Baumer PF55S User manual

Flow sensor PF55S
Operation manual
Read this manual prior to performing any task!
Translation of the original German document, dated 4/3/2020 English

PF55, 4, en_US
Translation of the original operation manual
© Baumer 2020
Baumer Electric AG
Hummelstrasse 17
CH – 8501 Frauenfeld
Telephone: [phone]
E-mail: [e-mail]
Internet: www.baumer.com
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This manual is an integral part of the PF55S and must be kept
within close proximity of the system for personnel to access at all
times. This manual enables the device to be handled safely and
efficiently. In the event of a resale, the PF55S manual must be
handed over to the new owner.
Personnel must have carefully read through and understood this
manual before starting any work. Following all safety guidelines
and instructions in this manual is the basic prerequisite for safe
work. Furthermore, the local health and safety regulations and gen-
eral safety regulations for the field of application of the PF55S also
apply.
The diagrams in this manual are examples. There may be differ-
ences at the discretion of Baumer.
Baumer will regularly update this operating manual. Should you
notice that information is missing or that there is an error, please
notify Baumer.
Contact Baumer if you have any questions concerning this manual.
We, Baumer Group, constantly strive to improve our products.
Help us to make Baumer products even safer.
Notify us of each hazardous situation that occurs in relation to
Baumer products:
nHazards that arise from the product
nHazards that arise from handling the product
nHazards that arise due to contact between materials and the
product
In this case, please include the following information, if known:
nAffected product
nDescription of the hazardous situation
nSketches, photos
nName and contact information in case of any queries
Baumer will process the information as soon as possible.
Due to the sometimes very short innovation cycles for electrical
parts, it is possible for the original manufacturer to withdraw prod-
ucts from the market early on (parts discontinuation).
This can mean that the availability of replacement parts being
limited, and that the original assembly cannot be repaired. There-
fore, in the event of repairs, Baumer Group reserves the right to
replace the entire assembly concerned with another assembly with
an identical or extended functionality.
In addition to this document, the operating manual and the safety
advice contained therein for the components of the PF55S and the
higher-level machine also apply.
Information on the operating
manual
Please help
Note on electrical parts
Other applicable documents
Supplemental directives
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Baumer Group operating manuals and handbooks are protected by
copyright. The copying, reproduction and translation, etc. of them
is prohibited. Additional copies of this operating manual and copies
in other languages can be obtained directly from Baumer.
The right to make changes at any time and without providing
advance notice is reserved.
The contractually agreed warranties only apply if the maintenance
work described within this operating manual is carried out at the
prescribed intervals and the operating manual are adhered to. The
instructions in the supplier’s documentation must also be observed.
All information and instructions in this operating manual have been
compiled in accordance with the applicable norms and specifica-
tions, the current state of technology and our many years of experi-
ence and knowledge.
The manufacturer does not accept any liability for damage caused
by the following:
nThe operating manual was not followed.
nThe system was not operated according to its intended use.
nUnqualified personnel were deployed.
nUnauthorized modifications were made.
nUnauthorized technical alterations were made.
The obligations agreed in the supply contract, the general terms
and conditions, the manufacturer’s and their supplier’s delivery
conditions and the legal regulations applicable at the time the con-
tract is concluded shall apply.
Baumer MDS GmbH
Bodenseeallee 7
78333 Stockach
Germany
Tel.: [phone]
Email: [e-mail]
Website: www.baumer.com
A current list of local contacts can be found on our website
under Contact .
Copyright protection
Warranty
Limitation of liability
Customer service
Supplemental directives
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Table of contents
1 General................................................................................. 7
2 Safety and responsibility................................................... 8
2.1 Symbols in this manual................................................. 8
2.2 Designated use........................................................... 10
2.3 Reasonably foreseeable misuse................................. 10
2.4 Work areas and danger zones.................................... 10
2.5 Safety marking............................................................ 11
2.6 Securing against restart.............................................. 11
2.7 Responsibility of the owner......................................... 11
2.8 Integrator responsibilities............................................ 13
2.9 Immediate measures following an accident................ 14
2.10 Personnel requirements............................................ 16
2.11 Personal protective equipment................................. 18
2.12 Safety guidelines for transport and storage.............. 19
2.13 Safety guidelines for assembly and commis-
sioning...................................................................... 20
2.14 Safety guidelines for maintenance and resolving
faults......................................................................... 23
2.15 Safety information for replacement parts.................. 24
3 Layout and functional description.................................. 26
3.1 Structure..................................................................... 26
3.2 Functional description................................................. 26
3.3 Ports........................................................................... 27
3.4 Control software BCP................................................. 28
4 Transport and storage...................................................... 29
4.1 Delivery....................................................................... 29
4.2 Transport inspection................................................... 29
4.3 Storage of packages................................................... 29
4.4 Disposing of packaging materials............................... 29
5 Assembly and installation................................................ 31
5.1 Prerequisites for installation........................................ 31
5.2 Installation position of the flow sensor........................ 32
5.3 Installation................................................................... 35
5.4 Electrical connection................................................... 38
6 Commissioning................................................................. 41
6.1 Create USB interface.................................................. 41
6.2 BCP software installation............................................ 42
7 Operation........................................................................... 47
7.1 BCP Software............................................................. 47
7.2 Visualization view........................................................ 50
7.3 Quick start menu......................................................... 53
7.4 Access codes.............................................................. 53
Table of contents
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7.5 Operation: Example.................................................... 54
7.5.1 Operation: Example quick start menu...................... 54
7.5.2 Operation: Example main menu.............................. 56
7.6 Menu navigation......................................................... 58
7.6.1 Sensor menu.......................................................... 60
7.6.2 Units menu............................................................ 62
7.6.3 Scales menu.......................................................... 66
7.6.4 Measure menu........................................................ 68
7.6.5 Alarms menu.......................................................... 71
7.6.6 Inputs menu.......................................................... 73
7.6.7 Outputs menu........................................................ 75
7.6.8 Communication menu........................................... 79
7.6.9 Display menu........................................................ 80
7.6.10 Functions menu................................................. 81
7.6.11 Diagnostic menu................................................ 82
7.6.12 System menu........................................................ 87
7.6.13 Process data menu........................................... 90
8 Maintenance...................................................................... 92
8.1 External cleaning........................................................ 92
8.2 Internal cleaning......................................................... 92
8.3 Replacing the seals.................................................... 92
9 Fault elimination............................................................... 93
9.1 Alarms......................................................................... 93
9.2 Error messages.......................................................... 95
10 Disassembly and disposal............................................... 97
11 Technical data................................................................... 98
12 Replacement parts.......................................................... 102
13 Index................................................................................. 103
Table of contents
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1 General
This operating manual is valid for the magnetic-inductive flow
sensor PF55S.
General
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2 Safety and responsibility
This section provides an overview of all important safety aspects
for the protection of people and for safe and failure-free operation.
Other task-related safety guidelines are included in the sections on
individual life phases.
2.1 Symbols in this manual
Safety guidelines in this manual are identified by symbols. The
safety guidelines are introduced by signal words, which convey the
extent of the hazard.
DANGER!
This combination of symbols and signal words indicates
an immediate dangerous situation that causes death or
serious injuries if not avoided.
WARNING!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
death or serious injuries if not avoided.
CAUTION!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
minor or slight injuries if not avoided.
NOTICE!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in
material damage if not avoided.
ENVIRONMENT!
This combination of symbols and signal words indicates
a potentially dangerous situation that can result in envi-
ronmental damage if not avoided.
Safety guidelines may relate to particular, individual instructions.
Such safety guidelines are embedded within the instructions so
that they do not interrupt the reading flow when performing opera-
tions. The signal words described above are used.
Example:
Safety guidelines
Safety guidelines in the instruc-
tions
Safety and responsibility
Symbols in this manual
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1. Loosen the screw.
2.
CAUTION!
Risk of getting caught in the lid!
Close the lid carefully.
3. Tighten the screw.
The following symbols are used in the safety instructions in order
to draw attention to specific hazards:
Warning signs Type of danger
Warning – dangerous electrical
voltage.
Warning – danger zone.
This symbol highlights useful tips and recommenda-
tions, as well as information for efficient and error-free
operation.
The following labels are used to highlight instructions, results, lists,
references and other elements in this manual:
Marking Explanation
Step by step handling instructions
ðResults of steps
References to sections of this manual and
other applicable documents
Lists without a specified order
[Enter] Screen elements (e.g. switch areas, layout
of function buttons)
Operating elements (e.g. buttons, switches)
Display Screen elements (e.g. menu titles, window
descriptions)
Function Screen elements (e.g. Interface texts)
Special safety instructions
Tips and recommendations
Other labels
Safety and responsibility
Symbols in this manual
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2.2 Designated use
The flow sensor PF55S is exclusively intended for use in confined
spaces within industrial working environments.
Proper application also includes adherence to all information given
in this manual. This relates in particular to adherence to the tech-
nical information.
The flow sensor measures and detects the flow rates of fluids.
This Fflow sensor complies with the Pressure Equipment Directive
(PED) and is designed and manufactured as per the state of the art
for media in fluid group 2.
The application range includes conductible fluids with the following
properties:
nConductibility ≥ 50 μS/cm
nViscosity < 70 mm²/s at 40 °C (< 70 cST at 104 °F)
Components can be assembled differently within a system. Please
note that technical limitations are defined by the limitations of the
weakest component of the system.
2.3 Reasonably foreseeable misuse
Misuse especially includes the following:
nAny use of the flow sensor beyond the intended use or any
other improper use.
nAny use of the flow sensor by unqualified or incorrectly quali-
fied personnel.
nUse of the flow sensor together with accessories not approved
by Baumer.
nUse of the flow sensor in potentially explosive atmospheres.
2.4 Work areas and danger zones
The work areas and danger zones depend on the layout of the
sensor PF55S of the higher-level production equipment and the
prevailing circumstances at the installation site. They must there-
fore be determined by the operating company.
DANGER!
Non-observance of operating company's obliga-
tions could result in serious injuries or death.
– Always ensure adherence to the operating compa-
ny's obligations.
Ä 2.7 “Responsibility of the owner” on page 11
Safety and responsibility
Work areas and danger zones
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2.5 Safety marking
Symbols and information signs can be found on the sensor PF55S
or in the working range. They refer to the immediate surroundings
in which they are mounted.
WARNING!
Danger due to illegible signage
Over time, stickers and signs may become dirty or oth-
erwise unrecognizable, meaning that the dangers are
not recognized, and necessary operating instructions
cannot be followed. This can lead to injury.
– All safety instructions, warnings and operating
instructions must be easily legible at all times.
– Damaged signs or stickers must be replaced imme-
diately.
DANGER!
Danger if the safety markings are missing or are
not understandable
Observe the component-specific safety information.
2.6 Securing against restart
When working on live components, you must ensure that they
cannot be restarted unintentionally. A system is secured against
unintentional restart when the power supply is switched off and the
main switch is secured with a lock.
If it is not possible to secure the main switch from being switched
on with a lock, the mains plug must be removed from the socket
and secured.
2.7 Responsibility of the owner
The owner is the person who operates or owns the sensor PF55S,
or who has assumed the decisive economic authority over the
technical operation of the equipment. Normally, the owner is not
Baumer, but rather the purchaser of the sensor PF55S.
The PF55S is used in the commercial sector. The PF55S owner is
therefore subject to the legal obligations concerning occupational
safety.
In addition to the safety instructions in this manual, the safety,
occupational health and safety and environmental protection regu-
lations applicable to the field of application of the system must also
be complied with.
Owner
Operating company's obligations
Safety and responsibility
Responsibility of the owner
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The following, in particular, applies:
nThe operating company must be familiar with the applicable
health and safety regulations and must compile a risk assess-
ment to identify additional hazards that arise due to the specific
working conditions at the PF55S installation site. The owner
must implement this in the form of operating instructions for
using the PF55S.
nThe operating company must define the work areas and
danger zones.
nThe operating company must define a procedure for preventing
the higher-level production equipment from being turned on
unintentionally. The description in this manual refers to the
sensor PF55S only.
nThe operating company must request and regularly evaluate
and update the safety data sheets for the operations and
process equipment used. He must produce operating instruc-
tions for handling the operations and process equipment safely.
nThroughout the entire operating life of the PF55S, the oper-
ating company must check whether the operating instructions
he created correspond with the latest regulations and must
adjust them as necessary.
nThe owner must clearly regulate and specify in writing the
responsibilities for installation, operation, troubleshooting,
maintenance and cleaning.
nThe operating company must ensure that all persons handling
the PF55S have read and understood this manual. Further-
more, he must also train the personnel and inform them about
the dangers at regular intervals. This training must be docu-
mented.
nThe operating company must provide personnel with the nec-
essary protective equipment and instruct them of their obliga-
tion to wear the necessary protective equipment.
Furthermore, the operating company is responsible for perma-
nently maintaining the sensor PF55S and other components of the
production system in a perfect technical condition. The following
therefore applies:
nThe operating company must ensure that the service intervals
described in this manual are adhered to.
nThe operating company must carry out checks at regular inter-
vals, or at least following any maintenance work, to ensure that
the safety devices of all components of the production system
are functional.
nIn the event of errors or irregular system behavior, the oper-
ating company must ensure that operation is stopped immedi-
ately, the cause is identified, and that the error is resolved
before operation is resumed.
nThe operating company must ensure that it is always possible
to disconnect the sensor PF55S power and compressed air
system during maintenance and repair works.
Safety and responsibility
Responsibility of the owner
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2.8 Integrator responsibilities
The integrator is the person responsible for installing the sensor
PF55S within the higher-level machine.
The integrator can be a machine manufacturer, an engineering
office, Baumer hhs or the operating company.
The integrator is to review and appropriately adapt the following
features and equipment:
nSafety features
nProtection equipment
nController interfaces
nConnections to the control system
The sensor PF55S is typically installed within a higher-level
machine. This installation creates new interfaces, which can lead
to additional hazards.
The following critical areas can result from this:
nThe installation environment for the sensor PF55S in the
higher-level machine may differ from the originally intended
installation environment.
Example: The sensor could be subjected to a strong electro-
magnetic field that generates a fault beyond the industry
standard measure.
nThe operating company’s desired installation position for the
sensor PF55S in the higher-level machine could differ from the
Baumer assumed installation conditions.
Example: The operator may not be able to use the sensor
without risk because of a conveying element in the higher-level
machine.
nThe protective measures intended by Baumer may no longer
be sufficient or may have to be removed a result of the installa-
tion conditions.
Example: Safety devices may have to be removed to increase
the installation space for the sensor.
nWarnings may be concealed by machine parts and therefore
not be legible.
This results in the following tasks for the integrator:
Integrator
Integrator tasks
Safety and responsibility
Integrator responsibilities
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nThe integrator must conduct a risk assessment that covers the
following areas:
– Installation of the sensor PF55S in the higher-level
machine and any associated interface resulting from this.
– Any change to the protection measures required due to
installation of the sensor PF55S in the higher-level
machines.
– Any change in the use of the machine.
nThe integrator must eliminate any hazards identified in the risk
assessment or mitigate the risk associated with such hazards
by means of the following hierarchically ordered protection
measures:
– Eliminate the hazards through design.
– Minimize the risk through design requirements and defini-
tion of the hazard zones.
– Minimize the risk through technical protection measures
and supplementary measures. Adapt the effective range of
the control system where appropriate.
– Mitigate the risk through user information.
nThe integrator must instruct the operating company with
respect to these measures and any remaining residual risks.
The technical documentation must be augmented where
appropriate.
2.9 Immediate measures following an accident
The machine and its environment are so designed that as far as
humanly possible accidents can be precluded if:
nAll safety devices are active.
nThere is compliance with all safety regulations.
nAll specified maintenance and repair work is carried out.
Despite all these measures, accidents cannot be excluded in prac-
tice. An accident is never planned. The cause is mostly misconduct
(foolhardiness, overconfidence or hectic pace) of the individuals
concerned. Defective components attributed to poor maintenance
can also be the cause.
In everyday life, the cause of an accident is often a combination of
different circumstances. This makes it virtually impossible to pro-
duce a detailed procedural instruction for the accident report. All
measures after an accident must be dealt with attentively and with
the necessary expertise, otherwise an increase in the damages or
loss is to be expected.
Measures required after an injury
In general it is impossible to preclude any type of injury. All imagi-
nable combinations are possible. It is therefore not possible to
make a sweeping statement on the measures required.
Recommendation
Medium and severe injuries must be treated by doctors. Initial
treatment (First Aid measures) by medics or by trained first res-
ponders is useful and necessary.
Safety and responsibility
Immediate measures following an ...
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For the event of contact with various chemicals and processed
material it is advisable to:
nManufacturer's data sheets:
– Follow them and keep them ready to hand.
– Always provide them to the doctor if one is called.
nAfter inhalation:
– Go into the fresh air.
– Visit a doctor in the event of persistent complaints.
nIf skin comes into contact with hot material:
– Do not remove material from your skin!
– Rinse with plenty of water, if possible.
– Remove contaminated clothing.
nAfter burns:
– Cool immediately.
nIf skin comes into contact with cold material:
– Rinse with plenty of soap and water.
– Remove contaminated clothing.
nAfter eye contact:
– Rinse with plenty of water for around 10 – 15 minutes. Hold
your eyelids open. Remove contact lenses if you wear
them.
nIf swallowed:
– Rinse your mouth thoroughly with water. Where appropriate
drink 1 – 2 glasses of water. Do not induce vomiting.
In any case, see a doctor as soon as possible.
Have even what appear to be minor injuries examined and treated
by specialists. Apparently insignificant injuries, where liquids such
as adhesives, hydraulic or lubricating oils, emulsions or other
chemical substances could have entered the wound, can lead to
severe consequential damages. They can cause life-threatening
circulatory disorders, infections and poisoning.
An electrical accident is the result of a human body closing the cir-
cuit between two energized parts.
In the event of an electrical accident the threat to individuals
depends on the following parameters:
nCurrent path
nContact voltage
nDuration of the current flow
nFrequency
nLevel of moisture of the skin
nSize of the contact surface
It can include heart rhythm disturbances, ventricular fibrillation and
burn injuries due to the arcing effect. It is always advisable to con-
sult a doctor.
Immediate measures following an
electrical accident
Safety and responsibility
Immediate measures following an ...
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Intrinsic safety in an electrical accident
The intrinsic safety of the rescuer has absolute priority
in the event of an electrical accident.
The power must be disconnected in low voltage accidents by fol-
lowing measures:
nSwitching off
nPulling the plug
nRemoving the fuse
nTurning off the main switch
Firstly separate the injured party from the power source using non-
conductive items and only then rescue them from the hazard zone.
No rescue attempts should be undertaken in high voltage acci-
dents because of the intrinsic risk. In the event of high voltage
accidents always immediately initiate the emergency call and
summon specialist safety personnel.
The safety personnel must undertake clearing and securing
according to the five safety rules:
nSummon qualified electrical staff (for shutdown)
nMaintain the safety clearance (at least 5m in the case of high
voltage)
nSwitch off the electrical circuit
nSecure it against being switched on again
nHave a qualified electrician determine voltage free status
nHave energized parts nearby covered or isolated by a qualified
electrician
nAssistance only in consultation with a qualified electrician
2.10 Personnel requirements
WARNING!
Risk of injury if personnel are insufficiently quali-
fied
Application of the required specialist knowledge for the
PF55S. Inadequate or missing personnel qualification
increases the risk of an accident. This can result in
severe injuries and substantial property damage.
Hazards arise that can result in serious injuries and
considerable material damage if unqualified personnel
perform work on the device or are present in the sys-
tem's hazard zone.
– Have all activities carried out by qualified personnel
only.
– Always keep unqualified personnel away from
hazard zones.
Safety and responsibility
Personnel requirements
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Only persons 18 years of age or above, who can therefore be
expected to carry out their work dependably, are permitted as per-
sonnel. Personnel must have carefully read through and under-
stood this manual before starting any work. Following all safety
guidelines and instructions in this manual is the basic prerequisite
for safe work.
Persons whose reactions are affected, e.g. by drugs, alcohol or
other medication, are not permitted.
Observe the age and occupation-specific regulations applicable to
the installation site when selecting personnel.
This manual distinguishes between the personnel qualifications
listed below for the different fields of activity:
Operator
In training by the owner, the operator has been informed of the
tasks assigned to him and the possible hazards in the event of
improper conduct. Tasks beyond operation in the regular operating
mode may only be carried out by the operator if this is indicated in
this manual and the owner has explicitly entrusted the operator
with the task.
Qualified electrician
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified electrician is able to carry out work on electrical systems,
and identify and avoid possible hazards independently.
A qualified electrician has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations.
Qualified mechanic
Due to his technical training, knowledge and experience, as well as
his understanding of the relevant standards and regulations, a
qualified mechanic is able to carry out work on mechanical sys-
tems, and identify and avoid possible hazards independently.
A qualified mechanic has been specially trained in the working
environment in which he operates and knows the relevant stand-
ards and regulations. A qualified mechanic is also familiar with the
superordinate production system.
Safety and responsibility
Personnel requirements
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WARNING!
Risk of death for unauthorized persons in the
danger zones and work areas
There are hazards in the working range that only quali-
fied personnel can safely assess and avert. Those who
are unauthorized and do not comply with the described
requirements face the risk of severe injuries and even
death.
– Always keep unauthorized individuals away from
the danger zone and work area.
– If in doubt, address people and direct them out of
the danger zone or work area.
– Always interrupt work as long as unauthorized indi-
viduals are in the danger zone or work area.
The owner must train personnel regularly. Training takes place
annually for safety-relevant aspects. For improved monitoring, a
training record with the following minimum content must be cre-
ated:
nDate of training
nName of trainee
nTraining content
nName of trainer
nSignatures of the trainee and trainer
2.11 Personal protective equipment
Personal protective equipment serves to protect people from
impairments to health and safety during work.
During different types of work on and with the PF55S, personnel
must wear the personal protective equipment specifically referred
to in the individual sections of this manual.
Protective work clothing
Protective work clothing is defined as close fitting work clothing
with low tear resistance, tight, long sleeves and no protruding
parts.
Safety boots
Safety boots protect feet from being crushed, from falling parts and
from slipping on slippery surfaces.
Unauthorized persons
Training
Description of personal protective
equipment
Safety and responsibility
Personal protective equipment
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2.12 Safety guidelines for transport and storage
WARNING!
Risk of injury to the musculoskeletal system
The weight of the package can be found on the consignment note
or printed on the packaging.
Use suitable transport and lifting aids for weights over 25 kg.
NOTICE!
Material damage due to improper transport
Packages may fall or topple over due to improper trans-
port. This can result in considerable material damage.
– Proceed with care when unloading transport items
upon delivery and during internal transport.
– Follow the symbols and information on the pack-
aging.
– Do not remove packaging until shortly before
assembly.
Improper transport
Safety and responsibility
Safety guidelines for transport ...
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2.13 Safety guidelines for assembly and commissioning
WARNING!
Risk of injury due to improper assembly and instal-
lation
Improper assembly or installation can result in haz-
ardous situations, causing serious injuries and consid-
erable property damage.
– Have assembly and installation work carried out by
authorized specialist personnel only.
Ä 2.10 “Personnel requirements” on page 16
– Ensure the following if assembly and installation are
to be carried out by other persons:
– The individuals must have read and understood
this operating manual.
– The individuals must follow the instructions in
this operating manual.
– The individuals must have the necessary spe-
cialist skills for such assembly and installation.
– If assembly and installation are to be carried out by
internal personnel, or by personnel contracted by
the operating company, the operating company is
responsible for ensuring the assembly and installa-
tion are carried out correctly and safely.
– Always ensure sufficient space for assembly before
beginning work.
– Always make sure that the assembly site is clean
and tidy. Loose components and tools lying around
or on top of each other are sources of accidents.
– Always determine installation locations to account
for hazard-free access and operation.
– Assemble all of the components correctly.
– Always follow the operation and assembly manuals
for additional components.
Improper assembly and installation
Safety and responsibility
Safety guidelines for assembly a...
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