Endress+Hauser OUSAF44 User manual

BA416C/07/EN/13.10
71125870
Operating Instructions
OUSAF44
Optical sensor combined with flow assembly OUA260 for
measurement of UV absorption

Endress+Hauser
OUSAF44
Table of contents
1 Safety instructions . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . 4
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Notes on safety icons and symbols . . . . . . . 5
2 Identification . . . . . . . . . . . . . . 7
2.1 Product structure . . . . . . . . . . . . . . . . . . . . 7
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . 8
2.3 Certificates and approvals . . . . . . . . . . . . . . 8
3 Installation . . . . . . . . . . . . . . . . 9
3.1 Incoming acceptance, transport, storage . . . 9
3.2 Installation conditions . . . . . . . . . . . . . . . 10
3.3 Installation instructions . . . . . . . . . . . . . . 13
3.4 Post-installation check . . . . . . . . . . . . . . . 14
4 Wiring . . . . . . . . . . . . . . . . . . 15
4.1 Electrical connection . . . . . . . . . . . . . . . . 15
4.2 Post-connection check . . . . . . . . . . . . . . . 16
5 Function . . . . . . . . . . . . . . . . . 16
5.1 Design of OUSAF44 with OUA260 flow
assembly . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Measuring principle . . . . . . . . . . . . . . . . . 17
5.3 Function check . . . . . . . . . . . . . . . . . . . . 17
5.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5 Optical check . . . . . . . . . . . . . . . . . . . . . . 20
6 Maintenance. . . . . . . . . . . . . . 22
6.1 Mercury lamp replacement for
OUSAF44 . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 OUSAF44 reference detector/filter
replacement . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Measurement filter replacement (Easycal™
assembly) . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4 Measurement filter replacement (standard
assembly) . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Sensor window and gasket replacement . . 29
6.6 Sensors without precision optical pathlength
adjuster option . . . . . . . . . . . . . . . . . . . . . 30
6.7 Sensors with precision optical pathlength
adjuster option . . . . . . . . . . . . . . . . . . . . . 30
7 Accessories . . . . . . . . . . . . . . . 34
7.1 Flow assembly . . . . . . . . . . . . . . . . . . . . . 34
7.2 Transmitters . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Trouble-shooting. . . . . . . . . . . 35
8.1 List of spare parts OUSAF44 Sensor . . . . . . 35
8.2 List of spare parts OUA260
Flow assembly . . . . . . . . . . . . . . . . . . . . . 36
8.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 Technical data . . . . . . . . . . . . . 40
9.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.2 Environment . . . . . . . . . . . . . . . . . . . . . . 40
9.3 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.4 Mechanical construction . . . . . . . . . . . . . . 41
Index. . . . . . . . . . . . . . . . . . . . 42

Safety instructions OUSAF44
4Endress+Hauser
1 Safety instructions
1.1 Designated use
The OUSAF44 sensor is used for measuring the spectral absorbance of process liquids in the
ultraviolet region of the electromagnetic spectrum. It is suitable for a variety of applications:
• Measurement of protein concentrations
• Chromatography control
• Product purification
• Concentration measurement of organic compounds
• Aromatics detection
• Filtration monitoring
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.
1.2 Installation, commissioning and operation
Please note the following items:
• Installation, commissioning, operation and maintenance of the measuring system must only
be carried out by trained technical personnel.
Trained personnel must be authorized for the specified activities by the system operator.
• Electrical connection must only be carried out by a certified electrician.
• Technical personnel must have read and understood these Operating Instructions and must
adhere to them.
• Before commissioning the entire measuring point, check all the connections. Ensure that
electrical cables and hose connections are not damaged.
• Do not operate damaged products and secure them against unintentional commissioning.
Mark the damaged product as being defective.
• Measuring point faults may only be rectified by authorized and specially trained personnel.
• If faults can not be rectified, the products must be taken out of service and secured against
unintentional commissioning.
• Repairs not described in these Operating Instructions may only be carried out at the
manufacturer’s or by the service organization.
1.3 Operational safety
The sensor has been designed and tested according to the state of the art and left the factory in
perfect functioning order.
Relevant regulations and European standards have been met.
As the user, you are responsible for complying with the following safety conditions:
• Installation instructions
• Local prevailing standards and regulations.

OUSAF44 Safety instructions
Endress+Hauser 5
1.4 Return
If the sensor has to be repaired, please return it cleaned to the sales center responsible.
Please use the original packaging, if possible.
Before returning the device, contact your regional sales or service representative to get the local
return procedure.
Please enclose the completed "Declaration of Hazardous Material and De-Contamination" (copy
the second last page of these Operating Instructions) with the packaging and the transportation
documents. No repair without completed declaration!
1.5 Notes on safety icons and symbols
1.5.1 Embedded safety symbols according to ANSI
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 Meaning
DANGER
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation will result in a fatal or serious
injury.
WARNING
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the situation can result in a fatal or serious
injury.
CAUTION
!
Cause (/consequences)
Consequences if safety
message is not heeded
►Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or medium
injury.
NOTICE
Cause/situation
Consequences if safety
message is not heeded
►Action/note
This symbol alerts you to situations that can result in damage
to property and equipment.

Safety instructions OUSAF44
6Endress+Hauser
1.5.2 Document symbols
È ä 1 This symbol stands for a cross-reference to a certain page (e.g. Page 1).
È å 2 This symbol stands for a cross-reference to a certain graphic (e.g. Fig. 2).
Additional information, tips
Permitted or recommended
Forbidden or not recommended

OUSAF44 Identification
Endress+Hauser 7
2 Identification
2.1 Product structure
Sensor OUSAF44
Cable set OUK40
Wavelength
A254nm
B280nm
C295nm
D302nm
E313nm
F365nm
Calibration / Validation
0Standard
1Easycal™
Lamp approval
AStandard
B FM Class 1 Div 1 groups B, C, D
C ATEX II 2G EEx d IIC T5
Assembly
0 Isolated order / spare part
1 Assembled to flow cell order position
OUSAF44- Complete order code
Sensor
1OUSAF44
2OUSAF46
Transmitter
A900series
B600series
C700series
DCVM40
Cable length
10 10 ft / 3 m
15 15 ft / 4.5 m
25 25 ft / 7.5 m
50 50 ft / 15 m
88 ..... ft
89 ..... m
Barrier
A No hazardous area
BFM,Busbar
C ATEX, Busbar
DFM,DINrail
EATEX,DINrail
OUK40- Complete order code

Identification OUSAF44
8Endress+Hauser
2.2 Scope of delivery
The scope of delivery depends on the ordered version.
Isolated order
• 1 detector and lamp arm without flow assembly
Assembled to flow assembly OUA260
• Detector and lamp arm
Operating Instructions depending on the used transmitter
If you have any questions, please contact your supplier or your local sales center.
2.3 Certificates and approvals
2.3.1 Ex approval
• ATEX II 2G EEx d IIC T5
• FM Cl.1, Div. 1, Group B, C, D
2.3.2 FDA conformity
All non metallic wetted parts as in rubber and plastics comply with FDA Regulations 21 CFR
177.2600. The plastic and elastomeric wetted parts of the sensor have passed the bio-reactivity
tests according to USP <87> and <88> class VI.

OUSAF44 Installation
Endress+Hauser 9
3 Installation
3.1 Incoming acceptance, transport, storage
• 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.

Installation OUSAF44
10 Endress+Hauser
3.2 Installation conditions
3.2.1 Angle of installation
Sensors are designed for in-line use with the related OUA260 flow assembly. The flow assembly
can be installed either directly in a process line or in a by-pass line. The OUSAF44 sensor cannot
be used without the OUA260.
• Make sure that the sensor and detector housings are horizontal. This will ensure that the
optical window surfaces are in a vertical position which will help to prevent buildup on the
window surfaces.
• Install the sensor upstream of pressure regulators.
• Allow adequate space for the connection of cables at the ends of the lamp and the detector
housing.
• Operating sensors under pressure will help to avoid air or gas bubble evolution.
a0007110
Fig. 1: Sensor installation
A
B
C
D
Preferred
Acceptable
Avoid
Best
E
1
2
Never
Process flow
Process piping
C
A
B
E
D
11
1
1
1
2
2
2
2
2

OUSAF44 Installation
Endress+Hauser 11
3.2.2 Dimensions
The sensor dimensions depend on the flow assembly.
Make sure to leave an additional clearance of approx. 5 cm (2") for installation of the sensor
cable.
a0009526
Fig. 2: General dimensions
1
2
3
Detector assembly
Flow assembly
Lamp assembly
Detector assembly type ALamp assembly type B
Standard OUSAF44 w/ ref
rod
60.2 mm (2.37") Standard lamp 142 mm (5.60")
Easycal™ 69 mm (2.70")
123
AB

Installation OUSAF44
12 Endress+Hauser
Example: OUSAF44 for non-Ex area with triclamp flow assembly
a0007106
Fig. 3: Dimensions of OUSAF44-xxAx sensor; dimensions A, B, C, D depend on the process connection size (see table
below)
Connection
size
A B C D
Standard Easycal™
¼" - ¾" 258.6 mm
(10.18")
88.3 mm (3.48") 96.6 mm (3.81") 170.3 mm
(6.71")
82.6 mm (3.25")
1" - 1 ½" 268.5 mm
(10.57")
93.2 mm (3.67") 101.6 mm (4.0") 175.3 mm (6.9") 82.6 mm (3.25")
2" 288.5 mm
(11.36")
103.3 mm (4.07") 111.6 mm (4.4") 185.3 mm (7.3") 82.6 mm (3.25")
2 ½" 301.2 mm
(11.86")
109.6 mm (4.32") 118.0 mm
(4.65")
191.6 mm
(7.55")
88.9 mm (3.5")
3" 310.1 mm
(12.21")
114.0 mm (4.49") 122.4 mm
(4.82")
196.1 mm
(7.72")
114.3 mm (4.5")
4" 334.3 mm
(13.16")
126.1 mm (4.97") 134.5 mm (5.3") 208.2 mm (8.2") 123.8 mm
(4.88")
D
A
BC
mm (inch)

OUSAF44 Installation
Endress+Hauser 13
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system is typically comprised of:
• Transmitter Memograph CVM40
• An optical sensor, e.g. OUSAF44
• Flow assembly, e.g. OUA260
• Cable set, e.g. OUK40
a0012117
Fig. 4: Example of a measuring system
1 Cable set OUK40
2 Transmitter Memograph CVM40
3 Optical sensor OUSAF44
4 Flow assembly OUA260
1
2
1
3
4
3

Installation OUSAF44
14 Endress+Hauser
3.3.2 Installing the sensor
NOTICE
External forces
Make sure to leave enough space when installing the sensor to prevent sensor damage. Make
sure the cable is not twisted.
►Ensure that sensor bodies are protected against damage caused by external forces.
►Remove the cable before screwing the lamp or detector onto the flow assembly.
►Avoid exerting excessive tensile force on the cable.
When using metallic assemblies and installation equipment, comply with national
grounding regulations.
If the OUSAF44 is ordered with the OUA260, it will be shipped mounted to the flow assembly
and is ready for commissioning.
Otherwise, for sensor installation, proceed as follows:
1. Install the flow assembly OUA260 via the process connections into the process.
2. Screw the sensor onto the flow assembly.
Before mounting the flow assembly adjust the precision optical pathlength (see Section 6.8).
The lamp and detector can be mounted and removed without affecting process line
integrity.
When installing, allow adequate space for the connection of cables at the ends of the lamp and
detector housings. Access to these areas is also important for connection/disconnection
purposes.
3.4 Post-installation check
• Sensor and cable undamaged?
• Compliance with permissible sensor installation position?

OUSAF44 Wiring
Endress+Hauser 15
4 Wiring
WARNING
!
Device is energized
Inappropriate connection can cause serious injuries 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 Electrical connection
The OUSAF44 sensor is connected to the transmitter via the pre-terminated and labeled cable
set OUK40 (to be ordered separately).
Terminals and labeling might vary with the transmitter in use.
a0007108
Fig. 5: Connecting cable for OUSAF44
A
B
Power supply for lamp
Signal transmission of measurement detector and reference detector
Terminal CVM40 Core OUSAF44 Assignment OUSAF44
S1.S GY Shield
S1.1 RD Measurement detector +
S1.2 BK Measurement detector -
S2.S GY Shield
S2.1 WH Reference detector +
S2.2 GN Reference detector -
V1.1 YE (bold) Lamp voltage +
V1.3 YE (thin) Lamp sense +
V1.4 BK (thin) Lamp sense -
V1.2 BK (bold) Lamp voltage -

Function OUSAF44
16 Endress+Hauser
4.2 Post-connection check
5 Function
5.1 Design of OUSAF44 with OUA260 flow assembly
Instrument status and specifications Remarks
Are the sensor, assembly or cable damaged? Visual inspection
Electrical connection Remarks
Are the installed cables strain-relieved and not twisted ?
No loops and cross-overs in the cable run? Check seating (pull slightly)
Are the signal cables correctly connected according to the wiring
diagram?
Are all screw terminals tightened?
Are all cable entries installed, tightened and sealed?
Are the PE distributor rails grounded (if present)? Grounding at place of installation
a0007111
Fig. 6: Design of OUSAF44 with OUA260 flow assembly
1
2
3
4
Environmental connector
Lamp housing
OUA260 flow assembly (to be ordered separately)
Detector housing
131
24

OUSAF44 Function
Endress+Hauser 17
5.2 Measuring principle
Absorption light method
The measuring principle is based on the Lambert-Beer law. There is a linear dependency
between the light absorption and the concentration of the absorbing substance. A light source
emits radiation through the medium and the transmitted radiation is measured on the detector
side. After passing a filter for wavelength selection, the light intensity is determined by a
photodiode and converted into a photo current. The final conversion into transmission (%) or
absorbance (AU, OD) units is done by the related transmitter.
5.3 Function check
Before first commissioning, check if:
• the sensor is installed correctly
• the electrical connection is correct.
a0007107
Abb. 7: E.g. Absorption sensor with reference
A
ε
c
OPL
Absorbance
Extinction coefficient
Concentration
Optical pathlength
1
2
3
4
5
6
Light source
Reference filter
Reference detector
Measurement filter
Measurement detector
Medium
1
2
3
4
5
6
A ref
A meas
A = -log A /A
meas ref
= c OPLe × ×

Function OUSAF44
18 Endress+Hauser
5.4 Calibration
Calibration is a means of adapting the transmitter to the characteristic values of the sensor.
OUSAF44 has been factory-calibrated, therefore, when first commissioning no calibration is
necessary.
There are two different calibration procedures: Liquid calibration and Easycal™.
Before calibrating, the unit has to be powered up for at least 30 minutes.
5.4.1 Liquid calibration procedure
A liquid solution of a known optical density (at the wavelength of the sensor) must be used for
instrument calibration. The following procedure is used in factory when Easycal™ option is not
ordered. Calibration liquid can be chosen by user in field depending on application.
Potassium Dichromate (K2Cr2O7) is most often used as an optical standard for calibration of UV
analyzers. A solution consisting of 182 ml of 0.1N K2Cr2O7, diluted with DI water to a 1 L
volume, has an absorbance of approximately 10 OD at 280 nm. Successive dilution will provide
a series of calibration solutions for sensor calibration at more than one point.
D-Tryptophan is a common protein used for optical calibration of UV analyzers at 280 nm.
1. Place a solution made of 1.000 grams of Tryptophan and 200 ml of de-ionized water into
the beaker.
2. Heat it on a magnetic stirrer.
3. As the Tryptophan dissolves add de-ionized water to a volume of about 450 ml. The
Tryptophan dissolves slowly.
4. Continue the stirring, maintaining a temperature of about 30 ºC until the Tryptophan is
completely in solution.
5. Transfer this solution into a 1000 ml volumetric flask and dilute with de-ionized water to
a final volume of 1000 ml.
This is a concentration of 1000 ppm D-Tryptophan in water and is used as the basic standard or
mother solution from which successive dilutions can be prepared. A solution diluted to 100 ppm
is about 2.6 OD at 280 nm.
When preparing solutions, it is very important to measure the optical absorbance of every
solution prepared (at the wavelength of the sensor) on a certified laboratory
spectrophotometer.

OUSAF44 Function
Endress+Hauser 19
5.4.2 Easycal™ set up and calibration
All OUSAF44 sensors can be fitted with the optional Easycal™ calibration system. The
Easycal™ allows NIST traceable calibration without using liquid standards and guarantees fast
and precise calibration of the UV system. This option is available in new systems and as a retrofit
item for existing units in the field. See Section "Accessories" for retrofit item ordering
information.
Each Easycal™ unit contains two traceable filters - a nominal 0.5 AU and 1 AU (Absorbance
unit) - which are placed into the optical measurement path of the instrument either separately
or together. These filters are scanned with a traceable source and their actual absorbance at
individual wavelengths is ascertained.
The Easycal™ system allows traceable calibration without using liquid standards. It is very
important to refer to the actual values of the Easycal™ optical filters as noted on the Calibration
Certificate supplied with the unit. These absorbance values should be entered into the
transmitter as part of the configuration setup. The Easycal™ screen appears only if it is installed
and configured in the System Data section.
Return the Easycal™ to your local service center on an annual basis for recertification. This
recertification includes a complete functional check and recertifies the filters to NIST
traceable sources. Use a spare Easycal™ to keep the unit in operation while the Easycal™
is being sent for recertification.
a0012944
Abb. 8: Easycal™ housing and controls

Function OUSAF44
20 Endress+Hauser
5.5 Optical check
Use reference rod for function check
A reference rod is supplied with each standard sensor (a sensor without Easycal™). It is used to
perform a function check of the instrument without requiring the use of calibration solutions.
The reference rod screws into the detector housing of the sensor, providing partial blockage of
the sensor light and therefore simulating absorbance in the optical chain. The cross-sectional
view of an OUSAF44 measurement detector shown below illustrates the placement and the
blocking effect that the reference rod has to the sensor's detector.
When used in conjunction with an initial liquid standard calibration procedure, the reference
rod can be used for routine system checking. During initial calibration of a sensor/analyzer pair,
liquid standards must be used to calibrate the full-scale response of the system. After calibration,
by filling the sensor with water and ensuring the analyzer reads zero, a value for the reference
rod can be obtained by inserting the reference rod into the sensor detector housing and noting
the analyzer display reading. At any time in the future, reinserting the reference rod and
checking that the analyzer reads the same with the sensor filled with water can check the
analyzer calibration.
All analyzers must be re-calibrated with liquid standards if there are any changes made to
the optical chain, including replacement of seals or lamp.
a0012844
Fig. 9: Cross sectional view of detector with reference rod
1 Reference rod (shown in place)
2 Plug screw (replaces reference rod)
3 Measurement detector assembly
4 When reference rod is inserted, a partial blockage of the detector’s aperture results in a repeatable change in
Optical Density; this allows sensor checking insitu
12
3
4