Turbimax CUS51D - Endress+Hauser Portal

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