BWTS 3
BWTS 3
Manual
ERMA FIRST BWTS FIT 800 for HN SEE VESSEL TABLE
P.1
© 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
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 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
Check the
polarity of the power
source (battery) before
removing it.
© 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
© 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
© 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®.
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
Singapore
Address: 56 Toh Tuck Road, #07-02 Signature Park, Singapore 596746
Phone: +65-8321-3739
Email: [email protected]
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 2 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 3 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 4 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 5 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 6 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 7 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 8 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 9 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 10 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 11 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 12 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 13 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 14 of 60
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:
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 15 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 16 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 17 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 18 of 60
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)
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 19 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 20 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 21 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 22 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 23 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 24 of 60
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 .
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 25 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 26 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 27 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 28 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 29 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 30 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 31 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 32 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 33 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 34 of 60
8.4.3 Testing the Scanner Motors 8.5 Testing the Pump
To test the proper functioning of the Scanner motors:
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 35 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 36 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 37 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 38 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 39 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 40 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 41 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 42 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 43 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 44 of 60
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
11.2.2 Multi-Filter
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 47 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 48 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 49 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 50 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 51 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 52 of 60
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
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 53 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 54 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 55 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 56 of 60
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.
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 57 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 58 of 60
17. User Notes
Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 59 of 60 Unclassified | Commercial Confidential |Document P/N DOC-00136 | Rev D Printed 18 July 2017 Page 60 of 60
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
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
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
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:
The manufacturer of PermaChlor® BWT cells, Permascand AB, is certified in accordance with following
management standards:
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.
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
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual
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
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
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.
* 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.
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
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
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
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.
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
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual
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
Table 7: Resistance control schedule for test and evaluation of cable contacting
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
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.
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
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual
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
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)
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)
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
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
Des i gn opera ti ng
0-6 0-6 Ba r(g)
pres s ure
Nomi na l worki ng
0.6 0.6 Ba r(g)
pres s ure (DP)
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 --
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
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual
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)
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 --
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
BWT Operations and Maintenance Manual BWT Operations and Maintenance Manual
Power s uppl y (V*A) 37.5 37.5 kW Lifetime > 5000 > 5000 h
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 --
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
Rev. B
USCG
1 Safety instructions
SAFETY INSTRUCTION
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.
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
User Guide Page 2(28) 77-107.0296 GB User Guide Page 3(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
Table of Contents
1.1 Description of safety symbols used on FlexKraft Marine:
Internal CUST-3051
User Guide Page 4(28) 77-107.0296 GB User Guide Page 5(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
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
3.1.1 Keypad
The display unit membrane keypad has the following keys:
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!
User Guide Page 8(28) 77-107.0296 GB User Guide Page 9(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
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.
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
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
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
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
Monitoring Temperature
Regulation
Configuration
External emergency stop
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.
User Guide Page 18(28) 77-107.0296 GB User Guide Page 19(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
SINGLE DUAL The time is set in the SET menu using 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
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
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
The number of ampere hours is set in the SET menu using AH-LIMIT A and AH-
LIMIT B.
User Guide Page 22(28) 77-107.0296 GB User Guide Page 23(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
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.
User Guide Page 24(28) 77-107.0296 GB User Guide Page 25(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
There are three adjustable Ah counters and three adjustable times. SINGLE DUAL
SINGLE DUAL
STATUS: STANDBY STANDBY STANDBY
← → ↓ ↑ ← → ↓ ↑
← → ↓ ↑ ← → ↓ ↑
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.
User Guide Page 26(28) 77-107.0296 GB User Guide Page 27(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
FlexKraft Marine 2018-01-02
Rev. B
USCG USCG
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.
User Guide Page 28(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
USCG
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.
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
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
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]
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.
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.
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.
IMPORTANT (NOTE)
Meters with 3A approval are labeled with an additional plate.
• 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.
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.
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.
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
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)
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)
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
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. 11
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.
Fig. 13 Fig. 16
Fig. 15
Fig. 19
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
Fig. 21
1 Insulation
Fig. 24
Fig. 22
Ch ang e f ro m o ne to t wo co lum ns
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.
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.
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.
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
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
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.
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
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.
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)
• Twist the wire mesh shield of the cable and connect to the ground terminal.
• Connect the ground wire of the cable to the SE clamp of the terminal strip.
• Connect all other wires as shown in Fig. 37.
• Connect the cable ground wire together with the foil shield continuity wire from D1, D2 to the
SE clamp of the terminal strip.
• When using the flowmeter sensor in systems with cathodic corrosion protection (CCP),
connect the cable ground wire together with the foil shield continuity wire from D1, D2 to the
SE clamp of the terminal strip.
• Connect all other wires as shown in Fig. 37.
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
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).
An installation set for sealing the cable conduit is available via order number
3KXF081300L0001.
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:
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
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.
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)
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
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)
IMPORTANT (NOTE)
Fig. 49: (I = internal, E = external) For additional information on configuring the current output, see chapter 7.2 „Configuring the
current output“
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.
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
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.
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
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
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.
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
Next Edit
15. Confirm the selection with . 30. Use to confirm your setting.
Next Edit
Next Edit
18. Use to confirm your setting. 33. Use to confirm your setting.
Next Edit
Next Edit
21. Confirm the selection with . 36. Confirm the selection with .
Next Edit
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)
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.
Meaning
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
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.
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
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
-----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.
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
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.
Menu / Parameter Value range Description Menu / Parameter Value range Description
Menu / parameter Value range Description Menu / parameter Value range Description
Menu / parameter Value range Description Menu / parameter Value range Description
Menu / parameter Value range Description Menu / parameter Value range Description
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.
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.
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.
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.
Menu / Parameter Value range Description Menu / Parameter Value range Description
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.
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).
2. To control the fill valve, the following settings must be applied: Menu / parameter Selection Description
3. The parameters for the fill function must be configured. Menu / parameter Value range Description
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 “).
... / 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.
No or minor disturbance:
• When the power spectrum is below 1000
• When the four measured amplitude values are above 10
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
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
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
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.
11.3.1 Transmitter
Fig. 69
Transmitter Sensor
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)
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
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
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
Fig. 76
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)
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.
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)
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
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
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.
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
Fig. 89
Fig. 87
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
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.
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
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.
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.
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.
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.
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.
DOSING PUMP(S)
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 13
GRUNDFOS INSTRUCTIONS
Further languages
http://net.grundfos.com/qr/i/98767821
English (GB) Installation and operating instructions
English (GB)
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.
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)
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.
2.1 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
In case of emergency and prior to all maintenance work and repairs, take the mains plug out
of the power supply!
2.4 Nameplate
Type Pmax W IP 65
Fig. 2 Nameplate
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
PV PVDF F EU (Schuko)
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
C Ceramics
Special variant
SS Stainless steel 1.4401
DDA 60-10 FCM-PVC/V/C-F-31U3U3FGC3
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)
13
TM06 7048 2916
14
17 16 15
8
3. Technical data / Dimensions
English (GB)
3.1 Technical data
9
Data 60-10 120-7 200-4
English (GB)
Sound
Max. sound pressure level [dB(A)] 80
pressure
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
194
Dosing head A A1 A2 B C D
Pump type
material [mm] [mm] [mm] [mm] [mm] [mm]
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
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.
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).
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
15
FlowControl signal connection (DDA-FCM) 5. Startup
English (GB)
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
16
5.3 Setting the menu language
English (GB)
For description of control elements, see section 6.
Confirm
settings?
17
5.4 Deaerating the pump
English (GB)
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.
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
STOP
Calibrat. volume: 0.0000ml
STOP
Calibrat. volume: 1.05l
STOP
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
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
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)
21
6.3 Main menus Counters
The "Info > Counters" menu contains the following
English (GB)
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
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* ❑
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
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:
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).
Operation
t1 t1
TM06 7087 2916
Timer
TM06 7090 2916
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 >
Timer 11.0s
Timer
MO TU WE TH FR SA SU
27
6.5 Analog output 6.6 SlowMode
English (GB)
AR
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
1
3
Stroke length
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"!
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.
31
6.13 Key lock 6.14.2 Additional display
The additional display provides additional
English (GB)
Operation mode /
Metric units US units
function
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
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)
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:
Contact type
* 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)
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.
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
37
7.4 Perform service 7.4.1 Dosing head overview
English (GB)
CAUTION
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.
39
7.6 Diaphragm leakage 7.6.1 Dismantling in case of diaphragm leakage
English (GB)
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
41
8.1 List of faults
English (GB)
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)
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.
flow temperature
analogue switching output analogue switching output
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.
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
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
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]
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
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
PRESSURE TRANSMITTERS
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 16
A c
T
>
£ W)
³ W
£
£
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
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
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
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 18
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1
SUCTION PUMP
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 19
GARANTIA WARRANTY
CONDICIONES DE LA GARANTIA WARRANTY CONDITIONS
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.
! !
! !
! ! ! !
! !
! !
! !
! !
! !
! !
! !
! !
! !
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.
• 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.
• 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
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
NOTAS / NOTES
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
2-1920-0801 Equipment Operation & Technical manual –Vol III Rev. 01
11/6/2019 HN SEE VESSEL TABLE
P.1
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
►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).
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.
· 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.
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.
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
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)
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.
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
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.
· To properly place the monitor in the charger, complete or observe the following.
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.
The Ventis MX4 can be configured manually as instructed below. Any changes made take effect immediately upon
exiting the configuration mode.
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
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.
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
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.
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
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.
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.
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
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.
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.
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.
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.
16 17139262 Screw, Phillips (torque value: 115 oz-in or .81 N.m +/- 10%)
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.
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
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
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).
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
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
传
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。
© 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.
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.
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.
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.
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
● 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)
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.
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.
1. Make sure the gear latch ① is in neutral position ③. The neutral position is between 33° and 90°.
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.
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".
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.
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:
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.
6. Secure the EMC filter module using the screw ⑥ loosened in the third step.
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
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)".
4. Slide the transparent cover ② up to the end stop of the basic electronics.
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.
41 (+) 1 - Brown
52 (-) 4 - Black
42 (-) 3 - Blue
51 (+) 2 - White
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
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.
●
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.
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:
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.
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:
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.
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:
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 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.
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.
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 %
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)
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)
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
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
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
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.
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 ) ®
Tag:
EN 19 ~ MSS SP-25 All valves are supplied with a metallic label in com-
pliance with PED directive.
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®
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
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
B B
K
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
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
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
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
© 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