Anton Paar Carbo 510 User manual

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Instruction Manual
Carbo 510 Smart Sensor

Instruction Manual
Carbo 510 Smart Sensor

Anton Paar GmbH assumes no liability for technical or printing errors or omissions in this document.
Nor is any liability assumed for damages resulting from information contained in the document.
Anton Paar GmbH reserves the right to content changes. This also extends to changes to delivery
volumes or any features of delivered parts.
All rights reserved (including translation). This document, or any part of it, may not be reproduced,
changed, copied, or distributed by means of electronic systems in any form (print, photocopy, microfilm
or any other process) without prior written permission by Anton Paar GmbH.
Trademarks, registered trademarks, trade names, etc. may be used in this manual without being marked
as such. They are the property of their respective owner.
Published by Anton Paar
Printed: Anton Paar, Austria
Copyright © 2013 Anton Paar GmbH, Graz, Austria
Address: Anton Paar GmbH
Anton-Paar-Str. 20
A-8054 Graz / Austria – Europe
Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.anton-paar.com
Date: 12.10.2013
Document number C98IB001EN-D.fm

C98IB001EN-D 5
Contents
1 About the Instruction Manual......................................................................................................... 7
2 Safety Instructions........................................................................................................................... 9
2.1 General Safety Instructions ..................................................................................................... 9
2.2 Warning Signs on the Instrument .......................................................................................... 10
3 Carbo 510 Smart Sensor - An Overview...................................................................................... 11
3.1 Components of the Carbo 510 Smart Sensor........................................................................ 12
3.2 Measuring Principle ............................................................................................................... 13
3.3 Calculation of the CO2Content ............................................................................................. 14
3.4 Interfaces............................................................................................................................... 15
3.5 Dimensions ............................................................................................................................ 16
4 Checking the Supplied Parts........................................................................................................ 17
5 Installing the Carbo 510 Smart Sensor........................................................................................ 19
5.1 Installation Requirements ...................................................................................................... 19
5.2 Mounting the Carbo 510 Smart Sensor ................................................................................. 20
5.2.1 Installation in a Horizontal Pipe .............................................................................. 20
5.2.2 Installation in a Vertical Pipe .................................................................................. 20
5.2.3 Installation Sequence and Position ........................................................................ 21
5.3 Optional Cut-off Valve Adapter .............................................................................................. 22
5.3.1 Operating the Cut-off Valve Adapter when Disconnecting and
Connecting the Carbo 510 Smart Sensor .............................................................. 22
5.4 Compressed Air Connection.................................................................................................. 24
5.5 Electrical Wiring ..................................................................................................................... 25
5.5.1 Interface Overview ................................................................................................. 25
5.5.2 Connecting the Power Supply ................................................................................ 26
5.5.2.1 Optional Connector Set 4-pole for Power Supply ................................... 27
5.5.3 Shielding................................................................................................................. 27
5.6 Anton Paar CANopen ............................................................................................................ 28
5.6.1 Wiring of the Anton Paar CANopen........................................................................ 29
5.6.2 Wiring with mPDS 5 ............................................................................................... 30
5.6.2.1 CAN Connection with one Smart Sensor ................................................ 31
5.6.2.2 CAN Connection with more than one Smart Sensor............................... 32
5.6.3 Optional Connector Set CAN ................................................................................. 33
6 Putting the Carbo 510 Smart Sensor into Operation with mPDS 5.......................................... 34
7 Integrated Self-diagnosis.............................................................................................................. 35
8 Maintenance Work......................................................................................................................... 36
8.1 Spare Parts List ..................................................................................................................... 37
9 CO2 Concentration Table.............................................................................................................. 38

6C98IB001EN-D
Appendix A: Technical Data ........................................................................................................... 39
Appendix B: Connectors................................................................................................................. 43
B.1 Connector Set 4-pole .......................................................................................... 44
B.2 Connector Set CAN............................................................................................. 45
Appendix C: CE Declaration of Conformity .................................................................................. 46
Appendix D: Document Numbers ................................................................................................. 47

1 About the Instruction Manual
C98IB001EN-D 7
1 About the Instruction Manual
This instruction manual informs you about the installation and the safe handling
and use of the product. Pay special attention to the safety instructions and
warnings in the manual and on the product.
The instruction manual is a part of the product. Keep this instruction manual for
the complete working life of the product and make sure it is easily accessible to
all people involved with the product. If you receive any additions or revisions to
this instruction manual from Anton Paar GmbH, these must be treated as part of
the instruction manual.
Conventions for safety messages
The following conventions for safety messages are used in this instruction
manual:
NOTICE Notice indicates a situation which, if not avoided, could result in damage to
property.
TIP Tip gives extra information about the situation at hand.
WARNING
Warning indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Caution indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

1 About the Instruction Manual
8C98IB001EN-D
Typographical conventions
Anton Paar has defined the following typographical conventions:
Convention Description
<key> The names of keys and buttons are
written inside angle brackets.
“Menu Level 1 > Menu Level 2” Menu paths are written in bold, inside
straight quotation marks. The menu
levels are connected using a closing
angle bracket.

2 Safety Instructions
C98IB001EN-D 9
2 Safety Instructions
• Read this instruction manual before using Carbo 510 Smart Sensor.
• Follow all hints and instructions contained in this instruction manual to
ensure the correct use and safe functioning of Carbo 510 Smart Sensor.
2.1 General Safety Instructions
Liability
• The instruction manual at hand does not claim to address all safety issues
associated with the use of the instrument and samples. It is your
responsibility to establish health and safety practices and determine the
applicability of regulatory limitations.
• Anton Paar GmbH only warrants the proper functioning of Carbo 510 Smart
Sensor if no adjustments have been made to the mechanics, electronics,
and firmware.
• Only use Carbo 510 Smart Sensor for the purpose described in this
instruction manual. Anton Paar GmbH is not liable for damages caused by
incorrect use of Carbo 510 Smart Sensor.
Installation and use
• The installation procedure should only be carried out by authorized
personnel who are familiar with the installation instructions.
• The Carbo 510 Smart Sensor impeller is safe to run dry. Regarding a long
service performance the Carbo 510 Smart Sensor should be switched off
when the plant is stopped for longer time.
• Make sure all operators are trained to use the instrument safely and correctly
before starting any applicable operations.
• Do not use any accessories or spare parts other than those supplied or
approved by Anton Paar GmbH.
• Mechanical knocks and vibrations may damage the Carbo 510 Smart
Sensor. Work on the instrument with care.
• In case of damage or malfunction, do not continue operating Carbo 510
Smart Sensor. Do not operate the instrument under conditions which could
result in damage to goods and/or injuries and loss of life.
• Check the Carbo 510 Smart Sensor for chemical resistance to the samples
and cleaning agents.

2 Safety Instructions
10 C98IB001EN-D
Maintenance and service
• Service and repair procedures may only be carried out by authorized
personnel or by Anton Paar GmbH.
• The Carbo 510 Smart Sensor is typically subject to harsh process conditions
like shock pressure, sudden temperature changes, aggressive samples,
vibrations, etc. Sudden changes of the measurement values or malfunctions
may occur. Check continuously that it is functioning perfectly.
Disposal
• Concerning the disposal of Carbo 510 Smart Sensor observe the legal
requirements in your country.
Returns
• For repairs send the cleaned Carbo 510 Smart Sensor unit to your Anton
Paar representative. Only return the instrument together with the filled out
"Maintenance/Error Report" and the "Standard Maintenance Contract". Find
the applicable forms on the Anton Paar homepage (www.anton-paar.com).
• Make sure you pack the Carbo 510 Smart Sensor securely to prevent
damage occurring during transport. This is especially important if you are
sending back an instrument under warranty. If possible, use the original
packaging.
2.2 Warning Signs on the Instrument
Warning!
• Do not exceed the defined maximum pressure, maximum sample and
maximum CIP temperature (see Appendix A - Technical Data).
• The Cut-off Valve Adapter (optional: Mat. No. 90281) must be closed before
dismantling the Carbo 510 Smart Sensor. (see Chapter 5.3.1 - Operating the
Cut-off Valve Adapter when Disconnecting and Connecting the Carbo 510
Smart Sensor).
• The surfaces of the sample connections and the wetted parts of the Carbo
510 Smart Sensor heat up to the temperature of the sample after a period of
time. The operator is responsible for ensuring protections from burns.
• The compressed air supply for Carbo 510 Smart Sensor must not exceed
7 bar (102 psi) (see Chapter 5.4 - Compressed Air Connection).

3 Carbo 510 Smart Sensor - An Overview
C98IB001EN-D 11
3 Carbo 510 Smart Sensor -
An Overview
The Carbo 510 Smart Sensor represents the third generation of Anton Paar CO2
analyzers which combines the benefits of the inline measurement with the well-
proven pressure-temperature-impeller method. The new maintenance free
impeller allows very short measuring cycles and has largely improved dry run
abilities (automatic stop in error case). The robust stainless steel construction
meets all requirements of the process environment and is fully CIP capable. All
seals and O-rings are FDA compliant.
Due to the integrated impeller with pump function (0,8 l/min) Carbo 510 Smart
Sensor is the first instrument which is able to measure an accurate CO2level in
tanks and under stop-and-go conditions.
The Carbo 510 Smart Sensor has integrated self-diagnosis and is connected via
CAN-Bus to the mPDS 5 or Remote Operating Terminal for data transfer.
Fig. 3 - 1 Carbo 510 Smart Sensor with Cut-off valve adapter

3 Carbo 510 Smart Sensor - An Overview
12 C98IB001EN-D
Features and Benefits
• High-precision CO2measurement with short measuring cycles
• Robust housing made of stainless steel
• Degree of protection IP67
• Safe to run dry
• Impeller with integrated pump function
• Fulfills the NAMUR recommendation NE 107 (self-diagnosis)
• Certified raw materials with material certificates for the metal parts and
O-rings which come into contact with the sample.
• Optional Cut-off valve adapter: service + maintenance every time
• Service-friendly and low maintenance (low running costs)
3.1 Components of the Carbo 510 Smart Sensor
Fig. 3 - 2 Carbo 510 Smart Sensor for installation with Remote Operating
Terminal or mPDS 5

3 Carbo 510 Smart Sensor - An Overview
C98IB001EN-D 13
3.2 Measuring Principle
The determination of the CO2content is based on Henry's Law, which defines the
relationship between the concentration of the dissolved gas and its saturation
pressure at a given temperature.
The measurement is repeated every 15 seconds (default setting).
1. The product is flowing through the measuring
chamber. The impeller generates the product
exchange.
2. The valves are closed. A sample of the
product is separate in the measuring chamber.
3. The sample is decompressed (9%) by a
decompression valve. The special Anton Paar
impeller brings the chamber pressure to the
corresponding saturation pressure within a few
seconds. The saturation pressure and
temperature of the sample are measured.

3 Carbo 510 Smart Sensor - An Overview
14 C98IB001EN-D
3.3 Calculation of the CO2Content
From the saturation pressure and the temperature of the sample the sensor
calculates the content of CO2. The relationship between CO2content and its
saturation pressure at a given temperature depends on the product composition,
e. g. alcohol content, sugar content, …
The Carbo 510 Smart Sensor has 7 product specific formulas for beer,
beverages, beverages light, wine, mineral water, strong beer, MID. Additionally
one user-defined formula can be created.
In laboratories different tables are used, which usually include the influence of the
head space of bottles. In addition from the online measurement to the bottle the
CO2content may vary due to loss of CO2after filling before closing the bottle or
additional carbonisation in the buffer tank of the filler.

3 Carbo 510 Smart Sensor - An Overview
C98IB001EN-D 15
3.4 Interfaces
Product matrix
Carbo 510 Smart Sensor
Material number
89080 (Carbo 510 Smart Sensor)
79233 (mPDS 5)
Carbo 510 Smart Sensor
with Operating Terminal
Material number
95256 (Carbo 510 Smart Sensor
with Operating Terminal)
Carbo 510 Smart Sensor with
Remote Operating Terminal
Material numbers
89080 (Carbo 510 Smart Sensor)
94636 (Remote Operating
Term i n a l )
Carbo 510 Smart Sensor with
Remote Operating Terminal for
panel installation
Material numbers
89080 (Carbo 510 Smart Sensor)
94636 (Remote Operating
Term i n a l )
95150 (Option Panel Installation)

3 Carbo 510 Smart Sensor - An Overview
16 C98IB001EN-D
3.5 Dimensions
Dimensions [mm]

4 Checking the Supplied Parts
C98IB001EN-D 17
4 Checking the Supplied Parts
The Carbo 510 Smart Sensor was tested and packed carefully before shipment.
However, damage could occur during transport.
1. Keep the packaging material (box, foam piece, transport protection) for
possible returns and further questions from the transport- and insurance
company.
2. Check the delivery for completion by comparing the supplied parts to table
below.
3. If a part is missing, contact your Anton Paar representative.
4. If a part is damaged, contact the transport company and your Anton Paar
representative.
Symbol Pcs. Article Description Mat. No.
1 Carbo 510 Smart Sensor
or
Carbo 510 Smart Sensor with Operating
Term i n a l
89080
95256
1 Instruction Manual
English
Options
1 Remote Operating Terminal 94636
1 Option panel installation for Remote Operating
Term i n a l
95150

C98IB001EN-D 18
1 Carbo 510 Cut-off valve adapter 90281
1 Power supply DC 24 V 2.5 A 96693
1 Connector set 4-pole 94633
1 Compressed air regulator 6530
1 m Hose 4x6 nylon bk 72595
Symbol Pcs. Article Description Mat. No.

5 Installing the Carbo 510 Smart Sensor
C98IB001EN-D 19
5 Installing the Carbo 510 Smart Sensor
NOTICE • Read this manual carefully before installing the Carbo 510 Smart Sensor.
Incorrect operation can result in damage to the Smart Sensor.
• Mechanical knocks and vibrations may damage the Carbo 510 Smart
Sensor. Work on the instrument with care.
5.1 Installation Requirements
Fig. 5 - 1 Type plate
WARNING
• Installation, putting into operation, maintenance and service work should
only be carried out by trained and authorized personnel.
• Observe the permissible operating and ambient conditions for the Carbo
510 Smart Sensor (see Appendix A - Technical Data).
• Do not exceed the defined maximum pressure, maximum sample
temperature and maximum CIP temperature for the Carbo 510 Smart
Sensor (see Chapter 5.1 - Installation Requirements).
WARNING
Comply with the safety instructions in Chapter 2.2 - Warning Signs on the
Instrument.
Line pressure Max. 10 bar / 145 psi
Sample temperature – 5 °C to + 40 °C
Maximum temperature (CIP) 120 °C (max. 30 min)
Power supply DC 24 V SELV (min. 2 A)
Compressed air supply 4 to 7 bar / 58 to 102 psi

5 Installing the Carbo 510 Smart Sensor
20 C98IB001EN-D
5.2 Mounting the Carbo 510 Smart Sensor
The Carbo 510 Smart Sensor can be installed in a horizontal or vertical pipe (see
Fig. 5 - 2 - Installation position in a horizontal pipe and Fig. 5 - 3 - Installation
position in a vertical pipe). The flow direction makes no difference in both
installation options.
The impeller of the Carbo 510 Smart Sensor is safe to run dry. Regarding a long
service performance the Carbo 510 Smart Sensor should be switched off when
the plant is stopped for a longer time.
NOTICE With the option Cut-off valve adapter (Mat. No. 90281) the flow direction must be
taken into consideration (see Chapter 5.3 - Optional Cut-off Valve Adapter)
5.2.1 Installation in a Horizontal Pipe
Fig. 5 - 2 Installation position in a horizontal pipe
5.2.2 Installation in a Vertical Pipe
Fig. 5 - 3 Installation position in a vertical pipe
CAUTION
In a horizontal pipe the Carbo 510 Smart Sensor must be installed horizontal
to the pipe. If the Carbo 510 Smart Sensor is installed vertical (90°) to the
horizontal pipe, air could enter the measurement chamber and a
measurement of CO2would not be possible.