Endress+Hauser OUSAF46 User manual

Products Solutions Services
Operating Instructions
OUSAF46
Optical sensor with the OUA260 flow assembly for
the measurement of UV absorption
BA01349C/07/EN/03.18
71430357
2018-10-31

Table of contents OUSAF46
2 Endress+Hauser
Table of contents
1 About this document ........... 3
1.1 Warnings ........................... 3
1.2 Symbols ............................ 3
1.3 Symbols on the product ............... 4
2 Basic safety instructions ....... 4
2.1 Requirements for the personnel ........ 4
2.2 Designated use ...................... 4
2.3 Occupational safety .................. 4
2.4 Operational safety ................... 5
2.5 Product safety ....................... 5
3 Product description ............. 6
3.1 Measuring principle .................. 6
4 Incoming acceptance and
product identification .......... 7
4.1 Incoming acceptance ................. 7
4.2 Product identification ................. 7
4.3 Manufacturer's address ............... 8
4.4 Scope of delivery ..................... 8
4.5 Certificates and approvals ............. 8
5 Installation ...................... 9
5.1 Installation conditions ................ 9
5.2 Mounting the sensor ................ 11
5.3 Post-installation check ............... 12
6 Electrical connection .......... 12
6.1 Connecting the sensor ............... 13
6.2 Lamp voltage ....................... 14
6.3 Ensuring the degree of protection ..... 14
6.4 Post-connection check ............... 15
7 Commissioning ................ 16
7.1 Function check ..................... 16
7.2 Calibrating/adjusting the sensor ...... 16
8 Maintenance .................. 18
8.1 Maintenance schedule ............... 19
8.2 Replacing the hazardous area lamp .... 19
8.3 Replacing the mercury lamp .......... 19
8.4 Replacing the reference filter ......... 22
8.5 Replacing the measurement filter ..... 24
8.6 Replacing the sensor window and
seal ............................... 28
9 Repair .......................... 30
9.1 Return ............................ 30
9.2 Disposal ........................... 30
10 Accessories .................... 30
10.1 Flow assembly ...................... 31
10.2 Cable ............................. 31
10.3 Calibration ......................... 31
11 Technical data ................. 31
11.1 Input .............................. 31
11.2 Environment ....................... 32
11.3 Process ............................ 32
11.4 Mechanical construction ............. 32
Index ................................. 34

OUSAF46 About this document
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1 About this document
1.1 Warnings
Structure of information Meaning
LDANGER
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation will result in a fatal or serious injury.
LWARNING
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid the dangerous situation can result in a fatal or serious injury.
LCAUTION
Causes (/consequences)
If necessary, Consequences of non-
compliance (if applicable)
‣Corrective action
This symbol alerts you to a dangerous situation.
Failure to avoid this situation can result in minor or more serious injuries.
NOTICE
Cause/situation
If necessary, Consequences of non-
compliance (if applicable)
‣Action/note
This symbol alerts you to situations which may result in damage to property.
1.2 Symbols
Symbol Meaning
Additional information, tips
Permitted or recommended
Not permitted or not recommended
Reference to device documentation
Reference to page
Reference to graphic
 Result of a step

Basic safety instructions OUSAF46
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1.3 Symbols on the product
Symbol Meaning
Reference to device documentation
2 Basic safety instructions
2.1 Requirements for the personnel
• Installation, commissioning, operation and maintenance of the measuring system may be
carried out only by specially trained technical personnel.
• The technical personnel must be authorized by the plant operator to carry out the specified
activities.
• The electrical connection may be performed only by an electrical technician.
• The technical personnel must have read and understood these Operating Instructions and
must follow the instructions contained therein.
• Faults at the measuring point may only be rectified by authorized and specially trained
personnel.
Repairs not described in the Operating Instructions provided must be carried out only
directly at the manufacturer's site or by the service organization.
2.2 Designated use
The sensor measures the spectral absorption of process liquids in the ultraviolet region of the
electromagnetic spectrum. The sensor is suitable for use in a wide range of applicationsin a
variety of industrial sectors , such as:
• Measurement of protein concentrations
• Chromatography monitoring
• Filtration monitoring
• Concentration measurement of organic compounds
• Detection of aromates
Use of the device for any purpose other than that described, poses a threat to the safety of
people and of the entire measuring system and is therefore not permitted.
The manufacturer is not liable for damage caused by improper or non-designated use.
2.3 Occupational safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
• Regulations for explosion protection

OUSAF46 Basic safety instructions
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Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable European standards for industrial applications.
• The electromagnetic compatibility indicated applies only to a product that has been
connected in accordance with these Operating Instructions.
2.4 Operational safety
Before commissioning the entire measuring point:
1. Verify that all connections are correct.
2. Ensure that electrical cables and hose connections are undamaged.
3. Do not operate damaged products, and protect them against unintentional operation.
4. Label damaged products as defective.
During operation:
‣If faults cannot be rectified:
products must be taken out of service and protected against unintentional operation.
2.5 Product safety
2.5.1 State of the art
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. The relevant regulations and
European standards have been observed.
2.5.2 Versions with hazardous area lamp
Also observe the safety instructions in the XA for these Operating Instructions.
Safety instructions for electrical apparatus in hazardous areas, photometer sensors,
XA01403C/07/A3

Product description OUSAF46
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3 Product description
3.1 Measuring principle
Light absorption
The measuring principle is based on the Lambert-Beer law.
There is a linear dependency between the absorption of light and the concentration of the
absorbing substance:
A = -log(T) = ε . c . OPL
T = I/I0
T ... Transmission
I ... Intensity of received light at detector
I0 ... Intensity of transmitted light of light source
A ... Absorption
ε ... Extinction coefficient
c ... Concentration
OPL ... Optical path length
A light source emits radiation through the medium and the incident radiation is measured on
the detector side.
The subsequent conversion to absorbance units (AU, OD) is performed in the associated
transmitter.
1OPL
23
4
5
68 7 2
A0029412
 1 Absorption measurement with reference
1 Light source
2 Optical windows
3 Measurement filter
4 Measuring detector
5 Lens
6 Medium flow
7 Reference filter
8 Reference detector
OUSAF46 has 2 pairs of reference and measuring detectors (= 2 channels). Only one
channel is shown for the sake of simplicity.

OUSAF46 Incoming acceptance and product identification
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4 Incoming acceptance and product identification
4.1 Incoming acceptance
1. Verify that the packaging is undamaged.
 Notify the supplier of any damage to the packaging.
Keep the damaged packaging until the issue has been resolved.
2. Verify that the contents are undamaged.
 Notify the supplier of any damage to the delivery contents.
Keep the damaged goods until the issue has been resolved.
3. Check that the delivery is complete and nothing is missing.
 Compare the shipping documents with your order.
4. Pack the product for storage and transportation in such a way that it is protected
against impact and moisture.
 The original packaging offers the best protection.
Make sure to comply with the permitted ambient conditions.
If you have any questions, please contact your supplier or your local Sales Center.
4.2 Product identification
4.2.1 Nameplate
The nameplate provides you with the following information on your device:
• Manufacturer identification
• Order code
• Serial number
• Safety information and warnings
‣Compare the information on the nameplate with the order.
4.2.2 Product identification
Product page
www.endress.com/ousaf46
Interpreting the order code
The order code and serial number of your product can be found in the following locations:
• On the nameplate
• In the delivery papers
Obtaining information on the product
1. Go to www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.

Incoming acceptance and product identification OUSAF46
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4. Search.
 The product structure is displayed in a popup window.
5. Click on the product image in the popup window.
 A new window (Device Viewer) opens. All of the information relating to your
device is displayed in this window as well as the product documentation.
4.3 Manufacturer's address
Endress+Hauser Conducta Inc.
4123 East La Palma Avenue, Suite 200
Anaheim, CA 92807 USA
4.4 Scope of delivery
The scope of delivery consists of the following :
• Detector and lamp module without flow assembly or
• Detector and lamp module mounted on flow assembly
• Operating Instructions
Ordering the sensor together with a transmitter:
If you select the calibration option in the Product Configurator for the transmitter, the
complete measuring system (transmitter, sensor, cable) is factory-calibrated and shipped
as one package.
‣If you have any queries:
Please contact your supplier or local sales center.
4.5 Certificates and approvals
4.5.1  mark
Declaration of Conformity
The product meets the requirements of the harmonized European standards. As such, it
complies with the legal specifications of the EU directives. The manufacturer confirms
successful testing of the product by affixing to it the  mark.
4.5.2 Hazardous area approvals
• ATEX II 2G Ex db IIC T5 Gb
• FM Cl.1, Div. 1, Groups B, C, D
4.5.3 FDA conformity
All non-metal parts in contact with medium, such as rubber and plastic parts, meet the
requirements of FDA 21 CFR 177.2600. The plastic and elastomer parts of the sensor in
contact with medium have passed the biological reactivity tests according to USP <87> and
<88> Class VI.

OUSAF46 Installation
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5 Installation
5.1 Installation conditions
5.1.1 Measuring system
An optical measuring system comprises:
• Sensor (photometer) OUSAF46
• Transmitter, e. g. Liquiline CM44P
• Cable set, e. g. CUK80
• Assembly OUA260
1 2
3
7
54
6
 2 Example of a measuring system with a photometer sensor
1 pipe 5 Flow assembly OUA260
2 Transmitter CM44P 6 Sensor: light source (lamp)
3 CUK80 cable set 7 CUK80 cable set
4 Sensor: detector

Installation OUSAF46
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5.1.2 Dimensions
A B
C
A0035258
 3 Sensor module
A Dimension of lamp → Table
B Dimension of detector → Table
C Assembly, see Technical Information for assembly
Lamp type Dimension A in mm (inch)
Standard lamp 146.1 (5.75)
Detector type Dimension B in mm (inch)
Standard version with test filter 80 (3.15)
Easycal 94 (3.70)
The total length of the sensor module is derived from the lengths of the lamp, the
detector and the assembly.
The dimensions of the OUA260 assembly are provided in Technical Information,
TI00418C.
‣Allow an additional gap of 5 cm (2") on both the lamp side and detector side of the sensor
to connect the sensor cable.

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5.1.3 Mounting angles
A
B
C
D
E
A0028250
 4 Mounting angles. The arrows indicate the direction of medium flow in the pipe.
A Suitable mounting angle, better than C
B Optimum mounting angle, best installation position
C Acceptable mounting angle
D Mounting angle to be avoided
E Forbidden mounting angle
5.2 Mounting the sensor
The sensors have been specifically designed so that they can be installed in the process
together with a flow assembly, such as the OUA260. The flow assembly can be installed either
directly in a process line or in a bypass line.
The sensor cannot be used without an assembly.
‣Make sure that the sensor housing and detector housing are aligned horizontally. This
ensures that the optical windows are vertically aligned as this prevents buildup on the
window surfaces.

Electrical connection OUSAF46
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‣Install the sensor upstream from the pressure regulators.
‣Leave enough room for the cable connector at the end of the lamp and at the end of the
detector housing. Unimpeded access to these areas is also required for connection/removal
tasks.
‣The operation of sensors under pressure prevents the formation of air or gas bubbles.
NOTICE
Mounting errors
Possibility of sensor damage, twisted cables or similar
‣Make sure that the sensor bodies are protected against damage from external forces - such
as trolleys on adjacent paths.
‣Remove the cable before you screw the lamp or detector onto the flow assembly.
‣Make sure to avoid exerting excessive tensile force on the cable (e.g. from jerky pulling
movements).
‣Make sure to observe the national grounding regulations when using metal assemblies.
If the sensor is ordered together with the assembly OUA260, the flow assembly is ready-
mounted on the sensor upon delivery. The sensor is ready for use immediately.
If the sensor and assembly are ordered separately, you must mount the sensor as follows:
1. Install flow assembly OUA260 in the process via the process connections.
2. Make sure to fit the O-ring seals on the lamp and detector.
Screw the lamp and detector onto the flow assembly.
The lamp and detector can be installed in and removed from the assembly without this
affecting the process line.
5.3 Post-installation check
Put the sensor into operation only if you can answer "yes" to the following questions:
• Are the sensor and cable undamaged?
• Have you chosen a correct mounting angle?
6 Electrical connection
LWARNING
Device is live!
Incorrect connection may result in injury or death!
‣The electrical connection may be performed only by an electrical technician.
‣The electrical technician must have read and understood these Operating Instructions and
must follow the instructions contained therein.
‣Prior to commencing connection work, ensure that no voltage is present on any cable.

OUSAF46 Electrical connection
Endress+Hauser 13
6.1 Connecting the sensor
The sensor is connected to the transmitter using the pre-terminated or labeled cable set
CUK80 (for connection to CM44P) or OUK (for connection to CVM40) . The terminals and
labeling may vary depending on the transmitter in use. The cable set must be ordered
separately.
BK
GY
RD
AB
YE
YE
BK
BK
GY
RD
BK
B
GY
WH
GN
GN
GY
WH
A0033423
 5 OUSAF46 connecting cable
A Light source (lamp) power supply
B Signals of measurement and reference detector
CM44P terminal CVM40 terminal Cable color Assignment
PEM module 1
P+ V1.1 YE (thick) Lamp voltage +
S+ V1.3 YE (thin) Detection of lamp voltage +
S- V1.4 BK (thin) Detection of lamp voltage -
P- V1.2 BK (thick) Lamp voltage -
A (1) S1.1 RD Channel 1 Sensor measuring detector +
C(1) S1.2 BK Channel 1 Sensor measuring detector -

Electrical connection OUSAF46
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CM44P terminal CVM40 terminal Cable color Assignment
SH (1) S1.S GY Channel 1 Shield
A (2) S2.1 WH (lamp) Channel 1 Sensor reference +
C(2) S2.2 GN (lamp) Channel 1 Sensor reference -
SH (2) S2.S GY (lamp) Channel 1 Shield
PEM module 2
A (1) S3.1 WH Channel 2 Sensor measuring detector +
C(1) S3.2 GN Channel 2 Sensor measuring detector -
SH (1) S3.S GY Channel 2 Shield
A (2) S4.1 RD (lamp) Channel 2 Sensor reference +
C(2) S4.2 BK (lamp) Channel 2 Sensor reference -
SH (2) S4.S GY (lamp) Channel 2 Shield
6.2 Lamp voltage
Sensor version Lamp type Lamp voltage [V]
OUSAF46-xxxx Low-pressure mercury lamp 10.0 ± 0.1
6.3 Ensuring the degree of protection
Only the mechanical and electrical connections which are described in these instructions and
which are necessary for the required, designated use, may be carried out on the device
delivered.
‣Exercise care when carrying out the work.
Individual types of protection permitted for this product (impermeability (IP), electrical safety,
EMC interference immunity, Ex protection) can no longer be guaranteed if, for example :
• Covers are left off
• Different power units to the ones supplied are used
• Cable glands are not sufficiently tightened (must be tightened with 2 Nm (1.5 lbf ft) for the
permitted level of IP protection)
• Unsuitable cable diameters are used for the cable glands
• Modules are not fully secured
• The display is not fully secured (risk of moisture entering due to inadequate sealing)
• Loose or insufficiently tightened cables/cable ends
• Conductive cable strands are left in the device

OUSAF46 Electrical connection
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6.4 Post-connection check
Device condition and specifications Notes
Are the sensor, assembly and cable free from damage on the outside? Visual inspection
Electrical connection Notes
Does the supply voltage of the connected transmitter match the data on the
nameplate?
Visual inspection
Are the installed cables strain-relieved and not twisted?
Has the cable been routed without loops and cross-overs? Check that it is firmly seated (by
pulling gently)
Are the signal cables connected correctly according to the connection diagram?
Are all cable entries mounted, tightened and leak-tight? For lateral cable entries, make sure
the cables loop downwards to allow
water to drip off.
Are the PE distributor rails grounded (if present)? Grounding at the point of
installation

Commissioning OUSAF46
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7 Commissioning
7.1 Function check
Prior to initial commissioning, ensure that:
• The sensor is correctly installed
• The electrical connection is correct.
7.2 Calibrating/adjusting the sensor
Measuring points consisting of a photometer sensor, flow assembly (if provided) and a
transmitter are adjusted at the factory. Normally adjustment is not required when
commissioning for the first time.
If an adjustment is desired nevertheless, you have the following adjustment options:
• Adjustment with calibration standards
• Use of Easycal
7.2.1 Calibration/adjustment with standard solutions
Use solutions with a known absorbance (at the sensor wavelength) for the calibration/
adjustment.
LWARNING
Potassium dichromate is toxic, flammable, carcinogenic and has mutagenic effects!
Can cause cancer, genetic defectives, affect fertility, harm the unborn child and intensify fires.
Potentially life-threatening if inhaled, toxic if swallowed, harmful if it comes into contact with
skin. Causes severe skin burns and severe eye damage!
‣When working with potassium dichromate, always wear protective gloves and protective
goggles.
‣Seek special advice before use.
‣Follow all of the instructions on the manufacturer's safety data sheet.
Use calibration solutions that are suitable for the measuring task. Examples of solutions which
are commonly used include:
Potassium dichromate, K2Cr2O7
A solution of 182 ml 0.1N K2Cr2O7, diluted to one liter, has an absorbance of approx. 10 OD at
280 nm. By diluting the solution, you can produce a series of calibration solutions which you
can use to adjust the measuring point.
AU = OD*OPL[cm]
AU ... absorbance units, OD ... optical density, OPL .... optical path length
Instead of potassium dichromate you can also use your process medium for calibrating/
adjusting and for application calibration. Here, also produce a series of dilutions of
known concentration and determine the absorbance in the laboratory.

OUSAF46 Commissioning
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7.2.2 Easycal
Easycal enables you to perform a calibration/an adjustment which is traceable to NIST
without any liquid standards.
Detector with Easycal: function
1 2
34
A0033709
 6 Filter in "out" position
1 NIST-traceable filter (high)
2 Locking screw
A0033708
 7 Filter in "in" position
3 Positioning pin
4 Lens assembly
Every Easycal device has two traceable filters - one filter with a nominal 0.5 AU and another
filter with 1 AU (absorbance unit) - which are placed individually or together in the device
measuring path. These filter(s) are scanned with traceable testing equipment and the actual
absorbance at individual wavelengths is determined.
It is very important that you use the actual values of the optical Easycal filter. These values are
given in the calibration certificate supplied.
‣Enter the absorbance values (CM44P): Menu/Setup/Inputs/Photometer/Extended
setup/Measurement channel/Calib. settings/EasyCal = Yes, NIST filter high and NIST
filter low.
Send Easycal in to your Service Center once a year for recertification. This comprises
complete functional testing and the recertification of the filters in accordance with
sources that are traceable to NIST.
7.2.3 Visual inspection
A reference rod is included in the delivery for every standard sensor (sensor without Easycal).
In this way, it is possible to perform a functional test on the device without having to use
calibration solutions.

Maintenance OUSAF46
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The reference rod is screwed into the sensor detector housing, thereby partially blocking the
sensor light. This simulates the absorbance in the optical chain.
The cross-sectional view of the measuring detector below illustrates the position of the
reference rod and its blocking effect.
A0035261
 8 Cross-section of detector module with reference rod inserted
Proceed as follows to obtain a value for the reference rod during commissioning:
1. Fill the flow assembly with water. Make sure that the measured value "zero" is displayed.
2. Insert the reference rod into the detector housing.
 Make a note of the measured value.
You can check the calibration any time later on by filling the flow assembly with water again
and re-inserting the reference rod. The measured value should be equal to the value noted
down.
8 Maintenance
Take all the necessary precautions in time to ensure the operational safety and reliability of
the entire measuring system.
NOTICE
Effects on process and process control!
‣When carrying out any work on the system, bear in mind any potential impact this could
have on the process control system and the process itself.
‣For your own safety, only use genuine accessories. With genuine parts, the function,
accuracy and reliability are also ensured after maintenance work.

OUSAF46 Maintenance
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NOTICE
Sensitive optical components
If you do not proceed with care, you can damage or severely dirty the optical components.
‣Maintenance work may only be carried out by appropriately qualified staff.
‣Use ethanol and a lint-free cloth which is suitable for cleaning lenses to clean all the
optical components.
8.1 Maintenance schedule
• Maintenance and servicing intervals are based on the individual application.
• Cleaning intervals depend on the medium.
Maintenance checklist
• Replace lamp
The lamp is typically replaced after 1000 to 3000 operating hours (→  33).
• Replace sensor window and seal
The window only needs to be replaced if it is damaged.
• Replace O-rings in contact with the medium
The replacement of O-rings in contact with the medium depends on the specific
requirements of the process.
Never re-use a used O-ring.
8.2 Replacing the hazardous area lamp
The disassembly and assembly process for the hazardous area lamp is the same as for the
non-hazardous area version.
Make sure you use the right spare parts kit.
8.3 Replacing the mercury lamp
LWARNING
Dangerous voltage
Risk of serious or fatal injury from electric shock!
‣Before performing any maintenance work on the lamp, remove all the cables and
disconnect the power supply to the sensor.
‣Only replace the lamp in a current-free state.
LCAUTION
Mercury lamp
UV radiation can damage the eyes!
‣Protect your eyes with protective goggles suitable for UV radiation.
‣Never look directly into a mercury lamp when it is switched on.

Maintenance OUSAF46
20 Endress+Hauser
Removing the used lamp
‣Switch off the lamp using the software function on the transmitter.
‣Remove the lamp cable.
‣Allow the lamp to cool down (30 minutes).
1.
Turn the lamp module counterclockwise to remove it from the flow assembly.
2.
Use a 1" open-ended wrench. With the wrench, hold the base plate of the cable
connector in position and unscrew the lamp housing in a counterclockwise direction by
hand.
 Remove the lamp and reflector unit from the housing.
3.
Loosen the securing screw holding the lamp by 1-2 rotations.