 Separate the main circuit board from the sensor board.
2 To remove the pump inlet filter cap, turn counter clockwise; set aside.
Replacing the LCD (if needed).
3 Remove the water barrier from inside the inlet.
1 Grasp the sides of the LCD and lift straight up to remove.
4 To properly place the new water barrier, its bottom will come into contact with the pump inlet surface on
2 To properly position the new LCD, align the pins on the LCD with their receptacles on the main which the barrier sits. The barrier’s bottom side has the smaller diameter opening in the black ring.
circuit board.
5 Re-place the pump inlet filter cap (or new cap); turn clockwise to tighten.
3 Gently press straight down and into place.
Pump Door Removal and Replacement (if needed).
Replacing the Sensor(s) (if needed).
1 Power off the monitor.
1 Identify the sensor to be removed.
2 Loosen the single captive screw on the pump module door.
2 Gently lift and remove the sensor.
3 Slide the door down and lift.
3 To add the new sensor, align its pins or connector(s), with the respective receptacles on the board.
4 The upper portion of the door has pegs on either side. The pegs fit into grooves where the door meets
4 Press down. A slight click indicates the sensor is securely in place. the module; they flex slightly for easy door removal. Angle the door so that one peg moves to the bottom
Replacing the Sensor Barrier (if needed). of its groove and the other moves the top of its groove. Lift to unhinge the pegs and remove the door.
To replace the sensor barrier assembly, follow instruction 1-5 below. 5 To properly place the new door, secure one of the pegs into its groove on the pump module.
To replace the entire case top, including its sensor barrier, skip to the next instruction set, “Reassembling
6 Angle the door and press the other peg into its groove.
the circuit board assembly and monitor.”
7 Close the door and slide up into place.
1 Observe the placement of the existing water barrier. Note that each cut-out is shaped to match the
sensor it protects. 8 Tighten the single captive screw on the pump door.

39 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 40


Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

KEY FOR VENTIS MX4 MONITOR THREE-DIMENSIONAL DIAGRAM


VENTIS MX4 MONITOR THREE-DIMENSIONAL DIAGRAM
Number Part Number (P/N) Description
1 17152380-X Ventis MX4 Diffusion Case Top Assembly (includes items 2 and 3)
X = Case Color, where: 0 = Black, 1 = Orange

2 17152429 Sensor Barrier Assembly


3 17145285 Vibrating Motor
4 17150772 Ventis MX4 LCD Assembly
5 17134495 Ventis MX4 Sensor, Combustible Gas (LEL/CH4)
6 17134461 Ventis MX4 Sensor, Oxygen (O2)
7 17134487 Ventis MX4 Sensor, Carbon Monoxide (CO)
7 17155564 Ventis MX4 Sensor, Carbon Monoxide/Low Hydrogen Interference (CO/H2 Low)
8 17134479 Ventis MX4 Sensor, Hydrogen Sulfide (H2S)
9 17134503 Ventis MX4 Sensor, Nitrogen Dioxide (NO2)
10 17143595 Ventis MX4 Sensor, Sulfur Dioxide (SO2)
11 17147281 Captive Case Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)
11 17147273 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)

12 17152506 Suspender Clip Spacer


13 17120528 Suspender Clip
14 17153137 Locking Washer
15 17152507 Screw, Phillips (for use with items 12, 13 and 14)
(torque value: 115 oz-in or .81 N.m +/- 10%)

16 17139262 Screw, Phillips (torque value: 115 oz-in or .81 N.m +/- 10%)

17 17134453-XY Lithium-ion Battery Kit


X = Battery Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 N.m +/- 10%)
Y=1: UL, CSA, ATEX, IECEx, GOST-R, GOST-K, KOSHA, MED, and SANS approvals
Y=2: MSHA
Y=3: China Ex
Y=4: ANZEx
Y=5: INMETRO
XY=0D: TIIS

18 17148313-Y Extended Range Lithium-ion Battery Pack


Y=1: UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, MED, SANS, and TIIS approvals
Y=2: MSHA
Y=3: China Ex
Y=4: ANZEx

19 17150608 Alkaline Battery Pack


UL, CSA, ATEX, IECEx, ANZEx, China MA, China KA, and INMETRO approvals (CSA, China MA, and
China KA approved for diffusion monitor only.)

20 17151184-XY Cover, Extended Range Lithium-ion or Alkaline


X = Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 n.m . +/- 10%)
Y=1: UL, CSA, ATEX, IECEx, GOST-R, GOST-K, and KOSHA approvals
Y=2: MSHA (Extended Range Lithium-ion only)
Y=3: China Ex
Y=4: ANZEx
Y=5: INMETRO
Y=C: China KA
* Item is not user replaceable. The Ventis MX4 monitor must be sent to an authorized ISC Service Center for this item to be replaced.

41 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 42


Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

VENTIS MX4 PUMP MODULE THREE-DIMENSIONAL DIAGRAM 8 17151002 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)

8 17151028 Captive Case Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)

9 17151010 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)

9 17151036 Captive Case Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)
* Item is not user replaceable. The Ventis MX4 Pump Module must be sent to an authorized ISC Service Center for this item to be replaced.

►Products, Specifications, and Certifications


VENTIS MX4 ACCESSORIES AND PARTS
Docking and Calibration Stations
18108630-0BC DS2 Docking Station™ for Ventis MX4
B = Quantity of iGas® Readers
C = Power Cord, where 0 = US, 1 = UK, 2 = EU, 3 = AUS, 4 = ITA, 5 = DEN, 6 = SWZ

18108631-AB V•Cal ™ Calibration Station


A = Instrument Type, where 0 = Diffusion, 1 = Aspirated
B = Power Cord, where 0 = US, 1 = UK, 2 = EU, 3 = AUS, 4 = ITA, 5 = DEN, 6 = SWZ

Printer
18107763 Serial data dot matrix printer for V•Cal™ – 120 VAC powered
Chargers
18108191 Ventis Single-Unit Charger
18108209 Ventis Single-Unit Charger/Datalink
18108651 Ventis Single-Unit Automotive Charger, 12VDC
18108652 Ventis Single-Unit Truck-Mount Charger, 12VDC, with Cigarette Adapter
18108653 Ventis Single-Unit Truck-Mount Charger, 12VDC, Hard Wired
18108650-A Ventis 6-Unit Charger
Pumps
18108830 Ventis MX4 Hand Pump (manual bulb)
VTSP-ABCD Ventis MX4 Pump Module*
A = Battery Type, where 0 = No Battery, 2 = Li-ion Extended Range Battery Pack, 3 = Alkaline Battery Pack
B = Color, where: 0 = Black, 1 = Orange
C = Approvals, where 1 = UL and CSA; 2 = ATEX, and IECEx,; 3=MSHA; 4= ANZEx; 5 = China EX; 7 = GOST-R and
GOST-K; 8 = KOSHA; 9 = INMETRO; A = MED; and D = TIIS
KEY FOR VENTIS MX4 PUMP MODULE THREE-DIMENSIONAL DIAGRAM D = Assembly Guide language, where: 1 = English, 2 = French, 3 = Spanish, 4 = German, 5 = Italian, 6 = Dutch, 7 =
Portuguese, 9 = Russian, A = Polish, B = Czech, C = Chinese, D = Danish, E = Norwegian, F = Finnish, G = Swedish,
Number Part Number (P/N) Description J = Japanese
1 17151150-X0 Ventis MX4 Pump Door Assembly *Ventis MX4 Pump Module replacement parts
X = Pump Door Assembly Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz. in. or .39 n.m . +/- 10%) 17151150-X0 Ventis MX4 Pump Door Assembly
X = Pump Door Assembly Color, where: 0 = Black, 1 = Orange
2 17129909 Pump Inlet Filter Cap
17129909 Pump Inlet Filter Cap
2 17141581 Pump Inlet-Filter Cap for use 6’ extendable probe
17152395 Water Barrier
2 17141599 Filter Cap, 1/8 NPT Female
17151275 Screw, Torx
3 17152395 Water Barrier
17052558 Screw
4 17151275 Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)
17148313-Y Extended Range Lithium-ion Battery Pack,
5 17052558 Screw (torque value: 25 oz-in or .17 N.m +/- 10%) Y = Approvals where:
1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, and TIIS
6 17148313-Y Extended Range Lithium-ion Battery Pack 2 = MSHA
Y = Approval where: 3 = China Ex
1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, and TIIS 4 = ANZEx
2 = MSHA
3 = China Ex 17151002 Captive Case Screw, Phillips
4 = ANZEx
17151028 Captive Case Screw, Torx
7 17150608 Alkaline Battery Pack: UL, ATEX, IECEx, ANZEx, and INMETRO approvals
(CSA, China KA and China MA approved for diffusion monitor only.) 17151010 Captive Case Screw, Phillips

43 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 44


Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

17151036 Captive Case Screw, Torx 17148313-Y Extended Range Lithium-ion Battery Pack
Y = Approvals where:
17116096 Calibration Tubing Assembly with Integrated “T” Fitting (For use when calibrating a monitor 1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, MED, SANS, and TIIS
with pump using a positive flow regulator) 2 = MSHA
3 = China Ex
Carrying Cases 4 = ANZEx

18108175 Ventis Diffusion Soft Carrying Case, Lithium-ion Battery (black) 17150608 Alkaline Battery Pack: UL, ATEX, IECEx, ANZEx, and INMETRO approvals (CSA, China KA
and China MA approved for diffusion monitor only.)
18109150 Ventis Diffusion Soft Carrying Case, Lithium-ion Battery (orange)
Conversion Kit** for the diffusion monitor.
18108183 Ventis Diffusion Soft Carrying Case, Extended Range Lithium-ion Battery or Alkaline (black) NOTE: For use in converting an aspirated monitor with a rechargeable Extended Range Lithium-ion battery pack to a diffusion monitor with a
rechargeable Extended Range Lithium-ion (or Alkaline) Battery Pack. (Batteries sold separately.) Kit parts listed below can be ordered separately as
18109151 Ventis Diffusion Soft Carrying Case, Extended Range Lithium-ion Battery or Alkaline replacement parts.
(orange)
**17151184-XY Cover, Extended Range Lithium-ion or Alkaline
18108813 Ventis Diffusion Hard Carrying Case with Display, Lithium-ion Battery X = Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 n.m . +/- 10%)
18108814 Ventis Diffusion Hard Carrying Case with Display, Extended Range Lithium-ion Battery or Y = Approvals where:
Alkaline 1 = UL, CSA, ATEX, IECEx, GOST-R, GOST-K, and KOSHA; MED (Lithium-ion only)
2 = MSHA (Extended Range Lithium-ion only)
18108815 Ventis Diffusion Hard Carrying Case without Display, Lithium-ion Battery 3 = China Ex
4 = ANZEx
18108816 Ventis Diffusion Hard Carrying Case without Display, Extended Range Lithium-ion Battery or 5 = INMETRO
Alkaline C = China KA

18108810 Ventis Aspirated Soft Carrying Case (black) **17152506 Suspender Clip Spacer
18109152 Ventis Aspirated Soft Carrying Case (orange) **17120528 Suspender Clip
18108811 Ventis Aspirated Hard Carrying Case with Display **17153137 Locking Washer
18108812 Ventis Aspirated Hard Carrying Case without Display ** 17152507 Screw, Phillips
Clip Assembly
17120528 Suspender Clip (for diffusion monitor with Lithium-ion Battery Pack)
MONITOR SPECIFICATIONS
17139262 Clip screw and washer (for diffusion monitor with Lithium-ion Battery Pack)
Item Description
Sensors, Sensor Barrier, Vibrating Motor, LCD, and Calibration Cup
Display Backlit Liquid Crystal Display (LCD)
17134495 Ventis MX4 Sensor, Combustible Gas (LEL/CH4)
Buttons Two (ON/OFF/MODE and ENTER)
17134461 Ventis MX4 Sensor, Oxygen (O 2)
Monitor case Polycarbonate with ESD protective rubber overmold
17134487 Ventis MX4 Sensor, Carbon Monoxide (CO)
Alarms Ultra-bright LEDs, loud audible alarm (95dB at 30 cm), and vibrating alarm
17155564 Ventis MX4 Sensor, Carbon Monoxide/Low Hydrogen Interference (CO/H2 Low)
Size and Weight Diffusion with Lithium-ion (typical) Aspirated with Extended Range
17134479 Ventis MX4 Sensor, Hydrogen Sulfide (H2S) Lithium-ion (typical)
17134503 Ventis MX4 Sensor, Nitrogen Dioxide (NO2) Size 103 mm x 58 mm x 30 mm 172 mm x 67 mm x 66 mm
17143595 Ventis MX4 Sensor, Sulfur Dioxide (SO2) (4.1” x 2.3” x 1.2”) (6.8” x 2.6” x 2.6”)

17152380-X Diffusion Case Top Assembly (includes Sensor Barrier Assembly) Weight 182 g (6.4 oz) 380 g (13.4 oz)
X = Case Top Color, where: 0 = Black, 1 = Orange

17152429 Sensor Barrier Assembly


17145285 Vibrating Motor OPERATING CONDITIONS
Warm-up time 40 seconds (includes stabilization time)
17150772 Ventis MX4 LCD Assembly
Temperature range -20 °C to +50 °C (-4 °F to +122 °F)
17156189 Ventis Calibration Cup Assembly, calibration cup with tubing
Humidity range 15–95% relative humidity (RH) noncondensing (during continuous operation)
17152455 Ventis Calibration Cup
Battery Packs and Components Pressure range 1 atm ±20%
17134453-XY Lithium-ion Battery Kit
X = Battery Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 N.m +/- 10%)
Y = Approvals where:
1 = UL, CSA, ATEX, IECEx, GOST-R, GOST-K, KOSHA, MED, and SANS
2 = MSHA
3 = China Ex
4 = ANZEx
5 = INMETRO
XY=0D; TIIS
STORAGE CONDITIONS

45 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 46


Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

Temperature range 0−25 ºC (32−77 ºF) The numbers were measured under these environmental conditions: 20 °C (68 °F) , 50% RH and 1 atm.
Humidity range 40–70% relative humidity (RH) noncondensing The specified cross-interference numbers apply to new sensors only, and may vary with time as well as from sensor
to sensor.
Pressure range 0.9–1.1 atm
“—” means no data available.
Maximum time Up to 6 months
Note: Industrial Scientific recommends that infrequently used lithium-ion batteries be This table is given as a reference only and is subject to change.
fully charged every four months.
LEL AND LEL CORRELATION FACTORS FOR COMBUSTIBLE GASES
SENSOR SPECIFICATIONS Sample gas* LEL LEL correlation factors
Gas Name Abbr. Measuring Resolution Accuracy at Time and Response Response (% vol)
Calibration gas
Range Temperature of Time Time
Calibration* (typical) (typical) Butane Hexane Hydrogen Methane Pentane Propane
T50 T90
Acetone 2.5% 1.00 0.70 1.70 1.70 0.90 1.10
Oxygen O2 0–30% vol 0.1% vol ± 0.5% 15 30
Acetylene 2.5% 0.70 0.60 1.30 1.30 0.70 0.80
Carbon Monoxide CO/H2 0–1000 ppm 1 ppm ± 5% (0-300 ppm) 8 17 Benzene 1.2% 1.10 0.80 1.90 1.90 1.00 1.20
with low H2 Low ± 15% (301-1000 ppm)
Butane 1.9% 1.00 0.58 1.78 1.67 0.83 1.03
interference
Ethane 3.0% 0.80 0.60 1.30 1.30 0.70 0.80
Carbon Monoxide CO 0–1000 ppm 1 ppm ± 5% 15 50
Ethanol 3.3% 0.89 0.52 1.59 1.49 0.74 0.92
Hydrogen Sulfide H 2S 0–500 ppm 0.1 ppm ± 5% 15 30 Ethylene 2.7% 0.80 0.60 1.40 1.30 0.70 0.90
Hexane 1.1% 1.71 1.00 3.04 2.86 1.42 1.77
Nitrogen Dioxide NO2 0–150 ppm 0.1 ppm ± 10% 10 30
Hydrogen 4.0% 0.56 0.33 1.00 0.94 0.47 0.58
Sulfur Dioxide SO2 0–150 ppm 0.1 ppm ± 10% 20 80 Isopropanol 2.0% 1.10 0.90 2.00 1.90 1.00 1.20
Methane 5.0% 0.60 0.35 1.06 1.00 0.50 0.62
Combustible LEL 0–100% LEL 1% LEL ± 5% 15 35
Methanol 6.0% 0.60 0.50 1.10 1.10 0.60 0.70
Methane CH4 0–5% vol 0.01% vol ± 5% 15 35 Nonane 0.8% 2.22 1.30 3.95 3.71 1.84 2.29
*The accuracy specification for each sensor is ± the stated percentage or 1 unit of resolution, whichever is greater. Pentane 1.4% 1.21 0.71 2.15 2.02 1.00 1.25
Propane 2.1% 0.97 0.57 1.72 1.62 0.80 1.00
Styrene 0.9% 1.30 1.00 2.20 2.20 1.10 1.40
TOXIC GAS SENSOR CROSS-SENSITIVITY TABLE
Toluene 1.1% 1.53 0.89 2.71 2.55 1.26 1.57
Xylene 1.1% 1.50 1.10 2.60 2.50 1.30 1.60
Target Gas Sensor
JP-4 — — — — — 1.20 —
CO JP-5 — — — — — 0.90 —
(H2
CO Low) H2S SO2 NO2 Cl2 ClO2 HCN HCl PH3 NO H2 NH3 JP-8 — — — — — 1.50 —

CO 100 100 1 1 0 0 0 0 0 0 0 20 0
NOTE: The table above provides the LEL for select combustible gases*. It also provides correlation factors that help the safety
H2S 5 5 100 1 -40 -3 -25 10 300 25 10 20 25 technician and instrument operator determine the actual percentage LEL when the sample gas differs from the gas that was used to
calibrate the unit.
SO2 0 5 5 100 0 0 0 — 40 — 0 0 -40 For example, if the unit reads 10% LEL in a pentane atmosphere, and was calibrated to methane, the actual percentage LEL is
NO2 -5 5 -25 -165 100 45 — -70 — — 30 0 -10 determined as follows:
1. Locate the table cell where the sample gas (pentane) intersects with the calibration gas (methane).
Cl2 -10 0 -20 -25 10 100 60 -20 6 -20 0 0 -50 2. Multiply the cell's value (2.02) by the unit's LEL reading (10%) to calculate the actual concentration of 20.2% LEL.
ClO2 — — — — — 20 100 — — — — — — * The combustible gas list is not a comprehensive list of all combustible gases that can be detected by the Ventis MX4. For
HCN 15 — 10 50 1 0 0 100 35 1 0 30 5 additional information about combustible gas detection and the Ventis MX4, contact the ISC Technical Service department.

HCl 3 — 0 5 0 2 0 0 100 0 15 0 0
PH3 — — — — — — -100 425 300 100 — — —
NO 25 40 1 1 5 — — -5 — — 100 30 0
H2 22 3 0.3 0.5 0 0 0 0 0 0 0 100 0
NH3 0 0 0 0 0 0 0 0 0 0 0 0 100
The Sensor Cross Sensitivity Table (above) reflects the percentage response provided by the sensor (top row) when
exposed to a known concentration of the target gas (column 1).

47 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 48


Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual

CERTIFICATIONS ►Warranty
Directive/Code Certification Marking
Industrial Scientific Corporation's Ventis MX4 portable gas monitors are warranted to be free from defects in material and workmanship for
ATEX Ex ia IIC T4 Ga and Ex ia I Ma; a period of two years after purchase. This warranty includes the sensors, the pump, and the lithium-ion battery pack as shipped with the
Equipment Group and Category II 1G and I M1; Ventis MX4.
IP66; IP67
Filters are warranted to be free from defects in material and workmanship for 18 months from date of shipment, or one year from
ANZEx Ex ia s Zone 0 I/IIC T4; IP66; IP67 date of first use, whichever occurs first, except where otherwise stated in writing in Industrial Scientific literature.

China Ex Ex ia IIC T4 Ga
China CMC Metrology Approval LIMITATION OF LIABILITY
INDUSTRIAL SCIENTIFIC MAKES NO OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT
China KA Ex ia d I Mb; Metalliferous and nonmetallic l Mine LIMITED TO THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

China MA Approved for Underground Mines; diffusion (without pump) alkaline version SHOULD THE PRODUCT FAIL TO CONFORM TO THE ABOVE WARRANTY, BUYER’S ONLY REMEDY AND INDUSTRIAL
only SCIENTIFIC’S ONLY OBLIGATION SHALL BE, AT INDUSTRIAL SCIENTIFIC’S SOLE OPTION, REPLACEMENT OR REPAIR OF
SUCH NON-CONFORMING GOODS OR REFUND OF THE ORIGINAL PURCHASE PRICE OF THE NON-CONFORMING
CSA Class I, Division 1, Groups A B C D, T4; Ex d ia IIC T4 GOODS.
C22.2 No. 152 for %LEL reading only
IN NO EVENT WILL INDUSTRIAL SCIENTIFIC BE LIABLE FOR ANY OTHER SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
GOST – R and GOST - K PBExdiaI X and 1ExdiaIICT4 X DAMAGES, INCLUDING LOSS OF PROFIT OR LOSS OF USE, ARISING OUT OF THE SALE, MANUFACTURE, OR USE OF
ANY PRODUCTS SOLD HEREUNDER WHETHER SUCH CLAIM IS PLEADED IN CONTRACT OR IN TORT, INCLUDING
IECEx Ex ia IIC T4 Ga; IP66; IP67 STRICT LIABILITY IN TORT.

It shall be an express condition to Industrial Scientific’s warranty that all products be carefully inspected for damage by Buyer upon
INMETRO Ex ia IIC T4 Ga; IP66; IP67
receipt, be properly calibrated for Buyer’s particular use, and be used, repaired, and maintained in strict accordance with the
-20°C ≤ Ta ≤ +50 °C instructions set forth in Industrial Scientific’s product literature. Repair or maintenance by non-qualified personnel will invalidate the
KOSHA Ex d ia IIC T4 warranty, as will the use of non-approved consumables or spare parts. As with any other sophisticated product, it is essential and a
condition of Industrial Scientific’s warranty that all personnel using the products be fully acquainted with their use, capabilities, and
MED Portable Multigas Detector; Category 2 (MED 2012/32/EU); Li-Ion only limitations as set forth in the applicable product literature.
Charger/Docking Station accessories; category 1
Buyer acknowledges that it alone has determined the intended purpose and suitability of the goods purchased. It is expressly
MSHA Permissible for Underground Mines; li-ion versions only agreed by the parties that any technical or other advice given by Industrial Scientific with respect to the use of the goods or services
SANS-1515 SANS 1515-1 is given without charge and at Buyer’s risk; therefore, Industrial Scientific assumes no obligations or liability for the advice given or
results obtained.
Type A; Ex ia I/IIC T4 IP66/67; Li-Ion only
TIIS Ex ia IIC T4 X

UL Class I, Division 1, Groups A B C D, T4; Zone 0, AEx ia IIC T4


Class II, Groups F G (Carbonaceous and Grain Dust);
Class I, Zone 0, AEx ia IIC T4
IP66 ; IP67
Marking Requirements
ATEX Markings IECEx Markings
Industrial Scientific Corp. Industrial Scientific Corp.
15071 USA 15071 USA
VENTIS MX4 VENTIS MX4
DEMKO 10 ATEX 1006410 IECEx UL10.0034
Ex ia IIC T4 Ga / Ex ia I Ma IP 66/67 Ex ia IIC T4 Ga IP 66/67
o o o o
-20 C ≤ Ta ≤ +50 C -20 C ≤ Ta ≤ +50 C
[Serial Number] [Month/Year of Production] [Serial Number] [Month/Year of Production]
Charging contact parameters: Um = 6.2V; Ii = 1.3A Charging contact parameters: Um = 6.2V; Ii = 1.3A
EN 60079-29-1; EN 50104
Diffusion Version: Aspirated Version:
Warning: Do not recharge or replace battery in hazardous Warning: Do not recharge or replace battery in hazardous
locations. Replace only with P/N 17148313-1, P/N locations. Replace only with P/N 17148313-1 or P/N 17050608
17134453-X1, or P/N 17050608
Li-Ion Battery Packs, P/N 17148313-1 or P/N 17134453-X1 Alkaline Battery Pack, P/N 17150608
Warning: Only charge instrument in non-hazardous Warning: Only replace batteries in non-hazardous locations;
locations. Charging contact parameters: Um = 6.2V; Ii = Only approved for use with three (3) AAA battery types Duracell
1.3A; Do Not Connect in Hazardous Locations MN2400 and Energizer EN92. Replace all batteries at the same
time.
Warning: Read and understand manual before use.
Warning: Read and understand manual before use.

49 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 50


Ventis™ MX4 Product Manual

►Ventis MX4 Resource Center


Product documentation.
Online training.
And more!
www.indsci.com/ventis

Contact Information
Industrial Scientific Corporation
1 Life Way
Pittsburgh, PA 15205-7500
USA
Web: www.indsci.com
Phone: +1 412-788-4353 or 1-800-DETECTS (338-3287)
E-mail: [email protected] To locate a nearby distributor of our products or an
Fax: +1 412-788-8353 Industrial Scientific service center or business
office, visit us at www.indsci.com.
Industrial Scientific France S.A.S.
5 Rue Frédéric Degeorge, CS 80097 Rendez-vous sur notre site Web www.indsci.com, si
vous voulez trouver un distributeur de nos produits
62002 Arras Cedex,
près de chez vous, ou, si vous recherchez un
France centre de service ou un bureau Industrial Scientific.
Web: www.indsci.com
Phone: +33 (0)1 57 32 92 61 Besuchen Sie uns unter www.indsci.com, um einen
E-mail: [email protected] Vertriebshändler unserer Produkte oder ein
Fax: +33 (0)1 57 32 92 67 Servicecenter bzw. eine Niederlassung von
Industrial Scientific zu finden.
英思科传
Para buscar un distribuidor local de nuestros
地址:中国上海市浦 区 290号 productos o un centro de servicio u oficina
编 201206 comercial de Industrial Scientific, visite
话 +86 21 5899 3279 www.indsci.com.
+86 21 5899 3280
如需查找就近的产品经销商或 Industrial

E-mail: [email protected] Scientific
网址: www.indsci.com 服务中心或业务办事处,请访问我们的网
服 热线 +86 400 820 2515 站 www.indsci.com。

51 © 2015 Industrial Scientific Corporation


2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

DIAPHRAGM AIR PUMP

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 21
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

BUTTERFLY VALVES

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 22
SIPART PS2 (6DR5...)

10/2015
1
The electropneumatic positioner is used for the continuous control of process valves with pneumatic drives in the following
industries.
● Chemicals
● Oil and gas
● Energy production
● Food and beverages
● Pulp and paper
● Water/waste water
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The
● Pharmaceutical industry
notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage
have no safety alert symbol. These notices shown below are graded according to the degree of danger. ● Offshore plants
Operate the device according to the specifications in section "Technical data (Page 43)".
indicates that death or severe personal injury result if proper precautions are not taken. For additional information, refer to the operating instructions for the device.

indicates that death or severe personal injury result if proper precautions are not taken.
1. Check the packaging and the delivered items for visible damage.
2. Report any claims for damages immediately to the shipping company.
indicates that minor personal injury can result if proper precautions are not taken.
3. Retain damaged parts for clarification.
4. Check the scope of delivery by comparing your order to the shipping documents for correctness and completeness.
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of
injury to persons with a safety alert symbol may also include a warning relating to property damage.

Danger of explosion in hazardous areas.


The product/system described in this documentation may be operated only by for the specific task in accordance with • Do not use damaged or incomplete devices.
the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their
training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Note the following:

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products
and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage,
installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any
problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

These instructions are a brief summary of important features, functions and safety information, and contain all information
required for safe use of the device. Read the instructions carefully prior to installation and commissioning. In order to use the
device correctly, first review its principle of operation.
The instructions are aimed at persons who mechanically assemble the device, connect it electrically, and start it up.
To achieve optimum usage of the device, read the detailed version of the instructions.

Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)


SIPART PS2 product information (http://www.siemens.com/sipartps2)

© Siemens AG 2015. All rights reserved SIPART PS2 (6DR5...)


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The packaging only provides limited protection against moisture and infiltration.
• Provide additional packaging as necessary.

Special conditions for storage and transportation of the device are listed in "Technical data" (Page 43).

The contents of this manual shall not become part of or modify any prior or existing agreement, commitment or legal
relationship. The sales contract contains all obligations on the part of Siemens as well as the complete and solely applicable
warranty conditions. Any statements regarding device versions described in the manual do not create new warranties or
modify the existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right to make technical changes in
the course of further development.
① Manufacturer ⑨ Auxiliary power (supply air PZ)
② Protection class ⑨ Software/hardware version
③ Consult operating instructions ⑩ Place of manufacture
④ Conformity with country-specific directives ⑩ Auxiliary power
⑤ Built-in option module ⑪ Ordering supplement (Order code)
⑥ QR code to the mobile website with device-specific ⑫ Article number
information on the product
This device left the factory in good working condition. In order to maintain this status and to ensure safe operation of the
⑦ Serial number ⑬ Product name device, observe these instructions and all the specifications relevant to safety.
Figure 1-1 Nameplate layout, example Observe the information and symbols on the device. Do not remove any information or symbols from the device. Always
keep the information and symbols in a completely legible state.

Consult operating instructions

Observe the test certification, provisions and laws applicable in your country during connection, assembly and operation.
These include, for example:
● National Electrical Code (NEC - NFPA 70) (USA)

① Approvals ③ FM/CSA marking for hazardous area ● Canadian Electrical Code (CEC) (Canada)
② ATEX/IECEx marking for hazardous area ④ Permitted ambient temperature for the hazardous Further provisions for hazardous area applications are for example:
area of the corresponding temperature class
● IEC 60079-14 (international)
Figure 1-2 Ex nameplate layout, example ● EN 60079-14 (EC)

To guarantee sufficient protection during transport and storage, observe the following: The CE marking on the device shows conformity with the regulations of the following European guidelines:
● Keep the original packaging for subsequent transportation. Electromagnetic Compatibility EMC Directive of the European Parliament and of the Council on the approximation of the
● Devices/replacement parts should be returned in their original packaging. 2004/108/EC laws of the Member States relating to electromagnetic compatibility and repealing
Directive 89/336/EEC.
● If the original packaging is no longer available, ensure that all shipments are properly packaged to provide sufficient
protection during transport. Siemens cannot assume liability for any costs associated with transportation damages. Atmosphère explosible ATEX Directive of the European Parliament and the Council on the approximation of the
94/9/EC laws of the Member States concerning equipment and protective systems intended
for use in potentially explosive atmospheres.

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LVD 2006/95/EC Directive of the European Parliament and of the Council of the harmonisation of the
laws of Member States relating to electrical equipment designed for use within certain
voltage limits.
The applied standards can be found in the EC conformity declaration of the device. If the device has already been operated in non-intrinsically safe circuits or the electrical specifications have not been
observed, the safety of the device is no longer ensured for use in hazardous areas. There is a danger of explosion.
• Connect the device with type of protection "Intrinsic safety" solely to an intrinsically safe circuit.
• Observe the specifications for the electrical data on the certificate and/or in Chapter "Technical data (Page 43)".

Danger to personnel, system and environment can result from modifications to the device, particularly in hazardous areas.
• Only carry out modifications that are described in the instructions for the device. Failure to observe this requirement
cancels the manufacturer's warranty and the product approvals.

Danger of explosion. The pneumatic terminal plate on the SIPART PS2 positioner 6DR5..6 is a safety-related component
Risk of injury when working on control valves due to the high operating force of the pneumatic actuator.
of the flameproof enclosure.
• Please observe the corresponding safety instructions for the pneumatic actuator in use.
• Never loosen the screws ① of the pneumatic terminal plate.

Danger of crushing and shearing with mounting kits which use a lever for position detection. During commissioning and
ongoing operation, severing or squeezing of limbs could occur as a result of the lever. Risk of injury when working on
control valves due to the high operating force of the pneumatic actuator.
• Do not reach into the range of motion of the lever following mounting of the positioner and mounting kit.

Figure 2-1 Screws of the pneumatic terminal plate on the positioner 6DR5..6

Danger of explosion in areas subject to explosion hazard.


• Only use original accessories or original spare parts.
Persons who install, connect, commission, operate, and service the device in a hazardous area must have the following • Observe all relevant installation and safety instructions described in the instructions for the device or enclosed with the
specific qualifications: accessory or spare part.

● They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety
regulations for electrical circuits, high pressures, aggressive, and hazardous media.
● They are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment according to the pertinent safety If the cover gasket is not positioned correctly in the groove of the base plate, it could be damaged when the cover is
regulations. mounted and screwed tight.
• Therefore make sure that the gasket is seated correctly.

Danger of explosion.
• Only use equipment that is approved for use in the intended hazardous area and labelled accordingly.
Danger of explosion in hazardous areas.
• Close the cable inlets for the electrical connections. Only use cable glands or plugs which are approved for the relevant
type of protection.
Technical data (Page 43)

Technical data (Page 43)

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Danger of explosion in hazardous areas.
Device damage. The device can be damaged, destroyed, or its functionality impaired through improper mounting.
• Make sure that the maximum permissible ambient and process media temperatures of the device are not exceeded. • Before installing ensure there is no visible damage to the device.
Refer to the information in Chapter "Technical data (Page 43)". • Make sure that process connectors are clean, and suitable gaskets and glands are used.
• Mount the device using suitable tools. Refer to the information in Construction (Page 44) for installation torque
requirements.

Device damage. As a general rule, the positioner must only be operated with dry and clean compressed air.
• Use the customary water separators and filters. An additional dryer is required in extreme cases.
• Use dryers, especially if you operate the positioner at low ambient temperatures. Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the nameplate or in
Chapter "Technical data (Page 43)" is no longer guaranteed.
• Make sure that the device is securely closed.

Danger of injury.
• Prior to working on the control valve, you must move the control valve into a completely pressureless state. Proceed as For linear actuators, use the "linear actuator" mounting kit 6DR4004-8V or the integrated attachment.
follows: You require different installation parts depending on the selected actuator type. The mounting kit is suitable for a stroke of 3
– Depressurize the actuator chambers. to 35 mm. For a larger stroke range, you require a separately ordered lever 6DR4004-8L. Refer to the detailed operating
– Switch off the supply air PZ. instructions for further information on mounting.
– Lock the valve in its position.
• Make sure that the valve has reached the pressureless state.
• If you interrupt the pneumatic auxiliary power to the positioner, the pressureless position may only be reached after a You require an actuator-specific VDI/VDE 3845 mount to install the positioner on a part-turn actuator. You receive the mount
certain waiting time. and screws from the actuator manufacturer. Ensure that the mount has a sheet metal thickness of > 4 mm and
• When mounting, observe the following sequence imperatively to avoid injuries or mechanical damage to the reinforcements. You also need the mounting kit 6DR4004-8D or the stainless steel coupling TGX: 16300-1556. Refer to the
positioner/mounting kit: detailed operating instructions for further information on mounting.
– Mount the positioner mechanically.
– Connect the electrical auxiliary power supply.
– Connect the pneumatic auxiliary power supply.
– Commission the positioner.
The positioner enclosure provides IP66 protection with an intended installation position. It can therefore be operated in a
moist or wet environment in the mounting positions shown below. Do not use other mounting positions since it would then be
possible for liquids, fluff, fibers or dusts to enter the device via the exhaust openings.

In order to ensure the degree of protection of the housing (IP66), protect the housing versions of the positioners listed here
from mechanical impact energy: Avoid the unfavorable mounting positions:
• 6DR5..3; not greater than 2 Joule
● To prevent fluids seeping through during normal operation of the device, e.g. through exhaust air openings.
• 6DR5..0; not greater than 1 Joule
• 6DR5..1 with inspection window; not greater than 1 Joule ● Otherwise the display becomes poorly legible.

Device damage. The maximum torque of the cable gland must not be exceeded.
• To avoid damage to the device, the NPT adapter must be held in place while the NPT gland is screwed into the NPT
adapter. Refer to the section "Technical specifications > Construction (Page 44)" for the torque value.

Figure 3-1 Favorable and unfavorable mounting positions

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Take additional measures to prevent liquids from seeping through if the conditions force you to operate the positioner in an
unfavorable mounting position.
Additional measures required to prevent liquids from seeping through depend on the selected mounting position. You may
also require:
● Gland with sealing ring, e.g. FESTO: CK - 1 / 4-PK-6
● Approximately 20 to 30 cm plastic hose, e.g. FESTO: PUN - 8 x 1.25 SW
● Cable tie; the number and the length depend on the local conditions.

1. Install the casing such that rain water or condensate running along the pipes can be drained before the terminal strip of
the positioner.
2. Check the seals of electrical connections for perfect fitting.
3. Check the seal in the enclosure cover for damage and contaminations. Clean and/or replace if required.
4. Install the positioner such that the sintered bronze attenuator at the bottom side of the enclosure points downwards in the
vertical mounting position. If this is not possible, replace the attenuator with a suitable gland with a plastic hose.

1. Unscrew the sintered bronze attenuator from the exhaust air opening at the bottom side of the enclosure.
2. Screw in the aforementioned gland into the exhaust air opening.
3. Install the aforementioned plastic hose into the gland and check whether it fits firmly.
4. Fasten the plastic hose with a cable tie onto the control valve such that the opening points downwards.
5. Ensure that the plastic hose does not have any kinks and the exhaust air flows out without any hindrance.
① Gear latch ⑥ Friction clutch
② Locking transmission ratio to 33° ⑦ Friction clutch latch
The electropneumatic positioner has an gear latch for the friction clutch and for the transmission ratio selector.
③ Neutral position ⑧ Locking friction clutch
④ Locking transmission ratio to 90° ⑨ Release friction clutch
Strong acceleration forces act on control valves that are subjected to heavy mechanical loads, e.g. breakaway valves,
strongly shaking or vibrating valves, as well as in case of "vapor shocks". These forces may be much higher than the
⑤ Transmission ratio selector
specified data. This may cause the friction clutch to move in extreme cases. Figure 3-2 Locking friction clutch and transmission ratio
The positioner is equipped with an gear latch for the friction clutch to counter these extreme cases. The setting of the
transmission ratio selector can also be locked. Using the accessory "NCS sensor for non contact position detection", it is
possible to mount the controller unit a certain distance away, e.g. on a mounting pipe or similar. ● The positioner is mounted.
The locking procedure is illustrated and described below. ● You know whether the transmission ratio is to be set to 33° or 90°.
● The positioner has been commissioned successfully, i.e. initialization was completed with "FINISH".

A different setting of the transmission ratio selector and the gear latch results in a hysteresis in position detection. The
hysteresis in position detection can result in unstable control behavior of the higher level control loop.
• A friction clutch is provided on the outside of the positioner axis. Change the work area using this friction clutch.
• Make sure the transmission ratio selector ⑤ and the gear latch ① are set to the same value, either to 33° or to 90°.
• Do not open the flameproof enclosure of the positioner in explosion-prone atmospheres.

Fix the setting acquired by initialization as follows:

1. Make sure the gear latch ① is in neutral position ③. The neutral position is between 33° and 90°.

2. Make sure the transmission ratio selector ⑤ is in the correct position.

3. Fix the transmission ratio with the gear latch ①. Turn the gear latch ① with a standard approx. 4 mm wide screwdriver
until the gear latch ① locks. Turning right locks the transmission ratio to 33°②. Turning left locks the transmission ratio
to 90°④. The transmission ratio is locked.

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The following option modules are available:
● Position feedback module
The setting of the transmission ratio selector ⑤ can only be changed effectively if the gear latch ① is in the neutral
position ③. ● Alarm module
● Internal NCS module
4. To fix the friction clutch ⑥ insert a standard approx. 4 mm wide screwdriver in the friction clutch gear latch ⑦.

5. Use the screwdriver to turn the friction clutch gear latch ⑦ counterclockwise until it engages. The friction clutch ⑥ is
locked. The internal NCS module is used for wear-free position detection and is an optional equipment version in the positioner. The
internal NCS module is installed as an alternative to position feedback module at the same slot in the positioner.

Versions with flameproof enclosures may not be operated with an external position detection system.

The aforementioned measures are not adequate in some applications. For example, continuous and strong vibrations, high
or too low ambient temperatures and nuclear radiation.
The position detection system and the controller unit are mounted separately for these applications. A universal component Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using direct current instead of alternating
is available for this purpose. It is suitable for part-turn and linear actuators. You will require the following: current.
● An external position detection system with the article number C73451-A430-D78 comprising a positioner enclosure with • Connect the device in accordance with the specified power supply and signal circuits. The relevant specifications can
an integrated friction clutch, potentiometer as well as different blanking plugs and seals. be found in the certificates, in Chapter "Technical data (Page 43)" or on the nameplate.
● Or a contactless explosion-proof non contacting system (e.g.6DR4004-6N).
● A positioner
● A three-pole cable to connect components.
● An EMC filter module with the article number C73451-A430–D23 is provided in a set along with cable clamps and M20 Risk of explosion in hazardous areas.
cable glands. For intrinsically safe device versions only the certified circuits may be connected as auxiliary power supply, control and
signal circuits.
The EMC filter module is always used for the controller unit whenever an external position detection system is used instead
of the internal sensor. An external position detection system is, for example, a potentiometer with a 10 kΩ resistance or an • Make sure that the power source of the used circuits is marked as intrinsically safe.
NCS.

A number of option modules are provided for the positioner. Different option modules are available depending on the version Danger of explosion in hazardous areas due to voltage flashover.
of the device. Only the available option modules are listed below.
• Connect the device to an extra-low voltage with safe isolation (SELV).
For additional information and the corresponding safety notes to be observed when installing the option modules, refer to the
detailed operating instructions for your respective device version.

The following option modules are available: Danger of explosion in hazardous areas.
● Position feedback module • Connect devices in hazardous areas only in a de-energized state.
:
● Alarm module
• Circuits of limited energy may also be connected in the energized state in hazardous areas.
● SIA module • Exceptions for type of protection "Non-sparking nA" (Zone 2) are regulated in the relevant certificate
● Mechanical limit switch module
● EMC filter module
● Internal NCS module
Danger of explosion through compensating currents or ignition currents through lack of equipotential bonding.
• Ensure that the device is potentially equalized.
: It may be permissible to omit connection of the equipotential bonding for devices with type of protection
"Intrinsic safety Ex i".

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Danger of explosion through unprotected cable ends in hazardous areas. The mechanical limit switch module 6DR4004- is approved for use for positioners with UL approval. The maximum
• Protect unused cable ends in accordance with IEC/EN 60079-14. supply voltage in this case is 30 V AC/DC.
The mechanical limit switch module 6DR4004- is not approved for use for positioners with UL approval.
If this information is ignored, the UL approval for the mechanical limit switch module for the positioner becomes invalid.

Danger of explosion through compensating currents between hazardous area and the non-hazardous area.
• Only ground shielded cables that run into the hazardous area at one end.
• If grounding is required at both ends, use an equipotential bonding conductor.

Device damage if a voltage source is connected to the current input Iw (terminals 6 and 7).
• Never connect the current input Iw to a voltage source, otherwise the positioner may be destroyed.
• Always use a voltage source with a maximum output current of I = 20 mA.
Danger of explosion in hazardous areas.
• Only use suitable cables and cable glands complying with the requirements specified in Chapter "Technical data
(Page 43)".
• Tighten the cable glands in accordance with the torques specified in Chapter "Technical data (Page 44)".
• When replacing cable glands use only cable glands of the same type.
• After installation check that the cables are seated firmly. • Lay signal cables separate from cables with voltages > 60 V.
• Use cables with twisted wires.
• Avoid getting too close to large electrical process cells.
• Use shielded cables to guarantee the full specification.
• Take account of the conditions for communication specified in the technical data.
Danger of explosion in areas subject to explosion hazard.
This device is approved for several types of protection.
1. Decide in favor of one type of protection.
2. Connect the device in accordance with the selected type of protection. If the bus shield is fully effective, the interference immunity and the interference emission conform to the specifications. The
following measures ensure that the bus shield is fully effective:
3. In order to avoid incorrect use at a later point, make the types of protection that are not used permanently
unrecognizable on the nameplate. ● The shields have been connected to the metallic connections of the positioner.
● The shields have been laid up to the terminal boxes, the distributor and the transceiver.

Damage to device through formation of condensation if the temperature difference between transportation or storage and
In order to dissipate glitch impulses, the positioner must be connected to an equipotential bonding cable (earth potential)
the mounting location exceeds 20 °C (36 °F).
using a low resistance. The positioner in the Makrolon enclosure is therefore equipped with an additional cable. Connect
• Before taking the device into operation let the device adapt for several hours in the new environment. the this cable to the shield of the bus cable and the equipotential bonding cable using a cable clamp.
Devices in the stainless steel or aluminum enclosure have a corresponding terminal on the outer side of the enclosure.
This terminal must also be connected to the equipotential bonding cable.
For applications in hazardous areas, ensure an adequately suitable equipotential bonding between the hazardous and
non-hazardous areas.
Damage to cable sheath.
• At an ambient temperature ≥ 60 °C (140 °F), use heat-resistant cables suitable for an ambient temperature at least The positioner is equipped with an additional input (terminal 81 [+] and terminal 82 [-]) to approach the safety position. After
20 °C (36 °F) higher. activating this function, this input must be continuously supplied with +24 V in order to retain the normal control function.
If the 24-V signal is interrupted, the safety position is set as described in chapter "Pneumatic connection (Page 29)".
Communication with the master is still possible. The "Jumper" on the basic electronics is used to activate this function. It can
be accessed after removing the module cover, and must be switched from the right position (delivery state) to the left
Device damage. position.
• Owing the reasons pertaining to tightness (IP enclosure rating) and the required tensile strength, only use the cables
having a diameter ≥ 8 mm for standard M20x1.5 cable gland, or use a suitable seal insert in case of smaller diameters.
• In the NPT version, the positioner is delivered with a coupling. When inserting a counter piece in the coupling, ensure
that the maximum permissible torque of 10 Nm is not exceeded.

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① Non-hazardous area ⑤ Power source
① Non-hazardous area ④ Binary input 1 ② Hazardous area ⑥ Signal source
② Hazardous area ⑤ Signal source ③ Basic electronics ⑦ HART communicator
③ Basic electronics ⑥ HART communicator ④ Binary input 1
Figure 4-1 Device version 2-wire Figure 4-3 Device version 2-/3-/4-wire, with wiring type 3-wire

① Non-hazardous area ④ Binary input 1


② Hazardous area ⑤ Signal source
③ Basic electronics ⑥ HART communicator
Figure 4-2 Device version 2/3/4-wire, with connection type 2-wire ① Non-hazardous area ⑤ Power source
② Hazardous area ⑥ Signal source
③ Basic electronics ⑦ HART communicator
④ Binary input 1
Figure 4-4 Device version 2-/3-/4-wire, with wiring type 4-wire

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You need the EMC filter module, article number C73451-A430-D23, for the electrical connection of the accessory part "NCS
sensor for contactless position measurement" to the positioner. The positioner supplies auxiliary power to the NCS sensor
via the EMC filter module.

① Non-hazardous area ④ Input: Safety shutdown


② Hazardous area ⑤ Binary input 1
③ Basic electronics ⑥ Signal source
Figure 4-5 Device version with PROFIBUS PA

① Positioner (open state) ⑦ Cable clamp


② Vcc: Yellow ⑧ Screw F3x8
③ Vref: Green ⑨ Cable gland
④ Vpos: Black ⑩ Four-pole NCS cable
⑤ Ground: Brown ⑪ Non Contacting Sensor (NCS)
⑥ EMC filter module C73451-A430-D23 ⑫ Cable shielding lug

① Non-hazardous area ④ Input: Safety shutdown Figure 4-7 Example of connecting the NCS to the EMC filter module
② Hazardous area ⑤ Simulation enable
③ Basic electronics ⑥ Power source
The NCS sensor is equipped with a shielded four-pole cable. Wire this cable to the positioner as follows:
Figure 4-6 Device version with FOUNDATION Fieldbus
1. Feed the four-pole NCS cable ⑩ through the union nut and the cable gland. Note: The type of cable gland depends on
the positioner version.

For further information about "Split-range" operation, refer to the detailed operating instructions for your respective device 2. Tighten the cable gland ⑨.
version.
3. Terminate the four-pole NCS cable ⑩ in the positioner in accordance with the wiring diagram.

4. Place the cable clamp ⑦ onto the outer insulation of the four-pole NCS cable ⑩.

5. Use the screw ⑧ to bond the cable shielding lug ⑫ and the cable clamp ⑦ to the ground terminal of the positioner.
6. Grounding:

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The rear steel panel of the NCS sensor is inevitably bonded to the ground potential of the system when mounting on the
console. This ground connection is only functional if there is a low-impedance connection to ground potential of the
system. Ensure this state by measuring the ground resistance. If necessary, ensure proper grounding by means of an 1. You have performed the steps described in the section "Auto-Hotspot".
additional cable from the NCS sensor to ground potential. 2. Unplug the ribbon cable connector ④ to the fitted potentiometer from the basic electronics ⑤.

3. Remove the basic electronics ⑤ from the positioner. To this end, remove the two screws that fix the basic electronics to
the pneumatic block.

4. Loosen screw ⑥ in the connection area of the positioner.


You need the EMC filter module with article number C73451-A430-D23 for the electrical connection of an external position
detection system, article number C73451-A430-D78, to the positioner. 5. Insert the connector of the ribbon cable (A) into the slot as shown below.
Note: There is no space for the ribbon cable (A) in earlier versions of the positioner. Here you fasten the ribbon cable
with the supplied cable tie at the container.

6. Secure the EMC filter module using the screw ⑥ loosened in the third step.

7. Fit the basic electronics ⑤ back into the positioner.

8. Insert the ribbon cable connector ④ of the EMC filter module onto the positioner basic electronics.
9. In hazardous environment:

– Stick the supplied nameplate over the nameplate on the external position detection system ⑧.

– Replace the blue cable gland ⑩ by the supplied gray cable gland.
Refer to section "Auto-Hotspot", items "Nameplate for device version explosion protection" and "Gray cable gland".
For further information on fitting of an option module, refer to the operating instructions of the respective positioner version in
section "Installing/mounting > Installing option modules".

1. Connect the three terminals of the external position detection system ⑨ to the three terminals of the EMC filter module

① EMC filter module terminals ⑧ External position detection system C73451-A430-


① using a cable as shown in the wiring diagram.
D78 2. Tighten the cable glands ⑩ and ⑫.
② Positioner with integral EMC filter module C73451- ⑨ External position detection system terminals
A430-D23
③ Yellow wheel for locking the position detection ⑩ External position detection system cable gland
④ Ribbon cable connector of fitted potentiometer, or ⑪ Cable
ribbon cable connector of EMC filter module
⑤ Basic electronics ⑫ EMC filter module cable gland
⑥ Screw ⑬ Input signal for positioner
⑦ EMC filter module C73451-A430-D23
Figure 4-8 Connection to positioner

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① Non-hazardous area ③ Position feedback module
② Hazardous area ④ Feed splitter
Figure 4-10 Position feedback module

① Non-hazardous area ④ Fault message


② Hazardous area ⑤ Limit
③ SIA module ⑥ Switching amplifier
Figure 4-11 SIA module

① Non-hazardous area ⑤ Fault message


② Hazardous area ⑥ Limit
③ Alarm module ⑦ Switching amplifier
④ Binary input 2 ⑧ Switching output
Figure 4-9 Alarm module

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6. Connect the cables of each switch to the lug of the printed circuit board in pairs. Use the provided cable ties ③ for this
purpose.

When you supply the non-intrinsically safe version of the module with hazardous voltage, you must read the following
safety rules before starting work on the device:
1. Isolate the device from power. Use a circuit breaker positioned near the device to do this.
2. Make sure that the device cannot be switched back on inadvertently.
3. Make sure the device is truly isolated from power.

The mechanical limit switch module 6DR4004- is approved for use for positioners with UL approval. The maximum
supply voltage in this case is 30 V AC/DC.
The mechanical limit switch module 6DR4004- is not approved for use for positioners with UL approval.
If this information is ignored, the UL approval for the mechanical limit switch module for the positioner becomes invalid.

① Screw
② Cover
③ Cable tie
Figure 4-13 Connecting the cables

This section describes which terminal of the devices and option modules listed below is connected with the respective pole
of the M12 connector.

Observe the specifications for the electrical data in the certificate and/or in section "Technical data (Page 43)".

Pole designation Wire color of M12


connector
1 Brown
① Non-hazardous area ⑤ Limit
4 Black
② Hazardous area ⑥ Switching amplifier
3 Blue
③ Mechanical limit switch module ⑦ Switching output
④ Fault message 2 White

Figure 4-12 Mechanical limit switch module

1. Loosen the screw ① on the transparent cover ②.

2. Pull the transparent cover ② up to the front end stop.


3. Tighten every cable in the corresponding terminal.

4. Slide the transparent cover ② up to the end stop of the basic electronics.

5. Tighten the screw ① of the transparent cover ②.

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You have a positioner 6DR50..-0. .. or 6DR50..-0. .. In this version of the positioner the current input IW 4 to 20 mA of the
basic electronics is connected via an M12 connector. You have a positioner with order suffix -Z order code D53. In this version of the positioner, an M12 connector is used to
electrically connect the current output of the position feedback module.
Table 4-1 Assignment diagram
Table 4-5 Assignment diagram

6 (+) 1 - Brown
Shield support of housing 4 - Black 61 (+) 1 - Brown
7 and 8 (-) 3 - Blue Shield support of housing 4 - Black
62 (-) 3 - Blue

You have a positioner 6DR55..-0. .. or 6DR55..-0. . In this case the M12 connector is connected to the bus circuit of the
basic electronics. You have a positioner with order suffix -Z order code D54. In this version of the positioner the M12 connector connects the
external position detection system with the built-in EMC filter module (C73451-A430-D23).
Table 4-2 Assignment diagram
Table 4-6 Assignment diagram

7 1 - Brown
Shield support of housing 4 - Black POT (X1/2) 3 - Blue
6 3 - Blue VCC (X1/4) 1 - Brown
GND (X1/1) 4 - Black
VREF (X1/3) 2 - White
You have a positioner 6DR56..-0. .. or 6DR56..-0. .. In this case the M12 connector is connected to the bus circuit of the
basic electronics.
You have a positioner with order suffix -Z order code D56. In this version of the positioner, an M12 connector is used to
Table 4-3 Assignment diagram electrically connect the outputs of the SIA module.

Table 4-7 Assignment diagram


7 1 - Brown
Shield support of housing 4 - Black
6 3 - Blue 41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White
You have a positioner with order suffix -Z order code D55. This version of the positioner is connected via an M12 connector
to the current output of the position feedback module.

Table 4-4 Assignment diagram

41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White

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The pneumatic connections are provided on the right side of the positioner.
Owing to safety reasons, the pneumatic auxiliary power supply must be fed after installation only if the positioner is
switched to the "P-manual mode" when an electrical signal is available, refer to the as-delivered condition.

Observe the specifications regarding the air quality, see section "Technical specifications > Pneumatic data (Page 43)".

● If required, connect the pressure gauge block for supply air and actuating pressure.
● Connection via female thread G¼ or ¼" NPT:
– Y1: actuating pressure 1 for single and double-acting actuators
– Y2: actuating pressure 2 for double-acting actuators
– Exhaust air outlet with a sound absorber. Remove the sound absorber if required.
● For double-acting actuators, connect actuating pressure Y1 or Y2 depending on the desired safety setting. ① Restrictor Y2 *) ⑤ Actuating pressure Y1
● Safety position in case of electrical auxiliary power supply failure: ② Restrictor Y1 ⑥ Exhaust air outlet
③ Actuating pressure Y2 *) ⑦ Enclosure ventilation (2x)
– Positioner with single-acting pneumatic system: Y1 depressurized
④ Supply air PZ
– Positioner with double-acting pneumatic system: Y1 pressurized (maximum actuating pressure), Y2 depressurized *) for double-acting actuators
– Positioner with Fail in Place pneumatic system: Hold Y1 and Y2 (current actuating pressure) Figure 4-15 Pneumatic connection in the flameproof enclosure

Besides continuous air consumption, a leakage can cause the positioner to try to compensate the position deviation. This ● Reduce the air output to achieve travel times of T > 1.5 s for small actuators. Use restrictors Y1 ① and Y2 ② for this
will result in premature wear in the entire control device. purpose.
• After installing the pneumatic connections, check the tightness of the entire control valve.
● When turned clockwise, they reduce the air output and finally shut it off.
● In order to set the restrictors, we recommend closing them and then opening slowly.
● In case of double-acting valves, ensure that both restrictors have approximately the same setting.

The pneumatic connections are provided on the right side of the positioner.

① Restrictor Y1
② Restrictor Y2, only in the version for double-acting actuators
③ Hexagon socket-head screw 2.5 mm
Figure 4-16 Restrictors
① Actuating pressure Y1 for single and double-acting actuators
② Positioner shaft
③ Supply air PZ
④ Actuating pressure Y2 for double-acting actuators
⑤ Exhaust air outlet with a sound absorber
Figure 4-14 Pneumatic connection on the standard controller

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If an error message appears, correct operation in the process is no longer guaranteed.
• Check the gravity of the error.
• Correct the error.
• If the error still exists:
– Take the device out of operation.
Device failure or danger of explosion in hazardous areas. – Prevent renewed commissioning.
• Do not commission the device until it has been mounted completely and connected in accordance with the information
in Chapter "Technical data (Page 43)".
• Before commissioning take the effect on other devices in the system into account.
When operating the positioner with natural gas, you must follow and adhere to the following safety notes:

Danger of explosion in hazardous areas if the device is open or not properly closed.
1. Only positioners and option modules which are connected to power supplies with type of protection "Intrinsic safety,
• Close the device as described in Chapter "Installing/mounting (Page 8)".
protection level [ia]" may be operated with natural gas.
2. Do not operate the positioner with natural gas in closed spaces.
3. Natural gas is continuously blown off in the servo-drive depending on the model. Special care must therefore be taken
during maintenance activities near the positioner. Always ensure that the immediate surroundings of the positioner are
adequately ventilated.
Danger of explosion in areas subject to explosion hazard.
The maximum values for ventilation are listed in section "Natural gas as actuator medium (Page 48)".
• Only open the device in a de-energized state. 4. The mechanical limit switch module must not be used when operating the positioner with natural gas.
• Check prior to commissioning that the cover, cover locks, and cable inlets are assembled in accordance with the
5. Depressurize the devices operated with natural gas adequately during maintenance activities. Open the cover in an
directives. explosion-free atmosphere and depressurize the device for at least two minutes.
: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in energized state in hazardous
areas.

Only use natural gas which is clean, dry and free from additives.

Device damage and possibly loss of type of protection. The factory setting for the purging air selector is "IN". In the "IN"
position, water from the compressed air line may enter the device from the pneumatics during initial commissioning.
• Before commissioning, make sure that no water is present in the compressed air line.
If you cannot be sure that there is no water in the compressed air line: • During the initialization process, the operating pressure must be at least one bar more than that required to close or open
the valve. However, the operating pressure should not be greater than the maximum permissible operating pressure for
• Set the purging air selector to "OUT". In this way, you prevent water from the compressed air line from penetrating the the actuator.
device.
• Only set the purging air selector to "IN" again when all water has been discharged from the compressed air line.

1. After installing the positioner on a pneumatic actuator, you must supply electric and pneumatic auxiliary power to it.
2. The positioner is in the "P manual mode" before initialization. At the same time, "NOINI" blinks in the lower line of the
display.
Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the nameplate or in
Chapter "Technical data (Page 43)" is no longer guaranteed. 3. Position feedback: You can adjust the range of position detection using the friction clutch if necessary.
• Make sure that the device is securely closed. 4. Adjust the positioner as per the respective actuator with the help of the initialization process and by setting the
parameters. If required, use the "PRST" parameter to cancel the adjustment of the positioner on the actuator. The
positioner is again in the "P manual mode" after this process.

You can initialize the positioner as follows:


● Automatic initialization:
during automatic initialization, the positioner determines the following one after the other:

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– The direction of action
– The actuator travel and angle of rotation
– The travel time of the actuator
The positioner also adjusts the control parameters as per the dynamic response of the actuator.
● Manual initialization:
the actuator travel and the angle of rotation of the actuator are set manually. The remaining parameters are automatically Parameters 1 to 5 are the same for all versions of the positioner. These parameters are used to adjust the positioner to the
determined. This function is useful for valves which are lined, for example, with PTFE. actuator. Normally, setting these parameters is sufficient to be able to operate the positioner on an actuator.


If you want to get to know all details of the positioner, gradually try out the effects of the remaining parameters by systematic
Copying the initialization data when replacing a positioner:
the initialization data of a positioner can be read and copied into another positioner. A defective device can thus be testing.
replaced without interrupting an ongoing process through initialization.
You have to define a few parameters for the positioner before initialization. Owing to the preset values, you cannot adjust
Factory-set parameter values are printed in bold in the following table.
further parameters for initialization.
You can use a suitably configured and activated binary input to protect the configured settings against accidental
adjustment.

1.YFCT Type of actuator Normal Inverted


See detailed operating instructions for information on sequence of automatic initialization. Part-turn actuator turn -turn
Linear actuator -WAY
Linear actuator - carrier pin on actuator spindle FWAY -FWAY
Linear actuator - external linear potentiometer LWAY -LWAY
Part-turn actuator with NCS ncSt -ncSt
Linear actuator with NCS ncSL -ncSL
Linear actuator with NCS and lever ncSLL -ncLL
2.YAGL Rated angle of rotation of positioner shaft 1)
Degrees
90°
3.YWAY2) Range of stroke (optional setting) 3)
mm
5 | 10 | 15 | 20
(Short lever 33°, range of stroke 5 to 20
mm)
25 | 30 | 35
(Short lever 90°, range of stroke 25 to 35
mm)
40 | 50 | 60 | 70 | 90 | 110 | 130
(Long lever 90°, range of stroke 40 to 130
mm)
4.INITA Initialization (automatic) | no / ###.# | Strt
5.INITM Initialization (manual) | no / ###.# | Strt

1) Set the transmission ratio selector accordingly.


2) Parameter only appears with "WAY", "-WAY", "ncSLL", and "-ncLL"
3) If used, the value on the actuator must correspond to the set range of stroke on the lever arm.
Carrier must be set to the value of the actuator travel or, if this value is not scaled, to the next larger scale value.

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1. Check whether the mechanical unit can be moved freely in the entire travel range. Move the actuator to the respective
When the enclosure is open, the purge air switch above the pneumatic terminal strip on the pneumatic block can be
end position for this purpose using the or button.
accessed.
End position
● In the IN position, the enclosure is flushed from inside with a small volume of clean and dry instrument air.
2. Now move the actuator to the horizontal position of the lever.
● In the OUT position, the purge air is directly directed towards outside.
3. A value between "P48.0" and ""P52.0" is shown on the display.
4. If a value beyond this range is shown on the display, you must move the friction clutch. Move the friction clutch until a
value between "P48.0" and "P52.0" is reached. The closer this value is to "P50.0", the more accurately the positioner
determines the stroke travel.

The inner friction clutch is fixed. Therefore, only move the outer friction clutch. This also applies when using an internal
NCS module.

The inner friction clutch has no function. This means you should only adjust the adjustment wheel of the magnet clamp.
Requirement: Parameter '1.YFCT' is set.
① Purging air selector
② Pneumatic connections Y1, PZ and Y2
Figure 5-1 Purge air switch on the pneumatic block; view of the positioner on the pneumatic connection side when the
cover is open

The factory setting is the "IN" position. The following conditions must be fulfilled before activating the automatic initialization:
1. The actuator spindle can be moved completely.
2. The actuator spindle is at a central position after moving.

You have already installed the positioner using the suitable mounting kit.
An ongoing initialization can be interrupted at any time. To do this, press . The settings configured until then are retained.
All parameters are reset to factory settings only if you have explicitly activated the preset settings in the "PRST" parameter.

1. Switch to the "Configuration" mode. To do this, press the button for at least 5 seconds. The display shows the
The setting of the transmission ratio selector is extremely important to commission the positioner. following:

5 ... 20 33°
25 ... 35 90°
40 ... 130 90°
2. Call the "2.YAGL" parameter. To do this, briefly press the button. The following is shown on the display depending on
the setting:
1. Connect a suitable current or voltage source. The positioner is now in the "P manual mode". The current potentiometer
voltage (P) in percent is shown in the upper line of the display, e.g.: "P37.5", and "NOINI" flashes in the bottom line:

3. Check whether the value displayed in the "2.YAGL" parameter matches the setting of the transmission ratio selector. If
2. Connect the actuator and the positioner to the pneumatic lines. required, change the setting of the transmission ratio selector to 33° or 90°.
3. Supply the pneumatic auxiliary power to the positioner. 4. Set the "3.YWAY" parameter to determine the total stroke in mm. The setting of parameter 3 is optional. The display
shows the determined total stroke only at the end of the initialization phase.
– Briefly press the button if you do not require any information about the total stroke in mm. You are then directed
to parameter 4.
– Call the "3.YWAY" parameter. To do this, briefly press the button. The display shows the following:

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The usual adjustment angle for part-turn actuators is 90°.
• Set the transmission ratio selector in the positioner to 90°.
Proceed as follows to set parameter 3:
1. On the scale of the lever, read the value marked by the carrier pin.
2. Set the parameter with the buttons or to the read value.
The following conditions must be fulfilled before activating the initialization:
5. Call the "4.INITA" parameter. To do this, briefly press the button. The display shows the following:
1. You have installed the positioner for the part-turn actuators using the suitable mounting kit.
2. You have connected the actuator and the positioner to the pneumatic lines.
3. Pneumatic auxiliary power is supplied to the positioner.
4. The positioner has been connected to a suitable current or voltage source.

6. Start the initialization process. To do this, press the button for at least 5 seconds until the display shows the
following:
1. The positioner is in the "P manual mode". The current potentiometer voltage P in percent is shown on the upper line in
the display. "NOINI" blinks in the lower line of the display. Examples of corresponding displays are given below:

The positioner runs through five initialization steps during the automatic initialization process. Displays for the
initialization steps from "RUN 1" to "RUN 5" are shown in the lower line on the display. The initialization process depends
on the actuator used, and takes up to 15 minutes. 2. Check whether the mechanical unit can be moved freely in the entire travel range. Move the drive to the respective end
position for this purpose using the or button.
7. The following display indicates that the automatic initialization is complete:

By simultaneously pressing the and buttons, you reach the end position faster.

3. After checking, move the actuator to a central position. This accelerates the initialization process.

1. Press the button. The display shows the following:

The following conditions must be fulfilled before activating the automatic initialization:
1. The travel range of the actuator can be passed through completely.
2. The actuator shaft is at a central position.
The positioner is in the "Configuration" mode.
2. Exit the "Configuration" mode. To do this, press the button for at least 5 seconds.
The software status is displayed.
After releasing the button, the positioner is in "P manual mode". The positioner is not initialized.

An ongoing initialization can be interrupted at any time. To do this, press . The settings configured until then are retained.
All parameters are reset to factory settings only if you have explicitly activated the preset settings in the "PRST" parameter.
See detailed operating instructions for information on manual initialization of linear actuators.
1. Switch to the "Configuration" mode. To do this, press the button for at least 5 seconds until the display shows the
following:

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See detailed operating instructions for information on manual initialization of part-turn actuators.

2. Use the button to change from linear actuator to part-turn actuator until the display shows the following:

3. Call the "2.YAGL" parameter. To do this, briefly press the button. This parameter has already been set to 90°
automatically. The display shows the following: • Repair must be carried out by Siemens authorized personnel only.

Danger of explosion in areas subject to explosion hazard.


4. Call the "4.INITA" parameter. To do this, briefly press the button. The display shows the following: • Only use original accessories or original spare parts.
• Observe all relevant installation and safety instructions described in the instructions for the device or enclosed with the
accessory or spare part.

5. Start the initialization process. To do this, press the button for at least 5 seconds until the display shows the
following: Danger of explosion in areas subject to explosion hazard.
• Connect the device correctly after maintenance.
• Close the device after maintenance work.
Refer to Chapter "Electrical (Page 17)".

The positioner runs through five initialization steps during the automatic initialization process. Displays for the
initialization steps from "RUN1" to "RUN5" are shown in the lower line on the display. The initialization process depends
on the actuator used, and takes up to 15 minutes.
Device damage.
6. The following display indicates that the automatic initialization is complete. The total angle of rotation of the actuator is • Make sure when carrying out cleaning and maintenance work that no moisture penetrates the inside of the device.
shown on the upper line on the display:

Improper modification of parameters could influence process safety.


• Make sure that only authorized personnel may cancel the key locking of devices for safety-related applications.

1. Press the button. The display shows the following:

Danger of explosion in hazardous areas if electrostatic charges develop, for example, when cleaning plastic surfaces with a
dry cloth.
• Prevent electrostatic charging in hazardous areas.

The positioner is in the "Configuration" mode.


2. Exit the "Configuration" mode. To do this, press the button for at least 5 seconds.
The software status is displayed.
Danger of explosion in hazardous areas. Device may overheat du to dust build up.
After releasing the button, the positioner is in "P manual mode". The part-turn actuator is not initialized.
• Remove any dust layers in excess of 5 mm.

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● Clean the outside of the enclosure with the inscriptions and the display window using a cloth moistened with water or a 1. Disconnect the pneumatic auxiliary power supply.
mild detergent. 2. Remove the pipelines.
● Do not use any aggressive cleansing agents or solvents, e.g. acetone. Plastic parts or the painted surface could be 3. Remove the metal screen from the bores carefully.
damaged. The inscriptions could become unreadable.
4. Clean the metal screens, e.g. using compressed air.
5. Insert the screens.

The positioner is maintenance-free to a large extent. Screens are installed in the pneumatic connections of the positioners to 6. Connect the pipelines again.
protect them from rough dirt particles. If there are dirt particles in the pneumatic auxiliary power supply, they damage the 7. Feed the pneumatic auxiliary power supply.
screens and hamper the function of the positioner. Clean the screens as described in the following two chapters.

Send defective devices to the repairs department, together with information on the malfunction and the cause of the
malfunction. When ordering replacement devices, please provide the serial number of the original device. You can find the
serial number on the nameplate.

Electrostatic charges develop when cleaning the positioner in the Makrolon enclosure with a dry cloth, for example.
Enclose the bill of lading, return document and decontamination certificate in a clear plastic pouch and attach it firmly to the
It is imperative you avoid electrostatic charges in the hazardous environment. outside of the packaging. Any devices/replacement parts which are returned without a decontamination declaration will be
cleaned at your expense before further processing. For further details refer to the operating instructions.

1. Disconnect the pneumatic auxiliary power supply.


Return document (http://www.siemens.com/processinstrumentation/returngoodsnote)
2. Remove the lines.
Decontamination declaration (http://www.siemens.com/sc/declarationofdecontamination)
3. Unscrew the cover of the Makrolon enclosure 6DR5..0 or aluminum enclosure 6DR5..3.
4. Unscrew the three screws on the pneumatic terminal strip.
5. Remove the screens and O-rings behind the terminal strip. Devices identified by this symbol may not be disposed of in the municipal waste
disposal services under observance of the Directive 2002/96/EC on waste electronic
6. Clean the screens, e.g. using compressed air.
and electrical equipment (WEEE).
They can be returned to the supplier within the EC or to a locally approved disposal
service. Observe the specific regulations valid in your country.

• The enclosure is damaged due to screwing in the self-tapping screws improperly.


• Ensure that the available thread pitches are used.
• Turn the screws anticlockwise until they engage noticeably in the thread pitch.
• Tighten the self-tapping screws only after they have engaged.

1. Insert the screens into the recesses of the enclosure.


2. Place the O-rings on the screens.
3. Insert the pneumatic terminal strip.
4. Tighten the three screws. Note: With the Makrolon enclosure, the screws are self-tapping.
5. Place the cover and tighten it.
6. Reconnect the pipelines and feed the pneumatic power supply.

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Unrestricted flow (DIN 1945)
• Inlet air valve (ventilate actuator) 2)
2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm)
4 bar (58 psi) 7.1 Nm³/h (31.3 USgpm)
6 bar (87 psi) 9.8 Nm³/h (43.1 USgpm)
Ambient conditions For use indoors and outdoors. • Exhaust valve (deaerate actuator for all versions except
Ambient temperature In hazardous areas, observe the maximum permissible fail in place) 2)
ambient temperature corresponding to the temperature 2 bar (29 psi) 8.2 Nm³/h (36.1 USgpm)
class. 4 bar (58 psi) 13.7 Nm³/h (60.3 USgpm)
• Permissible ambient temperature for operation 2)3) -30 ... +80 °C (-22 ... +176 °F) 6 bar (87 psi) 19.2 Nm³/h (84.5 USgpm)
• Height 2000 m above sea level. At altitudes greater than 2000 m • Exhaust valve (deaerate actuator for fail in place version)
above sea level, use a suitable power supply.
2 bar (29 psi) 4.3 Nm³/h (19.0 USgpm)
• Relative humidity 0 ... 100%
4 bar (58 psi) 7.3 Nm³/h (32.2 USgpm)
Degree of pollution 2
6 bar (87 psi) 9.8 Nm³/h (43.3 USgpm)
Overvoltage category II
Valve leakage < 6⋅10-4 Nm³/h (0.0026 USgpm)
Degree of protection 1) IP66 to IEC/EN 60529 / NEMA 4X
Throttle ratio Adjustable up to ∞: 1
Mounting position Any; in wet environment, pneumatic connections and
outlet opening not upward Auxiliary power consumption in the controlled state < 3.6⋅10-2 Nm³/h (0.158 USgpm)

Vibration resistance Sound pressure level LA eq < 75 dB


• Harmonic oscillations (sine) according to EN 60068-2- 3.5 mm (0.14"), 2 ... 27 Hz, 3 cycles/axle LA max < 80 dB
6/10.2008 1) The following applies to fail in place: 3 ... 7 bar (43.5 to 101.5 psi)
98.1 m/s² (321.84 ft/s²), 27 ... 300 Hz, 3 cycles/axle
2) When using device versions Ex d (6DR5..5-... and 6DR5..6-...), values are reduced by approximately 20%.
• Bumping (half-sine) according to EN 60068-2-27/02.2010 150 m/s² (492 ft/s²), 6 ms, 1000 shocks/axle
• Noise (digitally controlled) according to EN 60068-2- 10 ... 200 Hz; 1 (m/s²)²/Hz (3.28 (ft/s²)²/Hz)
64/04.2009
200 ... 500 Hz; 0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz)
4 hours/axle
How does it work?
• Recommended range of continuous operation of the entire ≤ 30 m/s² (98.4 ft/s²) without resonance peak
• Range of stroke (linear actuator) 3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the
control valve
positioner shaft 16 ... 90°)
Climate class According to IEC/EN 60721-3
• Angle of rotation (part-turn actuator) 30 ... 100°
• Storage 1K5, but -40 ... +80°C (1K5, but -40 ... +176°F)
Mounting method
• Transport 2K4, but -40 ... +80°C (2K4, but -40 ... +176°F)
• On the linear actuator Using mounting kit 6DR4004-8V and, where necessary,
1) Max. impact energy 1 Joule for enclosure with inspection window 6DR5..0 and 6DR5..1 or max. 2 Joule for 6DR5..3 an additional lever arm 6DR4004-8L on actuators
2) At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited. When using position feedback module, only T4 is according to IEC 60534-6-1 (NAMUR) with a fin, columns,
permissible. or a plane surface.
3) The following applies to order suffix (order code) : -40 ... +80 °C (-40 ... +176°F) • On the part-turn actuator Using mounting kit 6DR4004-8D on actuators with
mounting plane according to VDI/VDE 3845 and
IEC 60534-6-2: The required mount must be provided on
the actuator-side.
Weight, positioner without option modules or accessories
Auxiliary power (air supply) Compressed air, carbon dioxide (CO2), nitrogen (N), noble
gases or cleaned natural gas • 6DR5..0 Glass-fiber reinforced polycarbonate enclosure Approximately 0.9 kg (1.98 lb)
• Pressure 1) 1.4 ... 7 bar (20.3 to 101.5 psi) • 6DR5..1 aluminum enclosure, narrow Approx. 1.3 kg (2.86 lb)
Air quality to ISO 8573-1 • 6DR5..2 stainless steel enclosure Approx. 3.9 kg (8.6 lb)
• Solid particulate size and density Class 2 • 6DR5..3 aluminum enclosure Approx. 1.6 kg (3.53 lb)
• Pressure dew point Class 2 (min. 20 K (36°F) below ambient temperature) • 6DR5..5 aluminum enclosure, flameproof Approx. 5.2 kg (11.46 lb)
• Oil content Class 2 • 6DR5..6 stainless steel enclosure, flameproof Approx. 8.4 kg (18.5 lb)

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Material Connections, electrical
• Enclosure • Screw terminals 2.5 mm2 AWG30-14
6DR5..0 Makrolon Glass-fiber reinforced polycarbonate (PC) • Cable gland Without Ex protection as well as with Ex i: M20x1.5 or ½-
6DR5..1 aluminum, narrow GD AISi12 14 NPT
With explosion protection Ex d: Ex d certified M20x1.5, ½-
6DR5..2 stainless steel Austenitic stainless steel 316 Cb, mat. No. 1.4581
14 NPT or M25x1.5
6DR5..3 aluminum GD AlSi12
Connections, pneumatic Female thread G¼ or ¼-18 NPT
6DR5..5 aluminum, flameproof GK AISi12
6DR5..6 stainless steel enclosure, flameproof Austenitic stainless steel 316 L, mat. No. 1.4409 or 316 Ti,
mat. No. 1.4571
• Pressure gauge block Aluminum AIMgSi, anodized or stainless steel 316 L
Control unit
Versions
• Five-point controller Adaptive
• In Makrolon enclosure 6DR5..0 Single-acting and double-acting
• Dead zone
• In aluminum enclosure 6DR5..1 Single-acting
dEbA = auto Adaptive
• In aluminum enclosures 6DR5..3 and 6DR5..5 Single-acting and double-acting
dEbA = 0.1 ... 10 % Can be set as fixed value
• In stainless steel enclosures 6DR5..2 and 6DR5..6 Single-acting and double-acting
Analog-to-digital converter
Torques
• Scanning time 10 ms
• Part-turn actuator fixing screws DIN 933 M6x12-A2 5 Nm (3.7 ft lb)
• Resolution ≤ 0,05 %
• Linear actuator fixing screws DIN 933 M8x16-A2 12 Nm (8.9 ft lb)
• Transmission error ≤ 0,2 %
• Gland pneumatic G¼ 15 Nm (11.1 ft lb)
• Temperature influence ≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
• Gland pneumatic ¼" NPT
Without sealant 12 Nm (8.9 ft lb)
With sealant 6 Nm (4.4 ft lb)
• Cable glands Classification according to pressure For fluid group 1 gases; fulfills requirements according to article 3, paragraph
Screw-in torque for plastic gland in all enclosures 4 Nm (3 ft lb) equipment directive (PED 97/23/EC) 3 (good engineering practice SEP)
Screw-in torque for cable gland made of metal/stainless 6 Nm (4.4 ft lb) CE conformity The applicable directives and applied standards with their revision levels can
steel in Makrolon enclosure be found in the EC declaration of conformity on the Internet.
Screw-in torque for metal/stainless steel glands in 6 Nm (4.4 ft lb)
aluminum/stainless steel enclosure
Screw-in torque for NPT adapter made of 8 Nm (5.9 ft lb) Certificates (http://www.siemens.com/processinstrumentation/certificates)
metal/stainless steel in Makrolon enclosure
Screw-in torque for NPT adapter made of 15 Nm (11.1 ft lb)
metal/stainless steel in aluminum/stainless steel
enclosure
Screw-in torque for NPT gland in the NPT adapter 68 Nm (50 ft lb)
NOTE: To avoid damage to the device, the NPT
adapter must be held in place while the NPT gland is
screwed into the NPT adapter.
Tightening torque for union nut made of plastic 2.5 Nm (1.8 ft lb)
Tightening torque for union nut made of metal/stainless 4 Nm (3 ft lb)
steel
Manometer
• Degree of protection
Manometer made of plastic IP31
Manometer, steel IP44
Manometer made of stainless steel 316 IP54
• Vibration resistance In accordance with DIN EN 837-1

SIPART PS2 (6DR5...) SIPART PS2 (6DR5...)


A5E03436620-07, 10/2015 45 46 A5E03436620-07, 10/2015
Explosion protection in accordance with ATEX/IECEx FM/CSA
Option modules
Explosion protection in accordance with ATEX/IECEx FM/CSA • Non contacting sensor (NCS) T4: -40 ≤ Ta ≤ +90 °C T4: -40 ≤ Ta ≤ +85 °C
Flameproof enclosure encapsulation "d", II 2 G Ex d IIC T6/T4 Gb FM: XP, Class I, Division 1, GP.ABCD 6DR4004-6N..-0-... (-40 ≤ Ta ≤ +194 °F) (-40 ≤ Ta ≤ +185 °F)
"XP" 6DR5..5/6 CSA: XP, Class I, Division 1, GP.CD T6: -40 ≤ Ta ≤ +70 °C T6: -40 ≤ Ta ≤ +70 °C
FM/CSA: (-40 ≤ Ta ≤ +158 °F) (-40 ≤ Ta ≤ +158 °F)
XP, Class I, Zone 1, AEx d, IIC, T6/T4 • External position detection system T4: -40 ≤ Ta ≤ +90 °C T4: -40 ≤ Ta ≤ +85 °C
Intrinsic safety "i", "IS"
C73451-A430-D78 (-40 ≤ Ta ≤ +194 °F) (-40 ≤ Ta ≤ +185 °F)
T6: -40 ≤ Ta ≤ +60 °C T6: -40 ≤ Ta ≤ +60 °C
• 6DR5..0/1/2/3 II 2 G Ex ia IIC T6/T4 Gb IS / I, II / 1 / A-D (-40 ≤ Ta ≤ +140 °F) (-40 ≤ Ta ≤ +140 °F)
IS / 1 / AEx / Ex ib / IIC, Gb
II 3 G Ex ic IIC T6/T4 Gc
• 6DR5..1/2/3 II 2 D Ex ia IIIC T110°C Db IS / III / 1 / E-G
IS / 21 / AEx / Ex ib / IIIC, Db, T110°C Explosion protection in accordance with ATEX/IECEx FM/CSA

Non-sparking "nA", "NI" NI / I / 2 / A-D • 6DR5ayb-0 def-g.Ah-Z ... -30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
II 3 G Ex nA IIC T6/T4 Gc with the data (c = D or K)
NI / 2 / AEx / Ex nA, Ex ic / IIC, Gc
• 6DR5ayb-0 def-g.Ah-Z -40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F)
Dust, protection by means of enclosure II 2 D Ex tb IIIC T100°C Db DIP / II, III / 1 / E-G with the data (c= D or K)
"t", "DIP" DIP / 21 / AEx / Ex tb / IIIC, Db,
• 6DR5.. -.D/K... T100°C
• 6DR5.. -.D/K...
• 6DR5.. -.D/K...
• 6DR5.. -.E...
Note when using an actuator with natural gas that this can escape at the following points:
● At the exhaust air outlet with sound absorber.
● At the enclosure vent.
a = 0, 2, 5, 6 c = E, G, D, F, K g = 0, 2, 6, 7, 8 A20, A40, C20, D53, D54, ● At the control air outlet near the pneumatic connections.
D55, D56, F01, K**, L1A,
M40,
R**, S**, Y**
* = any character The positioner is supplied as standard with a sound absorber. To provide an outlet for the exhaust air, replace the sound
absorber by a G¼ pipe coupling.
y = 1, 2 d = G, N, M, P, R, S h = 0, 1, 2, 3, 4, 9
b = 0, 1, 2, 3 e = 0, 1, 2, 3
Enclosure ventilation and control air outlet cannot be collected and channeled off.
f = 0, 1, 2, 3
Please refer to the following table for the maximum ventilation values.

Explosion protection in accordance with ATEX/IECEx FM/CSA


• 6DR5ayb-0cdef-g.Ah-Z ... T4: -30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
T6: -30 ≤ Ta ≤ +50 °C (-22 ≤ Ta ≤ +122 °F)
• 6DR5ayb-0cdef-g.Ah-Z T4: -40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F)
T6: -40 ≤ Ta ≤ +50 °C (-40 ≤ Ta ≤ +122 °F)
Ventilation of the enclosure volume. Purge air switch is at Operation, typical 0.14 0.14
Position feedback module (already fitted "IN": Operation, max. 0.60 0.60
or can be retrofitted)
Error case, max. 60.0 60.0
• Already fitted:
6DR5ayb-0cde -g.Ah-Z ... Ventilation via the control air outlet near the pneumatic Operation, typical 1.0 2.0
T4: -30 ≤ Ta ≤ +80 °C (-22 ≤ Ta ≤ +176 °F)
with the data (f = 1 or 3) connections: Operation, max. 8.9 9.9
• Can be retrofitted 6DR4004-6J Error case, max. 66.2 91.0
• Already fitted and can be retrofitted: T4: -40 ≤ Ta ≤ +80 °C (-40 ≤ Ta ≤ +176 °F) Ventilation through the exhaust air outlet with a sound Operation, max. 358.21) 3391),
6DR5ayb-0cde -g.Ah-Z
absorber Error case, max.
with the data (f = 1 or 3)
Volume Max. [l] 1.26 1.23
1) Depending on the actuating pressure and volume of the actuator as well as the frequency of control. The maximum flow
rate is 470 Nl/min at a differential pressure of 7 bar.

SIPART PS2 (6DR5...) SIPART PS2 (6DR5...)


A5E03436620-07, 10/2015 47 48 A5E03436620-07, 10/2015
6DR52.. With HART, explosion-protected
6DR53.. Without HART, not explosion-protected
W
Load voltage at 20 mA ≤ 0.2 V (= 10 Ω) ≤ 0.2 V (= 10 Ω) ≤ 1 V (= 50 Ω) ≤ 1 V (= 50 Ω)
• Rated signal range 0/4 ... 20 mA
Auxiliary power UH 18 ... 35 V DC 18 ... 35 V DC 18 ... 30 V DC 18 ... 30 V DC
• Test voltage 840 V DC, 1 s
• Current consumption IH (UH - 7.5 V)/2.4 kΩ [mA]
• Binary input BIN1 (terminals Suitable only for floating contact; max. contact load
9/10; galvanically < 5 μA with 3 V For connecting to circuits with - - Ui = 30 V "ic":
connected to basic device) the following peak values Ii = 100 mA Ui = 30 V
Pi = 1 W Ii = 100 mA
"nA"/"t":
6DR50.. and 6DR53.. Without HART Un ≤ 30 V
6DR51.. and 6DR52.. With HART In ≤ 100 mA

Current to maintain the ≥ 3,6 mA Effective inner capacitance Ci - - 22 nF 22 nF


auxiliary power Effective inner inductance Li - - 0.12 mH 0.12 mH
Required load voltage UB Galvanic isolation Between UH and IW Between UH and IW Between UH and IW Between UH and IW
(corresponds to Ω at 20 mA) (2 intrinsically safe
• Without HART (6DR50..) circuits)

Typical 6.36 V (= 318 Ω) 6.36 V (= 318 Ω) 7.8 V (= 390 Ω) 7.8 V (= 390 Ω)


Max. 6.48 V (= 324 Ω) 6.48 V (= 324 Ω) 8.3 V (= 415 Ω) 8.3 V (= 415 Ω)
• Without HART (6DR53..) HART version 7

Typical 7.9 V (= 395 Ω) - - - PC parameter assignment SIMATIC PDM; supports all device objects. The software is not included in the scope of
software delivery.
Max. 8.4 V (= 420 Ω) - - -
• With HART (6DR51..)
Typical 6.6 V (= 330 Ω) 6.6 V (= 330 Ω) - -
Max. 6.72 V (= 336 Ω) 6.72 V (= 336 Ω) - -
• With HART (6DR52..)
Typical - 8.4 V (= 420 Ω) 8.4 V (= 420 Ω) 8.4 V (= 420 Ω)
Max. - 8.8 V (= 440 Ω) 8.8 V (= 440 Ω) 8.8 V (= 440 Ω)
Bus-powered
• Static destruction limit ± 40 mA ± 40 mA - -
Effective inner capacitance Ci - - Bus voltage 9 ... 32 V 9 ... 32 V 9 ... 24 V 9 ... 32 V
• Without HART - - 11 nF "ic": 11 nF For connecting to circuits with
• With HART - - 11 nF "ic": 11 nF the following peak values
Effective inner inductance Li - - • Bus connector with FISCO - - Ui = 17.5 V "ic":
supply unit Ii = 380 mA Ui = 17.5 V
• Without HART - - 207 µH "ic": 207 µH
Pi = 5.32 W Ii = 570 mA
• With HART - - 310 µH "ic": 310 µH "nA"/"t":
For connecting to circuits with - - Ui = 30 V "ic": Un ≤ 32 V
the following peak values Ii = 100 mA Ui = 30 V • Bus connector with barrier Ui = 24 V "ic":
Pi = 1 W Ii = 100 mA
Ii = 250 mA Ui = 32 V
"nA"/"t": Pi = 1.2 W "nA"/"t":
Un ≤ 30 V
Un ≤ 32 V
In ≤ 100 mA
Effective inner capacitance Ci - - Negligible Negligible
Effective inner inductance Li - - 8 μH "ic":
8 μH
Current consumption 11.5 mA ± 10 %

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A5E03436620-07, 10/2015 49 50 A5E03436620-07, 10/2015
Communication group and According to the technical specification of the Fieldbus Foundation for H1 communication
class
Additional fault current 0 mA
Function blocks Group 3, Class 31PS (Publisher Subscriber)
1 resource block (RB2)
Electrically isolated from bus circuit and binary input 1 analog output function block (AO)
1 PID function block (PID)
1 transducer block (standard advanced positioner valve)
• Input resistance > 20 kΩ Execution times of the blocks AO: 60 ms
PID: 80 ms
• Signal status "0" (shutdown 0 ... 4.5 V or unused
active) Physical layer profile 123, 511
• Signal status "1" (shutdown 13 ... 30 V FF registration Tested with ITK 5.0
inactive) Device address 22 (when delivered)
• For connecting to power - - Ui = 30 V "nA":
source with the following Ii = 100 mA Un ≤ 30 V
peak values Pi = 1 W In ≤ 100 mA
"ic":
Ui = 30 V
Ii = 100 mA
• Effective internal - - Negligible Negligible
capacitance and inductance

6DR4004-8A 6DR4004-6A 6DR4004-6A


Jumpered or connection to switch contact.
3 binary output circuits
Suitable only for floating contact; max. contact load
< 5 μA with 3 V • Alarm output A1: Terminals 41 and 42
• Alarm output A2: Terminals 51 and 52
• Fault message output: Terminals 31 and 32
Galvanic isolation
• Auxiliary voltage UH ≤ 35 V - -
• For basic device without Ex Galvanic isolation between the basic device and the input for safety shutdown and the
protection and for basic outputs of option modules. • Signal status
device with Ex d High (not addressed) Conductive, R = 1 kΩ, ≥ 2.1 mA ≥ 2.1 mA
• For basic device Ex "ia" The basic device, the input for safety shutdown, and the outputs of option modules are +3/-1 % *)
individual intrinsically safe circuits. Low *) (addressed) Deactivated, IR < 60 µA ≤ 1.2 mA ≤ 1.2 mA
• For basic device Ex "ic", Galvanic isolation between the basic device and the input for safety shutdown and the *) The status is also Low if the *) When using in the Switching thresholds for Switching thresholds for
"nA", "t" outputs of option modules. basic device is faulty or without flameproof housing, the supply as per EN 60947- supply as per EN 60947-
Test voltage DC 840 V, 1 s a auxiliary power. current consumption must 5-6: 5-6:
be restricted to 10 mA per UH = 8.2 V, Ri = 1 kΩ UH = 8.2 V, Ri = 1 kΩ
output.
• For connecting to circuits with the - Ui = 15 VDC "ic":
Communication Layers 1 + 2 as per PROFIBUS PA, transmission technique as per IEC 1158-2;
following peak values Ii = 25 mA Ui = 15 VDC
slave function layer 7 (protocol layer) as per PROFIBUS DP,
Pi = 64 mW I i = 25 mA
standard EN 50170 with the extended PROFIBUS functionality
(all data is acyclic, manipulated variable, feedbacks and statuses are additionally cyclic) "nA"/"t":
Un ≤ 15 VDC
C2 connections Four connections with the master class 2 are supported; automatic connection
termination 60 s after interruption in communication Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF
Device profile PROFIBUS PA profile B, version 3.0; over 150 objects Effective internal inductance - Li = negligibly small Li = negligibly small
Response time for a master Typically, 10 ms
telegram 1 binary input circuit
Device address 126 (in the as-delivered condition) • Binary input BI2: Terminals 11 and 12, terminals 21 and 22 (jumper)
PC parameter assignment SIMATIC PDM; supports all device objects. The software is not included in the scope of • Galvanically connected with the
software delivery. basic device
Signal status 0 Floating contact, open
Signal status 1 Floating contact, closed
Contact load 3 V, 5 μA

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A5E03436620-07, 10/2015 51 52 A5E03436620-07, 10/2015
6DR4004-8G 6DR4004-6G 6DR4004-6G
• Electrically isolated from the basic
device Limit encoder with slotted initiators
and fault message output
Signal status 0 ≤ 4.5 V or open
2 slotted initiators
Signal status 1 ≥ 13 V
• Binary output (limit transmitter) A1: Terminals 41 and 42
Internal resistance ≥ 25 kΩ
• Binary output (limit transmitter) A2: Terminals 51 and 52
• Static destruction limit ± 35 V - -
• Connection 2 wire technology in accordance with EN 60947-5-6 (NAMUR), for switching
• Connecting to circuits with the - Ui = DC 25.2 V "ic": amplifiers connected on load side
following peak values Ui = DC 25.2 V
• Signal state High > 2.1 mA
"nA"/"t": (not triggered)
Un ≤ DC 25.5 V • Signal state Low (triggered) < 1.2 mA
Effective internal capacitance - Ci = negligibly small Ci = negligibly small • 2 slotted initiators Type SJ2-SN
Effective internal inductance - Li = negligibly small Li = negligibly small • Function NC contact (NC, normally closed)
Galvanic isolation The three outputs, the BI2 input and the basic device are galvanically isolated from • Connecting to circuits with the Nominal voltage 8 V; Ui = DC 15 V "ic":
each other. following peak values current consumption: Ii = 25 mA Ui = DC 15 V
Test voltage DC 840 V, 1 s ≥ 3 mA (limit not Pi = 64 mW Ii = 25 mA
activated), "nA":
≤ 1 mA (limit activated) Un ≤ DC 15 V
Pn ≤ 64 mW
(only in temperature class Effective internal capacitance - Ci = 41 nF Ci = 41 nF
T4) Effective internal inductance - Li = 100 μH Li = 100 μH

6DR4004-8J 6DR4004-6J 6DR4004-6J


1 fault message output
Direct current output for position
• Binary output: Terminals 31 and 32
feedback
• Connection At switching amplifier in accordance with EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri =
1 current output, terminals 61 and 62
1 kΩ).
2-wire connection
• Signal state High R = 1.1 kΩ > 2.1 mA > 2.1 mA
Rated signal range 4 ... 20 mA, short-circuit proof (not triggered)
Dynamic range 3.6 ... 20.5 mA • Signal state Low (triggered) R = 10 kΩ < 1.2 mA < 1.2 mA
Auxiliary voltage UH +12 ... +35 V +12 ... +30 V +12 ... +30 V • Auxiliary power UH UH ≤ DC 35 V - -
External load RB [kΩ] ≤ (UH [V] - 12 V)/I [mA] I ≤ 20 mA

Transmission error ≤ 0.3 % • Connecting to circuits with the - Ui = DC 15 V "ic":


following peak values Ii = 25 mA Ui = DC 15 V
Temperature influence ≤ 0.1%/10 K (≤ 0.1%/18 °F) Pi = 64 mW Ii = 25 mA
Resolution ≤ 0.1 % "nA":
Residual ripple ≤1% Un ≤ DC 15 V
Pn ≤ 64 mW
For connecting to circuits with the Ui = DC 30 V "ic":
following peak values Ii = 100 mA Ui = DC 30 V Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF
Pi = 1 W Ii = 100 mA Effective internal inductance - Li = negligibly small Li = negligibly small
"nA"/"t": Galvanic isolation The 3 outputs are galvanically isolated from the basic device.
Un ≤ DC 30 V
In ≤ 100 mA Test voltage DC 840 V, 1 s
Pn ≤ 1 W
Effective internal capacitance - Ci = 11 nF Ci = 11 nF
Effective internal inductance - Li = negligibly small Li = negligibly small
Galvanic isolation Safe galvanic isolation from alarm option and basic device
Test voltage DC 840 V, 1 s

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A5E03436620-07, 10/2015 53 54 A5E03436620-07, 10/2015
6DR4004-8K 6DR4004-6K 6DR4004-6K EMC filter module type C73451-A430-D23 is required for NCS sensor or an external potentiometer.
Limit encoder with mechanical External position sensor (potentiometer or NCS; option) with the following maximum values
switching contacts Resistance of the external potentiometer 10 kΩ
2 limit contacts Maximum values when powered by the - Uo = 5 V Uo = 5 V
• Binary output 1: Terminals 41 and PROFIBUS basic device Io = 75 mA static Io = 75 mA
42 Io = 160 mA short-term Po = 120 mW
• Binary output 2: Terminals 51 and Po = 120 mW
52 Maximum values when powered by other - Uo = 5 V Uo = 5 V
• Max. switching current AC/DC 4A - - basic devices Io = 100 mA Io = 75 mA
Po = 33 mW Po = 120 mW
• For connecting to circuits with the - Ui = 30 V "ic": Co = 1 μF Co = 1 μ F
following peak values Ii = 100 mA Ui = 30 V Lo = 1 mH Lo = 1 mH
Pi = 750 mW Ii = 100 mA
Galvanic isolation Galvanically connected with the basic device
"t":
Un = 30 V
In = 100 mA
Effective internal capacitance - Ci = negligibly small Ci = negligibly small
Effective internal inductance - Li = negligibly small Li = negligibly small
Travel range
• Max. switching voltage AC/DC 250 V/24 V DC 30 V DC 30 V
• Linear actuator 6DR4004-.N.20 3 to 14 mm (0.12 to 0.55")
1 fault message output
• Linear actuator 6DR4004-.N.30 10 to 130 mm (0.39 to 5.12"); up to 200 mm (7.87") on request
• Binary output: Terminals 31 and
32 • Part-turn actuator 30 to 100°
• Connection On switching amplifier according to EN 60947-5-6: (NAMUR), UH = 8.2 V, Ri = Linearity (after corrections made by ±1%
1 kΩ). positioner)
• Signal state High R = 1.1 kΩ > 2.1 mA > 2.1 mA Hysteresis ± 0.2 %
(not triggered)
Temperature influence (range: ≤ 0.1 %/10 K (≤ 0.1 %/18 °F) for -20 to +90 °C (-4 to +194 °F)
• Signal state Low (triggered) R = 10 kΩ < 1.2 mA < 1.2 mA rotation angle 120° or stroke 14 mm) ≤ 0.2%/10 K (≤ 0.2%/18 °F) for -40 to -20 °C (-40 to -4 °F)
• Auxiliary power UH ≤ DC 35 V - -
Climate class According to IEC/EN 60721-3
I ≤ 20 mA
• Storage 1K5, but -40 to +90 °C (-40 to +194 °F)
• Connecting to circuits with the - Ui = 15 V "ic" :
following peak values Ii = 25 mA Ui = 15 V • Transport 2K4, but -40 to +90 °C (-40 to +194 °F)
Pi = 64 mW Ii = 25 mA Vibration resistance
"t": • Harmonic oscillations 3.5 mm (0.14"), 2 to 27 Hz, 3 cycles/axis
Un = 15 V (sine) according to IEC 60068-2-6 98.1 m/s² (321.84 ft/s²), 27 to 300 Hz, 3 cycles/axis
In = 25 mA
• Bumping according to IEC 60068- 300 m/s2(984 ft/s2), 6 ms, 4000 shocks/axis
Effective internal capacitance - Ci = 5.2 nF Ci = 5.2 nF 2-29
Effective internal inductance - Li = negligibly small Li = negligibly small Torque for cable gland nut made of Plastic Metal Stainless steel
Galvanic isolation The 3 outputs are galvanically isolated from the basic device 2.5 Nm (1.8 ft lb) 4.2 Nm (3.1 ft lb) 4.2 Nm (3.1 ft lb)
Test voltage DC 3150 V, 2 s Housing protection type IP68 according to IEC/EN 60529; NEMA 4X / Encl. Type 4X
Rated condition height Max. 2 000 m mean sea - - For connecting to circuits with the - Ui = 5 V Ui = 5 V
level Use a suitable power following peak values Ii = 160 mA
supply at an altitude of Pi = 120 mW
more than 2 000 m above
Effective internal capacitance - Ci = 180 nF Ci = 180 nF
sea level.
Effective internal inductance - Li = 922 μH Li = 922 μH

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A5E03436620-07, 10/2015 55 56 A5E03436620-07, 10/2015
CE conformity The applicable directives and applied standards with their revision levels can be
found in the EC declaration of conformity on the Internet.
• Enclosure Makrolon® glass-fiber reinforced polycarbonate (PC)
Weight, basic device Approximately 0.9 kg (1.98 lb)
Torque for cable gland nut made of plastic 2.5 Nm
• Intrinsic safety "ia" Zone 1: IS, Class I, Divison 1, ABCD
IS, Class I, Zone 1, AEx ib, IIC For connecting to circuits with the Ui = 5 V
II 2 G Ex ia IIC T6/T4 Gb
following peak values Ii = 100 mA
• Intrinsic safety "ic" Zone 2: - Pi = 160 mW
II 3 G Ex ic IIC T6/T4 Gc Ci = negligibly small
Li = negligibly small
• Non-sparking "nA" Zone 2: NI, Class I, Divison 2, ABCD
NI, Class I, Zone 2, AEx nA, IIC
II 3 G Ex nA IIC T6/T4 Gc
T4: -40 ... +90 °C (-40 ... +194 °F) T4: -40 ... +85 °C (-40 ... +185 °F) CE conformity The applicable directives and applied standards with their revision levels can
T6: -40 ... +70 °C (-40 ... +158 °F) T6: -40 ... +70 °C (-40 ... +158 °F) be found in the EC declaration of conformity on the Internet.

Intrinsic safety "ia" Zone 1:


6DR4004-5L 6DR4004-5LE 6DR4004-5LE
II 2 G Ex ia IIC T6/T4 Gb
Linearity (after corrections made by ±1% ±1% ±1%
positioner) Zone 21:
Hysteresis ± 0.2 % ± 0.2 % ± 0.2 % II 2 D Ex ia IIIC T110°C Db
Intrinsic safety "ic" Zone 2:
II 3 G Ex ic IIC T6/T4 Gc
Non-sparking "nA" Zone 2:
II 3 G Ex nA IIC T6/T4 Gc
• Perm. ambient temperature for operation -40 ... +90 °C (-40 ... +194 °F) T4: -40 ... +90 °C (-40 ... +194 °F)
T6: -40 ... +60 °C (-40 ... +140 °F)
Degree of protection 1) IP66 to IEC/EN 60529 / NEMA 4X
Climate class According to IEC/EN 60721-3
• Storage 1K5, but -40 ... +90 °C (1K5, but -40 ... +194 °F)
• Transport 2K4, but -40 ... +90 °C (2K4, but -40 ... +194 °F)
• Operation 4K3, but -40 ... +90 °C (4K3, but -40 ... +194 °F)
1 ) Impact energy max. 1 joule.

How does it work? The certificates can be found on the enclosed CD and on the Internet under:
• Range of stroke (linear actuator) 3 ... 130 mm (0.12 ... 5.12") (angle of rotation of the
Certificates (http://www.siemens.com/processinstrumentation/certificates)
positioner shaft 16 to 90°)
• Angle of rotation (part-turn actuator) 30 ... 100°
Mounting method
• On the linear actuator Using mounting kit 6DR4004-8V and, where necessary,
an additional lever arm 6DR4004-8L on actuators
according to IEC 60534-6-1 (NAMUR) with a fin, columns,
or a plane surface.
If this documentation does not provide complete answers to any technical questions you may have, contact Technical
• On the part-turn actuator Using mounting kit 6DR4004-8D on actuators with Support at:
mounting plane according to VDI/VDE 3845 and
IEC 60534-6-2: The required mount must be provided on ● Support request (http://www.siemens.com/automation/support-request)
the actuator-side. ● More information about our Technical Support is available at
Material Technical support (http://www.siemens.com/automation/csi/service)

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A5E03436620-07, 10/2015 57 58 A5E03436620-07, 10/2015
Internet Service & Support
In addition to our documentation, Siemens provides a comprehensive support solution at:
● Service&Support (http://www.siemens.com/automation/service&support) where you will find support news, support
documents including EDDs and software, and also support from experts.

If you have additional questions about the device, please contact your local Siemens representative.
Find your local contact partner at:
● Partner (http://www.automation.siemens.com/partner)
Documentation for various products and systems is available at:
● Instructions and manuals (http://www.siemens.com/processinstrumentation/documentation)

SIPART PS2 product information (http://www.siemens.com/sipartps2)


E-mail (mailto:[email protected])
Process instrumentation catalog (http://www.siemens.com/processinstrumentation/catalogs)

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose
use by third parties for their own purposes could violate the rights of the owner.

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot
be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any
necessary corrections are included in subsequent editions.

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG

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A5E03436620, 10/2015
A5E03436620-07, 10/2015 59
Declutchable manual gearboxes: aluminium - GD serie
A declutchable manual gear should be inserted between valve and actuator, in order to secure valve operation
in case of emergency.
In normal conditions, the gearbox is declutched so that the handweel does not rotate when working the ac-
tuator.
In case of emergency (air failure) the gearbox can be easily engaged by means of the side lever and the valve
can be easily operated by means af the handwheel.

A
D

release lever
C

B
E

GD series
body: aluminium handwheel: steel
worm gears: steel protection: IP65
sector gear: ductile iron T: -20 / +120 °C
shalt: stainless steel

gear output weight Emergency lever (only double acting)


A B C D E
ratio Nm Kg
A
GD070 118 150 34 200 52.2 1:38 470 3.5

GD102 125 180 35,5 300 65 1:36 810 5.6

GD140 162 300 50 400 85 1:50 1310 12.5


B
GD165 181 395 61 600 105 1:55 2800 22.5

GD254 205 400 80 700 130 1:52 5500 26

DA actuator SR actuator emergency gearbox


Ø valve
double action spring return type

DN 40÷150 UT 20÷45 UTS 20÷35 GD070

DN 40÷300 UT 35÷55 UTS 35÷50 GD102

DN 200÷400 UT 50÷65 UTS 55÷65 GD140


A B
DN 450÷600 UT 60 UTS 70÷75 GD165 UT10 ÷ UT20 218 35
UT25 ÷ UT35 218 35
DN 600÷800 UT 70÷75 ≈ GD254 UT40 ÷ UT50 385 40

« iNdEx ACT 02/13 - EN - pAgE 12


SOFT SEAT

PD, KI Series 1
• technical data 1
• components DN 50-300 2
• components DN 350-500 3
KI Series 4
• components DN 600-800 4
KA, KX tecnical data 5
• technical data 5
KA series 6
• components DN 40-300 6
• components DN 350-400 7
• components DN 450-500 8
• components DN 600-800 9
KX series 10
• components DN 50-250 10
PD, KI, KA Series 11
• dimensions tables 11
BFKI, BVKX, BLKX Series 12
• dimensions tables 12

Torque values tables 13


Head losses tables 14
Flange and bolts tables 15
Flanges 16
Tests 16

Installation instructions 17
Handlever 18
Gearbox 19
• aluminium body 19
• cast iron body 20

Ghibson Italia srl reserves the right to make alterations to this catalog and/or the
equipment produced without prior notice and accets no liability in this regard.
BVPD - Wafer BLPD - Lug BVKI - Wafer BLKI - Lug BFKI BVPD - Wafer BLPD - Lug BVKI - Wafer BLKI - Lug BFKI
DN 50 - 600 • 2” - 24” DN 40 - 800 • 1”1/2 - 32” DN 80 - 600 • 3” - 24” DN 50 - 300 • 2” - 12” DN 40 - 300 • 1”1/1 - 12” DN 80 - 300 • 3” - 12”
PN 6-10-16 • ANSI 150 PN 10-16 • ANSI 150 PN 6-10-16 • ANSI 150
Max working pressure:
BVPD/BLPD DN 50÷600: 6 Bar 12
• A150 11
BVKI/BLKI DN 40÷500: 16 Bar
• A150 10
1
BVKI/BLKI DN 600÷800: 10 Bar
• A150 6
BFKI DN 80÷600: 16 Bar GOST
7
• A150
KI series to be used also with vacuum
Design: 6*
EN 593 ~ EN 736 ~ EN 12516 ~ EN 1092
4
ISO 5211 ~ DIN 3337 ~ API 609
3
PED 97/23/EC(cat III) Mod H
Face to face: RAL 1018
for gas
DIN EN 558-1 Series 20 ~ ISO 5752 Series 20
BS-5155 Series 4 ~ MSS-SP67 RAL 5009
API609 cat.A ~ NFE 29305-1 standard

Testing:
EN 12266-1 Rate A ~ ISO 5208 Rate A 2
DIN 3230 ~ API 598
Tag: All valves are supplied with a metallic label in com-
EN 19 ~ MSS SP-25 pliance with PED directive.

BODY BVPD BVKI / BLKI BFKI


material references standard coating DN DN DN
Ductile iron EN-GJS 400-15 (GS400) Epoxy RAL 5009 50-600 40-800 80-600
Carbon steel ASTM A216-WCB Epoxy RAL 9005 50-600 40-800 -
Stainless steel ASTM A351 CF8M (A316) - 50-600 40-800 - Wafer body
Aluminuim-bronze ASTM B148-C958.00 - 50-600 40-800 - 8
Aluminium (Pmax 10Bar) EN AB 46400 Epoxy RAL 7024 50-600 40-500 -
9
DISC BVPD BVKI / BLKI BFKI 5
material references standard coating DN DN DN Double Flange body
Steel ASTM A105 Zinc 50-100 50-100 80-100
Ductile iron EN-GJS 400-15 (GS400) Zinc 125-600 125-800 125-600 Lug Body
Stainless steel ASTM A351 CF8M (A316) - 50-600 40-800 80-600 item q.ty part material item q.ty part material
Aluminuim-bronze ASTM B148-C958.00 - 50-600 40-800 80-600 • ductile iron GS400
1 1 body 4 1 upper shaft • AISI 430
Hastelloy® ASTM A494 CX2MW - 50-600 40-800 80-600 (BFKI only • A216 - WCB • AISI 316 (on request)
Monel® GS400) • A352 - LCB
ASTM A494 M35-1 - 50-600 40-800 80-600
• A351 - CF8M (AISI 316) 5 1 lower shaft • AISI 430
• aluminium-bronze • AISI 316 (on request)
BODY RUBBER SEAT DN 40/500 replaceable - DN 600/800 vulcanized not replaceable
• aluminium (only WAFER)
ref. designation trade name working temp. applications 1 bush • bronze
2 1 disc • ductile iron GS400
NBR nitrile rubber BUNA® -25°C / +100°C oils, hydrocarbons, gas, air, water • A351 - CF8M (AISI 316) 1 bush • bronze
EPDM copolymer EPDM - -35°C / +130°C water, sea water, steam, diluted acids • aluminium-bronze 1 shaft packing • NBR (BUNA®)
EPDM HT • Hastelloy® • FKM (VITON®) on request
copolimery EPDM HT - -30°C / +135°C water, sea water, steam, diluted acids
• Monel®
CO carboxide - -25°C / +100°C dust, air 8 1 plug packing • aluminium
FKM VITON® -20°C / +200°C oils, acids, hydrocabons 1 body seat • NBR (BUNA®)
• EPDM 9 1 threaded plug • zinc plated steel
(replaceable)
CR polychloroprene NEOPRENE® -20°C / +100°C alkali, bases, water • EPDM HT 10 1 stop ring • steel
NR natural rubber - -40°C / + 80°C glycols, abrasive media • FKM (VITON®)
11 1 • IXEF (DN 40-150)
MVQ silicon rubber SILOPREN ®
-60°C / +190°C water, food, drinks • carboxide
• aluminium (DN 200-300)
• polychloroprene (NEOPRENE®)
CSM chlorosulfonated polyethylene HYPALON® -20°C / +125°C acids, mineral bases, alcohols, hydrocarbons
• natural rubber 12 2 screw • zinc plated steel
On request can be supplied other materials as: LCB, Hastelloy, Monel, Uranus, Alloy, DUPLEX, Special steels, Special bronzes. • silicon
Coating on request: RILSAN®, Halar®, Chenisil®

« INDEX SM 05/15 - EN - PAGE 1 « INDEX SM 05/15 - EN - PAGE 2


BVPD - Wafer BLPD - Lug BVKI - Wafer BLKI - Lug BFKI BVPD - Wafer BLPD - Lug BVKI - Wafer BLKI - Lug BFKI
DN 350 - 500 • 14” - 20” DN 350 - 500 • 14” - 20” DN 350 - 500 • 14” - 20” DN 600 • 24” DN 600 - 800 • 24” - 32” DN 600 • 24”
PN 6-10-16 • ANSI 150 PN 10-16 • ANSI 150 PN 6-10-16 • ANSI 150 PN 6-10-16 • ANSI 150 PN 6-10-16 • ANSI 150 PN 6-10-16 • ANSI 150

14 17 18
15
10
14
13 16
12
11 1
1 5

6
7
15
6
20
4 21
3 19 4
3

Wafer body

2
2

20
21
19
8
6
9
7
11
5 12
6 Wafer body
10
13
7
8
5 Double Flange body
9 Double Flange body
Lug body
Lug body item q.ty part material item q.ty part material
1 1 body • ductile iron GS400 7 2 O.ring housing • AISI 316
item q.ty part material item q.ty part material
(BFKI only GS400) • A216-WCB
• ductile iron GS400 8 1 shaft support • Bronze
1 1 body 5 1 lower shaft • AISI 430 • A352-LCB
(BFKI only • A216-WCB • AISI 316 (on request) • A351-CF8M (AISI 316) 9 2 adjusting screw • AISI 316
GS400) • A352-LCB • aluminium-bronze
• A351-CF8M (AISI 316) 5 bush • bronze 10 1 • zinc plated steel
• aluminium-bronze • steel+PTFE 2 1 disc • ductile iron GS400
1 O.ring • NBR (BUNA®)
• aluminium (only WAFER) (DN 450-500) • A351 - CF8M (AISI 316)
• ductile iron GS400 • aluminium-bronze 1 O.ring • NBR (BUNA®)
2 1 disc 1 • NBR (BUNA ) ®

• A351-CF8M (AISI 316) • Hastelloy®


13 6 screw • zinc plated steel
• aluminium-bronze • Monel®
• Hastelloy® 8 1 • zinc plated steel 14 1 • zinc plated steel
3 1 body seat • NBR (BUNA®)
• Monel® 9 4 screw • zinc plated steel (vulcanized • EPDM 1 O.ring • NBR (BUNA®)
1 body seat • NBR (BUNA®) not replaceable) • EPDM HT
(replaceable) • EPDM 10 1 • zinc plated steel 1 O.ring • NBR (BUNA®)
• FKM (VITON®)
• EPDM HT 11 1 stop ring • steel 17 4 screw • zinc plated steel
• FKM (VITON®) 4 1 shaft • AISI 303
1 O.Ring • NBR (BUNA®) • AISI 316 (on request) 18 1 key • steel
• carboxide
• polychloroprene (NEOPRENE®) 1 O.Ring • NBR (BUNA®) 5 bush • steel + PTFE 19 3 screw • AISI 316
• natural rubber 14 2 screw • zinc plated steel 3 O.ring • PTFE
2 shaft O.ring • NBR (BUNA®)
• silicon
15 1 key • steel C40 • FKM (VITON®) on request 21 3 washer • AISI 316
4 1 upper shaft • AISI 430
• AISI 316 (on request)
« INDEX SM 05/15 - EN - PAGE 3 « INDEX SM 05/15 - EN - PAGE 4
BVKA - Wafer BLKA - Lug BVKX - Wafer BLKX - Lug BVKA - Wafer BLKA - Lug
DN 40 - 800 • 1"1/2 - 32” DN 50 - 250 • 2” - 10” DN 50 - 200 • 2” - 8” DN 40 - 150 • 11/2” - 6”
PN 10-16 • ANSI 150
item q.ty part material
Max working pressure: 12
1 1 body • ductile iron GS400
BVKA/BLKA DN 40÷800: 20 Bar 11 4 • A216 - WCB
• A150 • A352 - LCB
1
10 • A351 - CF8M (AISI 316)
BVKX DN 50÷250: 25 Bar
2 1 disc • A351 - CF8M (AISI 316)
BLKX DN 50÷200: 25 Bar 3 6 • aluminium-bronze
• A150 • Hastelloy®
To be used also with vacuum • Monel®
GOST BVKA
BVK 7
1 body seat • NBR (BUNA®)
Design: (replaceable) • EPDM
• EPDM HT
EN 593 ~ EN 736 ~ EN 12516 ~ EN 1092
• FKM (VITON®)
ISO 5211 ~ DIN 3337 ~ API 609
PED 97/23/EC(cat III) Mod H 4 1 upper shaft • AISI 430
• AISI 316 (on request)
5 1 lower shaft • AISI 430
Face to face: • AISI 316 (on request)
DIN EN 558-1 Series 20 ~ ISO 5752 Series 20 1 bush • bronze
BS-5155 Series 4 ~ MSS-SP67 1 shaft packing • NBR (BUNA®)
Wafer Body
API609 cat.A ~ NFE 29305-1 • FKM (VITON®) (on request)
2 8 1 plug packing • aluminium
9 1 threaded plug • zinc plated steel
Testing: 8
5 10 1 stop ring • steel
EN 12266-1 Rate A ~ ISO 5208 Rate A
9 11 1 • IXEF (DN 40-150)
DIN 3230 ~ API 598
12 2 screw • zinc plated steel

Tag:
EN 19 ~ MSS SP-25 All valves are supplied with a metallic label in com-
pliance with PED directive.

BVKA - Wafer BLKA - Lug


BODY BVKA/BLKA BVKX BLKX
DN 200 - 300 • 8” - 12”
material references standard coating DN DN DN
PN 10-16 • ANSI 150
Ductile iron EN-GJS 400-15 (GS400) Epoxy RAL 5009 40-800 50-250 50-200

Carbon steel ASTM A216-WCB Epoxy RAL 9005 40-800 50-100 50-100 14 item q.ty part material
1 1 body • ductile iron GS400
Stainless steel ASTM A351 CF8M (A316) - 40-800 50-100 50-100 1 12
• A216-WCB
4 • A352-LCB
Aluminium-bronze ASTM B148-C958.00 - 40-800 50-100 50-100 • A351-CF8M (AISI 316)
Wafer • aluminium-bronze
DISC BVKA/BLKA BVKX BLKX body 13 2 1 disc • A351-CF8M (AISI 316)
material references standard coating DN DN DN • aluminium-bronze
• Hastelloy®
Stainless steel ASTM A351 CF8M (A316) - 40-800 50-250 50-200 8 • Monel®
Aluminium-bronze ASTM B148-C958.00 - 40-800 50-250 50-200 3 1 body seat • NBR (BUNA®)
9 (vulcanized • EPDM
Hastelloy® ASTM A494 CX2MW - 40-800 50-250 50-200 6 not replaceable) • EPDM HT
7
Monel® 40-800 50-200 5 2 • FKM (VITON®)
ASTM A494 M35-1 - 50-250 3 4 1 shaft • AISI 430
• AISI 316 (on request)
KA DN 40/150 replaceable - DN 200/800 vulcanized not replaceable
BODY RUBBER SEAT KX DN 50/250 vulcanized not replaceable 5 2 screw • AISI 316
2 O.Ring • PTFE
ref. designation trade name working temp. applications
7 2 washer • AISI 316
NBR nitrile rubber BUNA® -25°C / +100°C oils, hydrocarbons, gas, air, water 1 bush • bronze
EPDM 1 shaft packing • NBR (BUNA®)
copolymer EPDM - -35°C / +130°C water, sea water, steam, diluted acids
• FKM (VITON®) (on req.)
EPDM HT copolimery EPDM HT - -30°C / +135°C water, sea water, steam, diluted acids 10 1 plug packing • aluminium
FKM 10 11 1 threaded plug • zinc plated steel
VITON® -20°C / +200°C oils, acids, hydrocabons
6 12 1 • aluminium
11 7
5 13 1 stop ring • steel
On request can be supplied other materials as: LCB, Hastelloy, Monel, Uranus, Alloy, DUPLEX, Special steels, Special bronzes. 14 2 screw • zinc plated steel
Coating on request: RILSAN®, Halar®, Chenisil®

« INDEX SM 05/15 - EN - PAGE 5 « INDEX SM 05/15 - EN - PAGE 6


BVKA - Wafer BLKA - Lug BVKA - Wafer BLKA - Lug
DN 350 - 400 • 14” - 16” DN 450 - 500 • 18” - 20”
PN 10-16 • ANSI 150 PN 10-16 • ANSI 150
5
6 1 1

15 7 Wafer body
7 Wafer body 5
10
4
8 8
9

9 6

2
3

2
3

12 13 14
14 15 16

6
9 4

11
10
12
11
13
16

Lug body Lug body

item q.ty part material item q.ty part material item q.ty part material item q.ty part material
1 1 body • ductile iron GS400 5 2 screw • zinc plated steel 1 1 body • ductile iron GS400 5 bush • steel + PTFE
• A216-WCB • A216-WCB
• A352-LCB 1 O.ring • NBR (BUNA®) • A352-LCB 7 4 screw • zinc plated steel
• A351-CF8M (AISI 316) 7 1 • zinc plated steel • A351-CF8M (AISI 316)
• aluminium-bronze • aluminium-bronze 1 O.ring • NBR (BUNA®)
1 O.ring • NBR (BUNA®)
2 1 disc • A351 - CF8M (AISI 316) 2 1 disc • A351 - CF8M (AISI 316) 9 5 stop ring • steel
5 bush • bronze
• aluminium-bronze • aluminium-bronze
• Hastelloy® 1 O.ring • NBR (BUNA®) • Hastelloy® 10 1 • zinc plated steel
• Monel® 11 1 • zinc plated steel • Monel® 1 O.ring • NBR (BUNA®)
3 1 body seat • NBR (BUNA®) 12 2 screw • AISI 316 3 1 body seat • NBR (BUNA®)
(vulcanized (vulcanized 12 1 • zinc plated steel
• EPDM • EPDM
not replaceable) • EPDM HT 13 2 washer • AISI 316 not replaceable) • EPDM HT 13 4 screw • steel
• FKM (VITON®) 2 O. ring • PTFE • FKM (VITON®)
14 2 screw • AISI 316
4 1 shaft • AISI 430 15 1 key • steel C40 4 1 shalt • AISI 430
• AISI 316 (on request) 16 4 screw • zinc plated steel • AISI 316 (on request) 15 2 washer • AISI 316
5 1 key • steel C40 2 O. ring • PTFE

« INDEX SM 05/15 - EN - PAGE 7 « INDEX SM 05/15 - EN - PAGE 8


BVKX - Wafer BLKX - Lug
BVKA - Wafer BLKA - Lug DN 50 - 100 • 2” - 4”
DN 600 - 800 • 24” - 32” PN 16-25 • ANSI 150
PN 16 • ANSI 150
item q.ty part material
1 1 body • ductile iron GS400 12
17 18
• A216 - WCB 4 11
15 • A352 - LCB
14 • A351 - CF8M (AISI 316) 10
16 2 1 disc • A351 - CF8M (AISI 316) 1
6
• aluminium-bronze
1
• Hastelloy®
5 • Monel®
3 1 body seat • NBR (BUNA®) 7
(vulcanized • EPDM
7 not replaceable) 13
• EPDM HT
6 • FKM (VITON®)
20 4 1 upper shaft • AISI 430
21 • AISI 316 (on request)
19 4 3
5 1 lower shaft • AISI 430
3
• AISI 316 (on request)
Wafer body 1 bush • bronze
2
1 shaft packing • NBR (BUNA®)
• FKM (VITON®) on req.

2 8 1 plug packing • aluminium


5 8
9 1 threaded plug • zinc plated steel 14
10 1 stop ring • steel 9
20 11 1 • IXEF (DN 50-100)
21 12 2 screw • zinc plated steel
19 Wafer
2 upper bush • steel + PTFE
8 body
2 lower bush • steel + PTFE
6
9
7
11
5 12 BVKX - Wafer BLKX - Lug
10 DN 125 - 250 • 5” - 10” DN 125 - 200 • 5” - 8”
13 PN 16-25 • ANSI 150 PN 16-25 • ANSI 150
item q.ty part material
1 1 body • ductile iron GS400 14
Lug body 2 1 disc • A351-CF8M (AISI 316)
4 12
• aluminium-bronze
• Hastelloy®
item q.ty part material item q.ty part material 1
• Monel®
1 1 body • ductile iron GS400 7 2 O.ring housing • AISI 316 3 1 body seat • NBR (BUNA®) 13
• A216-WCB (vulcanized • EPDM 8
• A352-LCB 8 1 shaft support • Bronze
not replaceable) • EPDM HT
• A351-CF8M (AISI 316) 9 2 adjusting screw • AISI 316 • FKM (VITON®) 9
• aluminium-bronze
10 1 • zinc plated steel 4 1 shaft • AISI 430
2 1 disc • ductile iron GS400 • AISI 316 (on request) 15
• A351 - CF8M (AISI 316) 1 O.ring • NBR (BUNA®)
5 2 screw • AISI 316
• aluminium-bronze 1 O.ring • NBR (BUNA®) 2
• Hastelloy® 2 O.Ring • PTFE
• Monel® 13 6 screw • zinc plated steel 7 2 washer • AISI 316
1 bush • bronze 3
14 1 • zinc plated steel
3 1 body seat • NBR (BUNA®)
(vulcanized • EPDM 1 O.ring • NBR (BUNA®) 1 shaft packing • NBR (BUNA®)
not replaceable) • EPDM HT • FKM (VITON®) (on req.)
1 O.ring • NBR (BUNA®)
• FKM (VITON®) 10 1 plug packing • aluminium
17 4 screw • zinc plated steel 11 1 threaded plug • zinc plated steel
4 1 shalt • AISI 303 5 7 6
• AISI 316 (on request) 18 1 key • steel 12 1 • IXEF (DN 125-150)
• aluminium (DN 200-250)
5 bush • steel + PTFE 19 3 screw • AISI 316
3 O.ring • PTFE 13 1 stop ring • steel 10
2 O.ring • NBR (BUNA®) Wafer
• FKM (VITON®) on request 14 2 screw • zinc plated steel 16
21 3 washer • AISI 316 11 body
2 upper bush • steel + PTFE
2 lower bush • steel + PTFE
« INDEX SM 05/15 - EN - PAGE 9 « INDEX SM 05/15 - EN - PAGE 10
BVPD - Wafer BLPD - Lug BVKI - Wafer BLKI - Lug BVKA - Wafer BLKA - Lug BFKI - Double Flange
ØI Ch
Ch F F
F
10 L
10 K
N1 N1
N
A H A
N
J
ØI
E
E
J K

B B
K

DN 40 - 150 F07 - 4 holes


D DN 200 - 300 F10 - 4 holes C N1 N1
C O
O J
O D Ch
O
11/2"÷12" ANSI B1.1UNC2B Kg DN 350 - 400 F12 - 4 holes
PN 6 PN 10 PN 16 ANSI 150 PD-KI KA DN 80 - 150 F07 - 4 holes DN 450 F14 - 4 holes
16"÷24" ANSI B1.1-8 UNC2B
DN 200 - 300 F10 - 4 holes DN 500 - 600 F16 - 4 holes
DN A B C D E F Ø I Ch H K J N n. O N n. O N n. O N n. O W L W L
PN 6 PN 10 PN 16 ANSI 150
DN “ A B C D E F Ø I Ch K J L N N1 n. O N N1 n. O N N1 n. O N N1 n. O Kg.
80 3 158 110 81 46 67 34 14 11 70 9 14 18 -- 4 150 18 -- 8 160 18 -- 8 160 18 -- 4 152.4 6.5
100 4 173 128 101 52 87 34 16 11 70 9 16 18 -- 4 170 18 -- 8 180 18 -- 8 180 18 -- 8 190.5 8
125 5 186 140 126 56 113 34 18 14 70 9 18 18 -- 8 200 18 -- 8 210 18 -- 8 210 22 -- 8 215.9 10
150 6 202 155 150 56 140 34 18 14 70 9 18 18 -- 8 225 22 -- 8 240 22 -- 8 240 22 -- 8 241.3 12
200 8 240 190 200 60 191 38 22 17 102 11 22 18 -- 8 280 22 -- 8 295 22 -- 12 295 22 -- 8 298.4 20
250 10 270 220 250 68 241 38 30 22 102 11 30 18 -- 12 335 22 -- 12 350 25 -- 12 355 25 -- 12 361.9 30
300 12 300 247 298 78 289 38 30 22 102 11 30 22 -- 12 395 22 -- 12 400 25 -- 12 410 25 -- 12 431.8 46
350 14 330 285 341 78 332 60 35 10 125 14 35 22 -- 12 445 22 -- 16 460 25 -- 16 470 28 -- 12 476.2 65
400 16 355 310 390 102 376 60 40 12 125 14 40 22 M20 16 495 25 M24 16 515 30 M27 16 525 30 M27 16 539.7 85
ØI 450 18 400 343 444 114 430 60 45 12 140 18 45 22 M20 16 550 25 M24 20 565 30 M27 20 585 30 M27 16 577.8 120
F 500 20 422 375 495 127 479 60 45 12 165 22 45 22 M20 20 600 25 M24 20 620 33 M30 20 650 30 M27 20 635.0 180
*N *N
600 24 495 460 595 154 575 75 60 18 165 22 60 25 M24 20 705 30 M27 20 725 36 M33 20 770 36 M33 20 749.3 270
N BVKX - Wafer BLKX - Lug
H
A Ch
ØI
F

E 10
Ch K H
J
A
B K N

*N *N E
DN 350 - 400 F12 - 4 holes
C DN 40 - 150 F07 - 4 holes
DN 450 F14 - 4 holes
O D O B DN 200 - 250 F10 - 4 holes
DN 500 - 600 F16 - 4 holes
DN 700 - 800 F25 - 8 holes
threading can be:
14" ANSI B1.1UNC2B C D O ANSI B1.1UNC2B
16"÷32" ANSI B1.1-8 UNC2B Kg
O PN 25 Kg.
PN 6 PN 10 PN 16 ANSI 150 PD-KI KA
DN A B C D E F Ø I Ch H K J N n. O N n. O N n. O N n. O W L W L DN “ A B C D E F ØI Ch H K J N n. O wafer lug

50 2 138 81 55 43 35 34 14 11 90 70 9 M16 4 125 2.8 3.7


65 21/2 144 98 68 46 50 34 14 11 90 70 9 M16 8 145 3.7 5.3
80 3 158 110 81 46 67 34 14 11 90 70 9 M16 8 160 4 6.1
100 4 173 128 101 52 87 34 16 11 90 70 9 M20 8 190 6 8.1
125 5 186 140 126 56 113 34 18 14 90 70 9 M24 8 220 7.2 9.7
150 6 202 155 150 56 140 34 18 14 90 70 9 M24 8 250 9.5 11.8
200 8 240 190 200 60 191 38 22 17 125 102 11 M24 12 310 16 29
250 10 270 220 250 68 241 38 30 22 125 102 11 -- -- 370 25 --
« INDEX SM 05/15 - EN - PAGE 11 « INDEX SM 05/15 - EN - PAGE 12
PD Series - Torque values - Nm - safety factor excluded Head losses
notes: values indicated in this page is only for information
disc opening valve
Seat body NBR/EPDM/Carboxide 2
O - 20°C 2 10° 20° 30° 40° 50° 60° 70° 80° 90°

working pressure BAR working pressure BAR 10 Liquids: KV


Q=
DN 0 6 DN 0 6 DN 0 6 6 6 6 6 PS
4
50/65 4 6 200 47 58 450 427 465 6 9 62 627 2
1
3
0.6
/h)
80 5 7 250 89 100 500 450 500 7 11 675 0.4
0.2 300.000
100 8 12 300 167 180 600 1330 1577 11 16 225 241 1795 0.1 200.000 pressure drop (bar)
0.07 150.000
100.000
125 22 31 350 345 370 125 29 42 465 495 0.04 80.000
0.02 60.000 KV
150 40 49 400 382 405 52 65 515 Gas: Q = 28.5
0.01 40.000
0.006 30.000 PS
0.004 20.000 P2
0.002 15.000
KI Series - Torque values - Nm - safety factor excluded 0.001 10.000 3
/h)
8.000
6.000
Seat body NBR/EPDM O - 20°C
2 4.000 pressure drop (bar)
working pressure BAR working pressure BAR working pressure BAR 3.000 (less than 1/2 inlet pressure)
2.000 P2 outlet pressure
DN 0 6 10 16 DN 0 6 10 16 DN 0 6 10 16
1.500

40 11 11 13 14 150 55 60 84 90 450 480 520 720 1050 1.000


800
600
50 11 12 13 15 200 100 107 180 210 500 550 600 810 1600 800
700
Steam: P2
400
65 11 16 16 18 250 160 175 220 320 600 1650 1960 2300 - 600 300
500
200
450 pressure drop (bar)
80 20 30 36 40 300 260 270 320 390 700 2270 3000 3350 - 400 150
350 (less than 1/2 inlet pressure)
100
100 40 43 45 48 350 410 450 590 850 800 3200 3400 4000 - 300
80 P2 outlet pressure
250 60
125 48 52 52 70 400 450 480 650 900
40
200
150 30

Seat body 125 20 2


O:
2
15
working pressure BAR working pressure BAR working pressure BAR 100
10 d
Qe = Q
6 16 6 16 6 16 8 1000
80 6
For different liquid, gas or steam head losses are
14 14 16 17 66 72 65 4
3
14 15 16 129 216 252 40-50

65 14 22 192 264
0.3 0.4 0.5 0.6 0.8 1 1.5 2 3 4 5 6 8 10 15 20 30 40 50 60 80
24 44

52 54 545

125 62 64 Values KV (CV = 1,16 KV)

angle 40/50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800
KA/KX Series - Torque values - Nm - safety factor excluded
5° - - - - - - - - - 53 68 85 106 151 206 270
10° - - - - - - - 21 49 123 161 199 246 354 482 629
Seat body NBR/EPDM O - 20°C
2
15° 0,2 0,6 1,8 2,4 4,2 5,6 14 80 188 228 299 369 457 658 900 1168
working pressure BAR working pressure BAR
20° 0,9 2,5 5,2 9,5 15 23 110 156 280 315 412 511 630 907 1234 2010
DN 0 6 10 16 20 25 DN 0 6 10 16 20 25° 3 6,1 12 22 38 61 125 225 354 457 597 740 914 1314 1789 2735
40 12 12 14 15 15 - 300 272 294 362 410 429 30° 6,1 11 21 39 69 112 211 310 381 661 863 1069 1320 1899 2585 5080
35° 9,9 18 33 60 105 166 303 433 521 890 1162 1440 1778 2560 3484 6254
50 12 13 14 16 17 20 350 431 557 714 1071 1122 40° 15 27 49 88 148 228 405 591 742 1184 1547 1916 2366 3407 4638 9700
65 12 17 17 19 20 31 400 683 767 893 1470 1540 45° 21 38 68 121 199 303 528 774 987 1552 2028 2512 3102 4466 6079 11581
50° 29 51 91 159 262 394 679 988 1252 2008 2620 3248 4010 5774 7860 15000
80 21 32 38 42 44 49 450 1000 1208 1313 1995 2090 55° 39 68 119 207 338 505 863 1247 1571 2548 3318 4123 5090 7329 9976 17765
100 42 45 47 50 53 65 500 1155 1418 1733 2625 2750 60° 53 90 156 269 434 641 1085 1591 2059 3225 4202 5218 6442 9277 12627 22200
65° 72 121 209 357 565 820 1364 2065 2807 3983 5196 6445 7957 11457 15595 26077
125 50 55 55 74 77 82 600 2300 2800 3700 4800 5280 70° 92 161 283 487 768 1097 1788 2715 3744 5195 6775 8412 10377 14944 20341 34500
150 58 63 88 95 99 103 700 3800 5050 5600 6900 7590 75° 109 209 381 662 1059 1507 2425 3625 4935 6964 9084 11269 13912 20032 27267 39546
80° 115 240 457 815 1303 1861 3043 4768 6831 9301 12142 15048 18578 26752 36413 47560
200 105 112 189 221 231 320 800 5200 6800 7900 10300 11330 85° 115 253 502 906 1457 2008 3642 4890 8230 10280 13408 16632 20533 29568 40246 52566
250 175 190 231 336 352 440 90° 116 257 508 925 1492 2168 3838 5010 9233 10792 14082 17840 22024 31715 43166 56381

« INDEX SM 05/15 - EN - PAGE 13 « INDEX SM 05/15 - EN - PAGE 14


Flanges to be used
EN1092-1 EN1092-1 EN1092-1 EN1092-1 EN1092-1 EN 1092-1 / EN 1092-2 ASME/ANSI BS 10 JIS B2220
Tipo 11 Tipo 01 Tipo 02/32 Tipo 04/34 Tipo 02/33 DN
PN 6 PN 10 PN 16 PN 25 PN 40 class 125 class 150 class 300 tab D tab E 5K 10K 16K
UNI UNI
UNI UNI 40
2280/81 2289/90
2276/77 6088/89
2282/67 2291 50
2278/67 6090
65
DIN DIN
DIN DIN 80
2631 2672 NOTE: only valves
2575 2641
2632 2673 with vulcanized seat 100
2576 2642
2633 2674 (KA/KX) are recom-
2577 2643 125 (1) (1) (1)
mended with these
A150 150 (1) (1)
A150
B16.5 B16.5 200 (2) (2)
welding neck slip on 250
300 (2) (2)
Bolts and rods dimensions 350
400
Wafer valves
450
DN PN 6 PN 10 PN 16 ANSI 150
500
Bolts Rods N° Bolts Rods N° Bolts Rods N° Bolts Rods N°
600
40 M12x80 M12x90 4 M16x90 M16x100 4 M16x90 M16x100 4 M14x90 M14x110 4
700
50 M12x90 M12x100 4 M16x100 M16x120 4 M16x100 M16x120 4 M16x100 M16x130 4
800
65 M12x100 M12x110 4 M16x110 M16x130 8 M16x110 M16x130 8 M16x110 M16x140 4
80 M16x100 M16x120 4 M16x110 M16x130 8 M16x110 M16x130 8 M16x120 M16x150 4 standard (1) only with ductile iron bodies
only body PN 6 version (2) standard with ductile iron and steel bodies, on request with different
100 M16x110 M16x120 4 M16x120 M16x140 8 M16x120 M16x140 8 M16x120 M16x150 8 on request materials
125 M16x120 M16x140 8 M16x120 M16x150 8 M16x120 M16x150 8 M20x130 M20x160 8 not possible
150 M16x120 M16x140 8 M20x130 M20x160 8 M20x130 M20x160 8 M20x140 M20x160 8
200 M16x130 M16x150 8 M20x140 M20x170 8 M20x140 M20x170 12 M20x150 M20x170 8
250 M16x140 M16x160 12 M20x150 M20x180 12 M24x150 M24x180 12 M22x160 M22x190 12
EN 1092-1 / EN 1092-2 ASME/ANSI BS 10 JIS B2220
300 M20x150 M20x180 12 M20x160 M20x190 12 M24x160 M24x190 12 M22x170 M22x210 12 DN
PN 6 PN 10 PN 16 PN 25 PN 40 class 125 class 150 class 300 tab D tab E 5K 10K 16K
350 M20x150 M20x180 12 M20x160 M20x190 16 M24x170 M24x200 16 M24x180 M24x220 12
40
400 M20x180 M20x210 16 M24x190 M24x220 16 M27x210 M27x240 16 M27x210 M27x250 16
50
450 M20x190 M20x220 16 M24x200 M24x230 20 M27x220 M27x250 20 M27x230 M27x270 16
65
500 M20x210 M20x240 20 M24x210 M24x240 20 M30x240 M30x280 20 M27x250 M27x290 20
80
600 M24x240 M24x270 20 M27x250 M27x290 20 M33x270 M33x320 20 M33x290 M33x340 20
100
700 M24x250 M24x280 24 M27x260 M27x310 24 M33x280 M33x330 24 M33x350 M33x400 28
125 (1) (1) (1)
800 M27x280 M27x320 24 M30x290 M30x350 24 M36x320 M36x360 24 M39x400 M33x460 28
150 (1) (1)
200
Lug valves - Double Flange valves NOTE 1: Screw and rod dimensions have been
250
DN PN 6 PN 10 PN 16 ANSI 150 PN 6/10/16 (EN1092-1 Tipe 11) 300 (1)
Bolts N° Bolts N° Bolts N° Bolts N° ANSI150 (ANSI B16.5) 350
40 M12x30 8 M16x30 8 M16x30 8 M14x30 8 NOTE 2: Number of nuts should be double when
400
50 M12x35 8 M16x35 8 M16x35 8 M16x35 8 WAFER valves are assembled with
threaded rods. 450
65 M12x35 8 M16x40 16 M16x40 16 M16x40 8 500
80 M16x40 8 M16x40 16 M16x40 16 M16x40 8 600
100 M16x40 8 M16x40 16 M16x40 16 M16x45 16 Ø min 700
125 M16x45 16 M16x45 16 M16x45 16 M20x50 16 800
G
150 M16x45 16 M20x45 16 M20x45 16 M20x50 16
200 M16x50 16 M20x50 16 M20x50 24 M20x55 16 standard (1) only with ductile iron bodies
only body PN 6 version (2) standard with ductile iron and steel bodies, on request with different
250 M16x55 24 M20x55 24 M24x55 24 M22x60 24 on request materials
300 M20x60 24 M20x60 24 M24x60 24 M22x60 24 not possible
350 M20x60 24 M20x60 32 M24x65 32 M24x65 24
400 M20x70 32 M24x70 32 M27x70 32 M27x80 32 Test
450 M20x80 32 M24x80 40 M27x80 40 M27x80 32 GHIBSON valves are built according to following international standards:
DIN body hydraulic pneu
500 M20x80 40 M24x80 40 M30x80 40 M27x90 40 Body test pressure: DIN 3230BA - API598 3230 test test test
600 M24x90 40 M27x90 40 M33x100 40 M33x100 40 Hydraulic test pressure: DIN 3230BN1 - API598 PN6 9 bar 7 bar 6 bar
700 M24x100 48 M27x100 48 M33x110 48 M33x130 56 Pneumatic test pressure: DIN 3230BO1 - API598
PN10 15 bar 11 bar 6 bar
800 M27x110 48 M30x120 48 M36x130 48 M39x150 56
UNI EN 10204 3.1 (on request) PN16 24 bar 17,6 bar 6 bar
Ø max UNI EN 10204 3.2 (on request) PN25 38 bar 27,5 bar 6 bar
DN 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 Test duration is indicated by API598 standard hydraulic
API598 body test
Body test pressure: Hydraulic test pressure: Pneumatic test pressure: test
G 36 35 50 67 87 113 140 191 241 289 332 376 430 475 575 670 757
< DN 65 = 15 sec. < DN 65 = 15 sec. < DN 65 = 15 sec. ANSI125 21 bar 18 bar
Ø min 46 44 60 75 98 122 148 196 244 296 342 378 440 485 585 681 782
DN 65 / DN 200 = 80 sec. DN 65 / DN 200 = 30 sec. DN 65 / DN 200 = 30 sec. ANSI150 30 bar 22 bar
Ø max 49 62 80 93 118 146 175 225 275 330 372 422 450 500 600 717 815
> DN 200 = 180 sec. > DN 200 = 60 sec > DN 200 = 60 sec ANSI300 78 bar 58 bar

« INDEX SM 05/15 - EN - PAGE 15 « INDEX SM 05/15 - EN - PAGE 16


Installation Handlevers
Assembly

1 - Leave a space between 2 - Open completely the B


valve before
can be easily inserted and
removed.

Lockable hole 0° - 90°

Lockable hole OPEN


DN A B D Kg
40 - 100 220 67 93 0.6
3 - Tighten bolts till 4 - NOTE: do not insert
other packing between 125 - 150 275 67 93 0.65 D
with valve body.
200 - 300 340 76 125 1
Note:
DN 250 - 300 handlever not recommended Lockable hole CLOSE
(PD series excluded)

Clean carefully the welding to avoid that slags damage the seat. DN40 - 300 DN40 - 150
1 lever aluminium A351 CF8M
1 2 trigger aluminium A351 CF8M
End piping installation 3 spring stainless steel stainless steel
4 disc positioning aluminium A351 CF8M
the valve with horizontal rotation axis, to allow sedi- as per dwg type B is needed to secure tightness at max 5 screws stainless steel stainless steel
pressure. 3
OPTIONALS

Wrong
Vertical rotation axis 4

Adjustable handlever

powders
or muddy

handlever with switch box


Type A installation Type B installation (only DN 40/150)
Right without end piping with end piping
Horizontal rotation axis
handlever with 2 SPDT or
Pmax (Bar)
valve inductive limit switches
type type A type B
powders installation installation
10 positions Open - Closed
or muddy BLPD 4 6
BLKI 6 16 positioning disc with two types of regulation: 10 positions or Open/Close
BLKA 16 20
This type of installation is always advisable with valve
BLKX 16 25
diameters over DN 400.

« INDEX SM 05/15 - EN - PAGE 17 « INDEX SM 05/15 - EN - PAGE 18


Gearboxes Gearboxes
Aluminium body - HW Series Cast Iron body - AB Series
Coupling valve - actuators Coupling valve - actuators
HW series AB series
KI KI
DN “ PD KA KX body: aluminium DN “ PD KA KX body: cast iron GG25
p = 6 bar p = 10 bar p = 16 bar worm gears: steel p = 6 bar p = 10 bar p = 16 bar worm gears: steel
40 1 -- HW070 HW070 HW070 -- -- sector gear: ductile iron 40 1 AB150 AB150 AB150 AB150 AB150 AB150 sector gear: ductile iron
shaft: stainless steel 50 2 AB150 AB150 AB150 AB150 AB150 AB150 shaft: steel
50 2 HW070 HW070 HW070 HW070 HW070 HW070 handwheel: steel handwheel: steel
65 2 AB150 AB150 AB150 AB150 AB150 AB150 protection: IP67
65 2 HW070 HW070 HW070 HW070 HW070 HW070 protection: IP65
T: -20 / +120 °C 80 3 AB150 AB150 AB150 AB150 AB150 AB150 T: -20 / +120 °C
80 3 HW070 HW070 HW070 HW070 HW070 HW070 low/high temperature execu-
100 4 AB150 AB150 AB150 AB150 AB150 AB150
100 4 HW070 HW070 HW070 HW070 HW070 HW070 125 5 AB150 AB150 AB150 AB150 AB150 AB150 tion on request
125 5 HW070 HW070 HW070 HW070 HW070 HW070 150 6 AB150 AB150 AB150 AB150 AB150 AB150
150 6 HW070 HW070 HW070 HW070 HW070 HW070 200 8 AB215 AB215 AB215 AB215 AB215 AB215
200 8 HW102 HW102 HW102 HW102 HW102 HW102 250 10 AB550 AB550 AB550 AB550 AB550 AB550
250 10 HW102 HW102 HW102 HW102 HW102 HW102 300 12 AB550 AB550 AB550 AB550 AB550 --
350 14 AB880 AB880 AB880 AB880 AB880 --
300 12 HW102 HW102 HW102 HW102 HW102 --
400 16 AB880 AB880 AB880 AB880 AB880 --
350 14 HW140 HW140 HW140 HW140 HW140 --
450 18 AB880 AB880 AB880 AB880 AB1250 --
400 16 HW140 HW140 HW140 HW140 HW165 -- 500 20 AB880 AB880 AB880 AB880 AB1250 --
450 18 HW165 HW165 HW165 HW165 HW165 -- 600 24 -- AB1250 AB1250 -- AB1954 -- Waterproof valve
500 20 HW165 HW165 HW165 HW165 HW254 -- 700 28 -- AB1950 AB1950 -- AB6804 -- shaft extension
600 24 -- HW254 HW254 -- -- -- 800 32 -- AB1950 AB1954 -- AB6806 -- When necessary, it's possible
700 28 -- HW254 HW254 -- -- -- F to extend the valve shaft as
800 32 -- HW254 HW254 -- -- --
I Construction is in carbon
steel with protective paint
E
DN “ A (on request steinless steel).
E
40 1 130
C D "L" measure shoul be
50 2 138 G
C indicated when ordering.
D
65 2 144
80 3 158
100 4 173 F H
125 5 186 A
A
150 6 202
DN “ A
200 8 240 40 1 130
G
250 10 270
50 2 138
300 12 300
65 2 144
350 14 330
80 3 158
400 16 355 H 100 4 173
450 18 400
125 5 186
500 20 422
150 6 202
600 24 495
200 8 240
700 28 550 B
B 250 10 270
800 32 640
300 12 300 Mod. B C D E F G H I Kg
AB150 134 55 125 27 80 124 43 58 2.2
Mod. B C D E F G H Kg 350 14 330
AB215 197 63 200 29 102 128 52 48 3.5
HW070 160 48 140 27 80 115 42 1.6 400 16 355 AB550 282 88 300 41 138 174 71 69 8.5
HW102 215 56 300 33 120 150 60 3 450 18 400 AB880 282 93 400 42 200 226 86 100 14
500 20 422 AB1250 322 102 500 48 220 258 105 110 22
HW140 325 95 400 51 185 225 80 10 AB1950 425 126 600 55 285 323 130 143 32
600 24 495
HW165 395 105 600 61 230 268 105 20 AB195-PR4 398 126 600 55 285 323 130 143 39 Our tecnical department is
700 28 550 AB680-PR4 451 159 600 59 370 407 182 170 62.5 available to solve special
HW254 416 125 700 80 265 332 130 25 applications.
800 32 640 AB680-PR6 451 159 600 59 370 407 182 170 64.2

« INDEX SM 05/15 - EN - PAGE 19 « INDEX SM 05/15 - EN - PAGE 20


2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

PRESSURE & TEMPERATURE SWITCH

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 23
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1

LEVEL SENSORS

© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 24

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