Endress+Hauser Flexdip CYA112 User manual

Products Solutions Services
Operating Instructions
Flexdip CYA112
Wastewater assembly
BA00432C/07/EN/14.19
71460314
2019-01-07

Flexdip CYA112 Table of contents
Endress+Hauser 3
Table of contents
1 About this document ................ 4
1.1 Warnings ............................ 4
1.2 Symbols used .......................... 4
2 Basic safety instructions ............ 5
2.1 Requirements for personnel ............... 5
2.2 Designated use ........................ 5
2.3 Workplace safety ....................... 5
2.4 Operational safety ...................... 6
2.5 Product safety ......................... 6
3 Product description ................. 7
3.1 Product design ......................... 7
4 Incoming acceptance and product
identification ....................... 8
4.1 Incoming acceptance .................... 8
4.2 Product identification .................... 8
4.3 Scope of delivery ....................... 9
4.4 Certificates and approvals ............... 10
5 Installation ....................... 11
5.1 Installation conditions .................. 11
5.2 Mounting the assembly ................. 12
5.3 Post-installation check .................. 20
6 Maintenance ...................... 21
6.1 Maintenance tasks ..................... 21
7 Repair ............................ 23
7.1 Return .............................. 23
7.2 Disposal ............................ 23
8 Accessories ....................... 24
9 Technical data .................... 33
9.1 Environment ......................... 33
9.2 Process ............................. 33
9.3 Mechanical construction ................ 33
Index .................................. 35

About this document Flexdip CYA112
4 Endress+Hauser
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 used
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
1.2.1 Symbols on the device
Symbol Meaning
Reference to device documentation

Flexdip CYA112 Basic safety instructions
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2 Basic safety instructions
2.1 Requirements for 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
CYA112 is designed as a modular assembly system for sensors in unpressurized operation
in open basins, channels and tanks.
The assembly is designed exclusively for use in liquid media.
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 Workplace safety
As the user, you are responsible for complying with the following safety conditions:
• Installation guidelines
• Local standards and regulations
• Regulations for explosion protection

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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 technology
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
international standards have been observed.

Flexdip CYA112 Product description
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3 Product description
3.1 Product design
1
2
3
4
A0037921
 1 CYA112 assembly without float (left) and with float (right)
1 Multifunctional clamp ring
2 Immersion tube
3 Bracket
4 Float
The assembly is suitable for installation at different heights in a variety of basins.
The assembly must be installed depending on the ambient conditions.

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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
• Extended order code
• Serial number
• Ambient and process conditions
• Safety information and warnings
‣Compare the information on the nameplate with the order.
4.2.2 Identifying the product
Product page
www.endress.com/cya112
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.
4. Search.
 The product structure is displayed in a popup window.

Flexdip CYA112 Incoming acceptance and product identification
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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.
4.2.3 Manufacturer's address
Endress+Hauser Conducta GmbH+Co. KG
Dieselstraße 24
D-70839 Gerlingen
4.3 Scope of delivery
The scope of delivery comprises:
• Ordered version of assembly
• Operating Instructions
‣If you have any queries:
Please contact your supplier or local sales center.

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10 Endress+Hauser
4.4 Certificates and approvals
4.4.1 Ex approval
The stainless steel version of the CYA112 assembly (CYA112-**21*2**) may also be used
in the hazardous area in Zone 1 and 2.
It does not have special Ex identification labeling, as the assembly does not have a
potential ignition source of its own and ATEX Directive 2014/34/EU therefore does not
apply.
If sensors have accessible metal surfaces, these sensors must be included in the potential
equalization system as indicated in the Operating Instructions for the sensor in question.

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5 Installation
5.1 Installation conditions
5.1.1 Mounting instructions
• Select the mounting location so that a sufficient distance to fixed installations is
ensured. No damage to the sensor may occur even when the medium is moving.
• For fixed installation, select the retaining point so that the proper operation and
maintenance of the assembly is guaranteed.
• The immersion tube must protrude over the retaining point by at least
100 mm (3.94 in).
• Potential equalization must be implemented at the place of installation.
• All electrically conductive parts must be interconnected.
100
(3.94)
A0011037
 2 Retaining point (shown without splash protection cap). Dimensions: mm (in)
For use in hazardous areas:
• There must be an electrically conductive connection between the immersion tube side of
the assembly and the holder.
• If the assembly is secured using a chain and retaining bracket, a separate conductor for
potential matching must be routed alongside the measuring cable.
• If sensors have accessible metal surfaces, these sensors must be included in the potential
equalization system as indicated in the Operating Instructions for the sensor in question.

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5.2 Mounting the assembly
For more information on mounting the assembly with the holder, see Operating
Instructions BA00430C
5.2.1 Measuring system
A complete measuring system consists of:
• CYA112 assembly
• CYH112 holder
• Transmitter, e.g. Liquiline CM44
• Sensor, e.g. CUS71D
1
2
3
45
6
A0010959
 3 Measuring system with CYA112 assembly
1 Main pipe of CYH112 holder
2 Transmitter
3 Protective cover
4 Transverse pipe of CYH112 holder
5 Cable ties
6 CYA112 assembly
5.2.2 Mounting stainless steel parts
‣Screw the tubes together finger-tight (no gaps).
The threads are lubricated and provided with an O-ring.

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5.2.3 Gluing PVC parts
PVC assemblies measuring up to 1 200 mm (47.2 in) are delivered as ready-to-install
units and do not have to be glued.
Cleaning cloths and adhesive are included in the delivery.
Gluing PVC parts
1. Clean the surfaces to be glued (exterior of pipe end, adhesive fitting or inside of
connecting pipe) with the cleaning cloth.
2. Allow the cleaned surfaces to dry for approx. 5 minutes.
3. Apply the glue evenly (closed adhesive layer) to the surfaces (first adhesive fitting,
then pipe).
4. Push the parts together to the end stop.
 Join them within one minute.
5. Remove any excess glue.
6. Allow the glued parts to harden for at least 5 minutes.
5.2.4 Mounting the sensor
Preparation:
1. Screw or glue the connecting pipe onto the immersion tube.
2. Where necessary, screw the sensor adapter onto the connection pipe.
1
2
3
4
A0011111
 4 Cable routing
1 Splash protection cap
2 Sensor cable
3 Rubber plug
4 Immersion tube
Mounting Memosens sensors
1. Route the sensor cable through the immersion tube.
2. Connect the sensor cable to the sensor.
3. Screw the sensor into the adapter or the connecting pipe.
4. Shorten the tip of the rubber plug to match the cable diameter.
5. Fit the rubber plug onto the sensor cable.

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6. Press the rubber plug onto the immersion tube.
7. Route the sensor cable downwards in a loop (do not bend).
8. Fit the splash protection cap.
 The splash protection cap is fixed in place by the lip of the rubber plug.
Mounting sensors with a fixed cable
1. Route the sensor cable through the immersion tube.
2. Screw the sensor into the adapter or the connecting pipe.
3. In doing so, turn the assembly and not the sensor to ensure that the sensor cable is
not twisted.
4. Shorten the tip of the rubber plug to match the cable diameter.
5. Fit the rubber plug onto the sensor cable.
6. Press the rubber plug onto the immersion tube.
7. Route the sensor cable downwards in a loop (do not bend).
8. Fit the splash protection cap.
 The splash protection cap is fixed in place by the lip of the rubber plug.
5.2.5 Fixed installation of the assembly on a transverse pipe
Prerequisite
The sensor is already mounted.
1
2
3
4
A0011292
 5 Mounting the cross clamp
1 Main pipe
2 Cross clamp, closed side facing center of basin
3 Cross clamp, closed side facing upwards
4 Transverse pipe of CYH112 holder
‣Mount the cross clamp in such a way that one closed side faces the center of the basin
while the other closed side faces upwards →  5,  14.

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1
2
3
4
4
A0038430
 6 Cross clamp
1 Cross clamp
2 Clamps
3 Clamp screw
4 Hook-and-loop cable ties
1
2
3
A0038382
 7 Adjusting the clamps
1 Pipe
2 Clamps
3 Clamp screw
Mounting the main pipe
1. Adjust the clamps on the cross clamp →  7,  15.
2. Slide the cross clamp over the main pipe.
 Make sure that the closed side of the cross clamp faces upwards →  5,  14.
3. Mount the multifunctional clamp ring on the immersion tube above the cross clamp
(funnel-shaped side facing upwards →  8,  16).
 The multifunctional clamp ring acts as an anti-slip lock.
4. Attach the cross clamp, along with the immersion tube, to the transverse pipe of the
bracket.
 Make sure that the closed side of the cross clamp faces towards the basin.
5. Align the assembly and the holder.
6. Tighten the clamp screws finger-tight. Finger-tight corresponds to 13 Nm (9.6 lbf ft).

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12
A0038457
 8 Multifunctional clamp ring
1 Slot in the multifunctional clamp ring
2 Multifunctional clamp ring, funnel-shaped side
5.2.6 Installing the assembly on a chain retainer
Prerequisite:
• The immersion tube is fitted with the sensor.
• The CYH112 holder with chain is installed.
For detailed information on the CYH112 holder, see Operating Instructions
BA00430C
1234
x
A0011420
 9 Mounting the chain retainer
1 Mount the multifunctional clamping ring
2 Guide the bracket into the chain
3 Hook the bracket into the multifunctional clamping ring
4 Fit the splash protection cap
x 60 to 80 mm (2.35 to 3.15 in)
Installing the chain retainer:
1. Insert weights into the immersion tube (only for PVC immersion tubes).
2. Mount the multifunctional clamp ring on the immersion tube (with the funnel-
shaped side pointing downwards →  8,  16).
3. Guide the bracket into the bottom chain link.

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4. Hook the bracket into the multifunctional clamp ring.
5. Mount the sensor →  13.
6. Secure the chain on the holder with the triangular carabiner.
7. Determine the maximum immersion depth of the assembly.
The assembly may not be flooded. Pay attention to the maximum immersion depth
for this purpose.
5.2.7 Installing the assembly with a float
3
2
1
A0011422
 10 Float mounting
1 Immersion tube with adhesive fitting and sensor adapter (ready-to-install ex works)
2 Float
3 Second immersion tube with 45° adhesive fitting
Preparation:
1. Fit the float (item 2) onto the immersion tube (item 1).
2. Glue the second immersion tube (item 3) and the adhesive fitting (item 3) onto the
immersion tube (item 1) →  13.
3. Adjust the clamps on the cross clamp →  7,  15.
4. Slide the cross clamp over the immersion pipe →  5,  14.
 Make sure that the closed side of the cross clamp faces upwards.

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5. Above the cross clamp, mount the multifunctional clamp ring on the immersion tube
(funnel-shaped side facing upwards).
 The multifunctional clamp ring acts as an anti-slip lock.
Mounting the sensor →  13
For detailed information on the CYH112 holder, see Operating Instructions
BA00430C
Installing the assembly with a float:
1. Mount the sensor →  13.
2. Mount the float on the CYH112 pendulum holder.
3. Align the assembly and holder.
4. Tighten the clamp screws finger-tight (finger-tight corresponds to 13 Nm (9.6 lbf ft).
5.2.8 Installing the quick fastener
12
3
4
A0016947
 11 Quick fastener
1 Bore hole (makes it easier to screw the adapter on tightly)
2 Adapter
3 Union nut
4 O-rings
Installing the quick fastener:
1. Provide both O-rings (item 4) with a thin film of lubricant.
2. Screw the adapter (item 2) into the connection pipe of the immersion tube.
3. Insert a screwdriver or a similar tool (serves as lever) through the bores (item 1).
4. Tighten the adapter with the screwdriver.
5. Slide the union nut (item 3) over the adapter until the union nut engages with a click.
6. Route the sensor cable through the quick fastener and the immersion tube.
 The Memosens coupling is secured in the quick fastener and cannot slip.
7. Connect the cable to the sensor.
8. Guide the sensor through the quick fastener (hold the sensor steady when doing so).
9. Using the quick fastener, install the sensor without twisting the measuring cable.
10. Turn the union nut to tighten the sensor.
11. Align the sensor if necessary.

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5.2.9 Disassembling the quick fastener
1
A0016950
 12 Removing the quick fastener
1 Quick fastener with union nut
2
A0016951
 13 Removing the quick fastener
2 Connection clips
3
A0016952
 14 Removing the quick fastener
3 Mounting tool
413
A0016953
 15 Removing the quick fastener
1 Quick fastener - union nut
3 Mounting tool
4 Quick fastener - adapter

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Removing the quick fastener:
1. Move the union nut in the direction of the arrow until the stop position
→  12,  19.
 This pushes the two connection clips towards the center.
2. Fit the mounting tool onto the connection clips →  14,  19.
3. Push the mounting tool in firmly.
 This releases the two connection clips from the fixture.
4. Remove the union nut and the mounting tool →  15,  19.
5. Unscrew the adapter from the immersion tube.
5.3 Post-installation check
• After mounting, check that all the screws are securely tightened.
• When fastening via the pendulum holder, check that the assembly can move freely.