Endress+Hauser Turbimax CUS71D User manual

BA490C/07/EN/02.11
71155719
Operating Instructions
Turbimax CUS71D
Ultrasonic interface sensor
Immersion sensor for interface measurement

Endress+Hauser

Turbimax CUS71D
Endress+Hauser 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Notes on safety icons and symbols . . . . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . . . . . . . 6
2.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Certificates and approvals . . . . . . . . . . . . . . . . . . . . 6
3 Installation . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Incoming acceptance, transport, storage . . . . . . . . . . 7
3.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 11
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Connecting to the transmitter . . . . . . . . . . . . . . . . 12
4.2 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 12
5 Device description . . . . . . . . . . . . . . . 13
5.1 Sensor design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Sensor monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Cyclic cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Commissioning. . . . . . . . . . . . . . . . . . 15
6.1 Firmware update . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Maintenance. . . . . . . . . . . . . . . . . . . . 24
7.1 Cleaning the sensor . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Accessories. . . . . . . . . . . . . . . . . . . . . 25
8.1 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Troubleshooting . . . . . . . . . . . . . . . . . 26
9.1 Troubleshooting instructions . . . . . . . . . . . . . . . . . 26
9.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.3 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10 Technical Data. . . . . . . . . . . . . . . . . . . 28
10.1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2 Performance characteristics . . . . . . . . . . . . . . . . . . 28
10.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.4 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.5 Mechanical construction . . . . . . . . . . . . . . . . . . . . 28
Index . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Safety instructions Turbimax CUS71D
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1 Safety instructions
1.1 Designated use
CUS71D is an immersion sensor designed for interface measurement in water and wastewater.
The sensor is particularly suited for use in the following applications:
• Wastewater treatment: primary clarifier, sludge thickener, secondary clarifier
• Water purification: settling basin after flocculant dosage, sludge height in contact sludge process
• Chemical industry: static separation process
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.
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, please clarify all formalities - such as obtaining an identification number
- with your sales center.
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!

Turbimax CUS71D Safety instructions
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1.5 Notes on safety icons and symbols
#Warning!
This symbol alerts you to hazards that can cause serious damage to the instrument or to persons if
ignored.
"Caution!
This symbol alerts you to possible faults which could arise from incorrect operation. They could
cause damage to the instrument if ignored.
!Note!
This symbol indicates important items of information.

Identification Turbimax CUS71D
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2 Identification
2.1 Nameplate
Compare the order code indicated on the nameplate to the product structure and your order.
The nameplate contains the following information:
• Manufacturer data
• Order code (device version)
• Extended order code
• Serial number
!Note!
To discover what sensor version you have, enter the order code on the nameplate into the search
screen at the following address:
www.products.endress.com/order-ident
2.2 Scope of delivery
The scope of delivery comprises:
• 1 sensor Turbimax CUS71D in the ordered version
• 1 Operating Instructions BA490C/07/EN
If you have any questions, please contact your supplier or your local sales center.
2.3 Certificates and approvals
Declaration of conformity
The product meets the requirements of the harmonized European standards. It thus complies with
the legal requirements of the EC directives.
The manufacturer confirms successful testing of the product by affixing the 4symbol.

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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.
3.2 Dimensions
a0014922
Fig. 1: Dimensions of standard sensor
a0014921
Fig. 2: Dimensions of sensor with wiper
mm (inch)
20 (0.79)
12 (0.47)
NPT 3/4"
G1
74.3 (2.93)
43.3 (1.70)
68.8 (2.71)
34.7 (1.37)
46 (1.81)
mm (inch)
20 (0.79)
12 (0.47)
NPT 3/4"
G1
74.3 (2.93)
110 (4.33)
135.5 (5.33)
34.7 (1.37)
46 (1.81)
19 (0.75)

Installation Turbimax CUS71D
8Endress+Hauser
3.3 Installation instructions
3.3.1 Measuring system
A complete measuring system comprises:
• Ultrasonic sensor Turbimax CUS71D
• Multi-channel transmitter Liquiline CM44x
and optional:
• Weather protection roof CYY101
• Holder system Flexdip CYH11
• Fixed or rotatable immersion pipe Flexdip CYA112
a0014923
Fig. 3: Ultrasonic sensor with holder system and multi-channel transmitter
1
2
3
4
1
5
1 Holder system Flexdip CYH112 4 Assembly Flexdip CYA112
2 Multi-channel transmitter Liquiline CM44x 5 Ultrasonic sensor Turbimax CUS71D
3 Weather protection roof

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3.3.2 Measuring system with pendulum holder
a0015156
Abb. 4: Measuring system with pendulum holder
The PVC wiper (C-UA 110818-60) protects the ultrasonic sensor from getting damaged by the
surface skimmer.
123
4
1 Holder system Flexdip CYH112 (cross clamp) 3 Assembly Flexdip CYA112 with CUS71D
2 Holder system Flexdip CYH112 (pendulum holder) 4 PVC wiper (C-UA 100826-61)

Installation Turbimax CUS71D
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3.4 Installation conditions
Basin configuration
a0002181
Fig. 5: Basin configuration
ASensor
B Minimum distance of sensor to basin wall = 45 cm (1.48 ft.)
C Reference point e.g. water surface
DZeropoint
E Basin depth
F Opening angle of ultrasonic cone, 6°
Installation instructions
Look at the construction drawing of the basin for a suitable position for the sensor. In doing so, you
must take the following factors into account:
• The minimum distance between the basin wall and the sensor is 45 cm (1.48 ft.) (sensor emits
ultrasound in conical form).
• There should not be any basin wall protrusions or piping in the measuring range below the sensor.
Scrapers that are only temporarily in this area are permitted.
• Do not install the sensor in zones in which air bubbles, turbulence, high levels of turbid material
or suspended matter or foam formation occur (e.g. inlet).
• Using an immersion tube, install the sensor 20 cm ( 0.66 ft.) beneath the surface of the water.
• The transmitter may not be installed in a second enclosure (heat accumulation).
• If possible, do not install the transmitter near high voltage sources. In addition, also avoid sources
of magnetic fields, e.g. large transformers or frequency converters.
• The system can only detect a separation zone if there is a clear transition between the zones.
Unclear transition from the liquid to the solid phase cannot be detected.
AB
C
D
E
6°
F

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Circular Clarifier
a0015232
Fig. 6: Basin configuration in circular clarifier
3.5 Post-installation check
• Sensor and cable undamaged?
• Cap undamaged?
• Compliance with permissible sensor installation position?
• Is the sensor installed in an assembly and is not suspended from the cable?
• Avoid moisture by rain by putting the protective cap on the assembly?
1/3 2/3
1
2
3
4
5
1/3 2/3
11
12 13
14
A
B
A View from top B Cross section
1 Surface skimmer 11 Sensor
2Walkway 12Handrail
3 Sensor mounting 13 Surface skimmer
4 Bottom rake 14 Bottom rake
5 Rake direction

Wiring Turbimax CUS71D
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4 Wiring
#Warning!
• 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.
• Ensure that there is no voltage at the power cable before beginning the connection work.
4.1 Connecting to the transmitter
The sensor will be connected to the transmitter as follows:
a0012460
Fig. 7: Sensor connection
The maximum cable length is 100 m (328 ft).
You can connect only 1 sensor to the transmitter Liquiline CM442.
You can connect up to 4 sensors to the transmitter Liquiline CM444 and CM448.
4.2 Post-connection check
Instrument status and specifications Remarks
Are the sensor, assembly, junction box or cable damaged? Visual inspection
Electrical connection Remarks
Does the supply voltage of the transmitter match the specifications on the
nameplate?
Are the installed cables strain-relieved and not twisted ?
Is the cable type route completely isolated ? Power cable/weak current cable
Are the power supply and signal cable correctly connected to the
transmitter ?
Use the connection diagram of the
transmitter.
Long enough length of cable core stripped and correct in terminal? Check seating (pull slightly)
Are all the screws terminals properly tightened ? Tighten
Are all the cable entries installed, tightened and sealed ? For cable entries lateral: cable loops
downwards for water to be able to drip off.
Are all the cable entries installed downwards or lateral ?

Turbimax CUS71D Device description
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5 Device description
5.1 Sensor design
The sensor is designed for continuous in-situ determination of interfaces.
The sensor includes all necessary modules:
• Power supply
• Ultrasonic source sends the measurement signals.
• Ultrasonic receiver receives the measurement signals, digitalizes and converts the signals to a
measurement value.
• The microcontroller of the sensor controls the internal operations and the data transmission.
All data - including calibration data - are stored in the sensor. That means:
• A pre-calibrated sensor can be used at the measuring point.
• The sensor can be calibrated externally.
• The sensor can be used at multiple measuring points with different calibration data.
5.2 Measuring principle
A piezoelectric crystal is integrated in a flat cylindrical plastic housing. When the crystal is excited
by an electrical voltage, it generates a sonar signal. The ultrasonic waves are transmitted at a
frequency of 657 kHz at an angle of 6° to scan the separation zones.
The parameter measured is the time it takes for the transmitted ultrasonic signal to reach the solid
particles in the separation zone and return to the receiver.
A sensor version with wiper avoids film formation at the sensor membrane. If a turbidity signal is
also needed a sensor version with wiper and integrated turbidity measurement is available.
5.3 Function
The speed of the sound varies according to the physical properties of the measuring medium and is
affected by temperature and air pressure. The liquid zones and solids content of the medium also
vary.
To obtain precise measurement results, it is therefore vital to adapt system variables to the process,
e. g. pulselength and the speed of the sound.
The CM44x offers the following possibilities for signal evaluation:
• Mask out regions where the separation zone is not expected.
• Evaluate received signal strengths differently.
• Select leading or trailing signal edges in the evaluation.
• Amplify sensor signals at different rates, e. g. for floating sludge.
• Define a region (gate) above and below the separation zone. Signal evaluation only takes place in
the defined region. The gate wanders with the separation zone. This makes smoothing algorithms
unnecessary.
• Arrow indicator for basin floor.
5.4 Sensor monitoring
The optical signals are continuously monitored und checked for plausibility.
Discrepancies are reported via error messages by the transmitter.
The sensor check system of the Liquiline CM44x reports the following failure conditions:
• Implausible high or low measuring values
• Disturbed controlling due to erroneous measuring values

Device description Turbimax CUS71D
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5.5 Calibration
5.5.1 Factory calibration
The sensor is precalibrated when leaving the factory. After adaption of the basin parameters, the
sensor can be used in a wide range of applications without additional calibration.
The factory calibration cannot be deleted and can be retrieved at any time. All other calibrations -
performed as customized calibrations - are referenced to this factory calibration.
5.5.2 Calibration in the process
Sensor calibration in the process is performed by inputs at Liquiline CM44x (see BA451C/07/EN).
5.6 Cyclic cleaning
For cyclic cleaning a ultrasonic sensor with integrated wiper is available. The time interval is
selectable via software.

Turbimax CUS71D Commissioning
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6 Commissioning
6.1 Firmware update
Turbimax CUS71D needs a firmware version "01.02.02-0048" or later.
Your current firmware version can be found at:
Menu/Diagnostics/System information/Software version
If your controller is equipped with an older firmware version you have to perform a firmware
update.
!Note!
First save your current setup on an SD card since a firmware update overwrites your settings with
the factory settings. After updating the firmware, you can restore your setup by uploading it from
the SD card.
To install a firmware update, you must have the update available on an SD card.
1. Insert the SD card into the controller card reader.
2. Go to: Menu/Setup/General settings/Extended setup/Data management/Firmware update.
--> The update files on the SD card are displayed.
3. Select the desired update and select yes when the following question is displayed: The current
firmware will be overwritten. After this the device will reboot. Do you want to proceed?
--> The firmware is loaded and the device is then started with the new firmware.

Commissioning Turbimax CUS71D
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6.2 Basic settings
After switching on the controller you have to perform some settings to get correct measurement
Path: Menu/Setup/Inputs/UIS/Tank configuration
The menu Tank configuration defines tank depth and
zero adjust. The quality of the measuring results
depends on the accuracy of these inputs.
Select the blanket definition:
•Interface level
The distance from bottom to blanket is displayed.
•Interface range
The distance from waterline to blanket is displayed.
Any change to the Unit of measure applies
automatically to all other displays (example: cm to m).
Enter the Tank depth (distance from the waterline to
the bottom of the tank or vessel).

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Enter the Zero adjust (distance from the waterline to
the sensor diaphragm)
Outside the Blanking zone (above Upper window
limit and below Lower window limit) the permanent
echo signals are blanked as interference signals.
For upper and lower window limit enter the distance to
the waterline.
In the adjacent example the permanent echo signals are
blanked outside the range of 0.3 to 3.3 m.

Commissioning Turbimax CUS71D
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Path: Menu/Setup/Inputs/UIS/Sensor signal
The parameters in the menu Sensor signal are factory
preset.
If measurement failures are observed the parameters
can be adjusted.
Acoustic control
•Automatic
Automatic amplification control
•Manual
Manual amplification control
In automatic mode you cannot modify the parameter
Current gain.
In the manual mode you can modify the parameter
Current gain in the range of 0 to 100.
(In standard applications the Current gain shows 20 to
60)
The Gain control set point (automatic mode only)
determines the relative signal strength.
You can enter a value from 1 to 50.
Increase this parameter to cause Auto Gain to seek a
generally higher level of signal amplification.
Decrease this parameter to cause Auto Gain to seek a
generally lower level of signal amplification.

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Path: Menu/Setup/Inputs/UIS/Extended Setup
The Refresh rate determines the time span to update
the current measurement. You can select 2, 4, 6, or 8
seconds.
Damping
This parameter establishes the number of updates that
are averaged to determine the current measurement. It
is used to remove the effects of random fluctuations
caused by settling or disturbed material. Also it
prevents sudden changes in the measurement resulting
from the action of rakes and skimmers.
Enter a value from 5 to 255.
You can adjust the parameters of the Sensor signal to
fit to the measuring point.
!Note!
Before changing the parameter Sound speed contact
E+H service.
You can compensate the influence of the ambient
conditions to the sound speed.

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You can change the parameters of the Tank zone.
Gain band establishes the maximum amount that
Current gain (with Automatic ON) can vary once the
initial gain level has been established.
Enter a value from 5 to 30.
Gain increment determines the change rate of the
gain.
Enter a value from 0.1 to 5.
You can change the parameters of the Bottom
definition.