Endress+Hauser CE 4 User manual

BA 160R/09/en/08.03
51006364 CE 4
Measurement station
Operating instructions

CE 4
2Endress+Hauser
Short overview
For quick and simple commissioning.
Safety notes ⇒Chap. 1, Page 4
⇓
Step 1: Install measurement station ⇒Chap. 3, Page 7
In this chapter the foundation template, installation levels and hose
installation and measurement station installation can be found.
⇓
Step 2: Wire measurement station ⇒Chap. 4, Page 12
Here hints how to wire and electrical connect the measurement
station can be found.
⇓
Step 3: Operating and set-up of the measurement station ⇒Chap. 5, Page 13
The operation of individual components can be found in the
respective operating manuals!
⇓
Step 4: Commissioning the measurement station ⇒Chap. 6, Page 15
Here the mothod for initial and re-commissioning of the
measurement station can be found.
⇓
Step 5: Maintenance and cleaning of the measurement station ⇒Chap. 7, Page 17
Here the procedure for manual and automatic cleaning of the
measurement station can be found.

CE 4 Endress+Hauser
Endress+Hauser 3
Table of contents
1 Safety instructions . . . . . . . . . . . . . . 4
1.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning, operation . . . . . . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Safety pictograms and symbols . . . . . . . . . . . 5
2 Identification . . . . . . . . . . . . . . . . . . . 6
2.1 Device designation . . . . . . . . . . . . . . . . . . . . . 6
2.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Certificates and approvals . . . . . . . . . . . . . . . . 6
3 Mechanical installation . . . . . . . . . . 7
3.1 Delivery, transport, storage . . . . . . . . . . . . . . . 7
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . 8
3.3 Mechanical installation . . . . . . . . . . . . . . . . . 10
3.4 Check installation . . . . . . . . . . . . . . . . . . . . . . 12
4 Electrical connection . . . . . . . . . . . 12
4.1 Wiring the measurement station . . . . . . . . . . 12
4.2 Screening and potential compansation . . . . . 12
4.3 Ingress protection . . . . . . . . . . . . . . . . . . . . . 12
4.4 Checking the connections . . . . . . . . . . . . . . . 13
5 Operation . . . . . . . . . . . . . . . . . . . . . 13
5.1 Communication and data security . . . . . . . . . 13
6 Commissioning . . . . . . . . . . . . . . . . 15
6.1 Installation check . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Commissioning the measurement station . . . 15
6.3 Device set-up . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Maintenance and cleaning . . . . . . 16
7.1 Manual cleaning of the measurement system 16
7.2 Sensor control and cleaning . . . . . . . . . . . . . 16
7.3 Operating the cleaning system . . . . . . . . . . . 17
7.4 Maintenance plan . . . . . . . . . . . . . . . . . . . . . 25
8 Accessories . . . . . . . . . . . . . . . . . . . 25
8.1 Accessories for the measurement station . . . 25
9 Fault-finding . . . . . . . . . . . . . . . . . . 25
9.1 Fault-finding instructions . . . . . . . . . . . . . . . . 25
9.2 Process fault messages . . . . . . . . . . . . . . . . . 25
9.3 Process faults without messages . . . . . . . . . 26
9.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5 Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Technical Data . . . . . . . . . . . . . . . . . 29
10.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.4 Operating conditions . . . . . . . . . . . . . . . . . . . 31
10.5 Mechanical construction . . . . . . . . . . . . . . . . . 32
10.6 Certificates and approvals . . . . . . . . . . . . . . . 33
10.7 Additional documentation . . . . . . . . . . . . . . . . 33
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Safety instructions CE 4
4Endress+Hauser
1 Safety instructions
Safe and secure use of this measurement station can only be ensured if these operating
instructions are read and the safety notes are followed.
1.1 Correct use
The measurement station is designed for automatic online measurement of liquids, not
abrasive media. The station independently and continuously feeds the media to be
measured using either a built-in pump or a pump supplied on site. The resulting
measurements are displayed on the individual tranmitters. The measured values can
also be displayed on a built-in paperless recorder or they can be transmitted to a control
system using various transmission systems. The built-in ASP-Station 2000 water
sampler takes samples from the measurement point in line with the programme set up.
– The measurement station must not be installed in hazardous areas.
– The manufacturer cannot be held responsible for any damage caused by incorrect
use of the measurement station. Rebuilding of the station and constructive changes
must not be done.
1.2 Installation, commissioning, operation
This measurement station has been designed and built for safe operation using state-
of-the-art technology and in line with the necessary regulations and EU guidelines. If the
measurement station is missued or used in an inappropriate manner, could be
dangerous.
Mechanical and electrical installation, commissioning and maitenance of the
measurement station must only be carried out by skilled and trained personnel. Skilled
personnel must have read, understood and followed these operating instructions. The
entries regarding the electrical connections (see Chap.4 "Wiring") must be followed to
the letter. The measurement station must only operated by trained personnel.
#Warning!
Before opening the electronic compartment:
•No commissioning without earth/ground protection connection! If faults cannot be
cured then the measurement station must be removed from operation and protected
against unintentional operation. Always isolate the station from the mains power (main
switch) before opening the electronic compartment (opening the swing frame).
1.3 Operational safety
The measurement system complies with the general safety requirements laid down in
the EN 61010-1, Protection class I, overvoltage category II.
CE mark according to the directives 89/336/EWG (EMC) and 73/237/EWG (low voltage
directives).
Technical advancement
The manufacturer reserves the right to improve or update the technical detail without
any special notification. For details on improvements or additions to these instructions,
please contact your E+H sales office or agent.

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Endress+Hauser 5
1.4 Returns
Before units are returned to Endress+Hauser for repair, the following must be taken care
of:
•The unit should always be accompanied by a completed ’Safety Regulation Form’.
Only then can Endress+Hauser transport, check and repair the returned unit.
•If required place a special handling recommendation form with the returned unit, e.g.
a safety data note to EN 91/155/EWG.
•Remove all materials soiling the unit. Please take special note of the gasket cut-outs
and rims into which solids can seep. This is especially important if the medium
measured could constitute a health hazard, e.g. flammable, poisonous, corrosive,
carcinogenic, etc.
!Note!
A copyable sample of the ’Safety Regulation Form’ can be found at the end of these
instructions.
"Caution!
•Do not return a unit if it is deemed impossible to remove all hazardous materials, e.g.
material seepage in scratches or media diffused by the plastic.
•Costs incurred for disposal due to lack of cleaning of the unit or for personal injury
(corrosion burns etc.) will be invoiced to the user.
It is always recommended to protect the unit correctly when returning it e.g. in case of
repairs. Optimum protection is given by the original packaging. Repairs must only be
carried out by the Endress+Hauser service personnel. For the nearest service
department, see the addresses at the rear of this manual.
!Note!
When returning the unit for repair please enclose a note detailing the fault and the
application.
1.5 Safety pictograms and symbols
The safety hints in these operating instructions are indicated by the following symbols:
"Caution!
This symbol means activities or sequences that, if done incorrectly, could lead to faulty
operation or destruction of the unit.
#Warning!
This symbol means activities or sequences that, if done incorrectly, could lead to
serious personal injury, to a safety risk or destruction of the unit.
!Note!
This symbol means activities or sequences that, if done incorrectly, could have an
indirect influence on the unit’s operation or could cause an unforeseen unit reaction.

Identification CE 4
6Endress+Hauser
2 Identification
2.1 Device designation
2.1.1 Legend plate
Compare the legend plate on the unit with the following figure:
Fig. 1: Legend plate entries for the measurement station (example)
Pos. 1: Order code and series number for the measurement station
Pos. 2: Commission number
Pos. 3: Power supply
Pos. 4: Power consumption
2.2 Delivery
Please check the consignment for complete delivery by comparing the delivery note
and your order:
•Unit type and model from the legend plate
•Operating instructions (see sections 5, 6, 7, 8 in the ring binder)
•Measurement station accessories (see chapter 8 "Accessories" )
The measurement station is built either exactly to the order code or tailored to customer
requirements. This means that each unit delivered will be different:
•Analysis system
•ASP-Station 2000 water sampler
•CE 4 operating instructions
•ASP-Station 2000 operating instructions
•CE 4 technical instructions
•Operating instructions and certificates for the indidual units and components fitted
•Accessories that have been ordered under the same order number
2.2.1 Identification lists
The identification list for this measurement station can be found in section 1 in the ring
binder. In this section, all individual components are listed including order code and unit
numbers.
2.3 Certificates and approvals
This measurement station has been designed, built and tested for safe operation using
state-of-the-art technology and has left our factory in a safe operational condition. All
necessary and available certificates, test reports and approvals are included (see
section 11 in the ring binder).
CE 4
1
2
3
4
Order Code:
CE4-xxxxxxx
Ser. No.: 123456789B5
Spec.: 30000001/0001
U: 230 VAC
P: 1000 W
ENDRESS+HAUSER
87484 Nesselwang / Germany 2003

CE 4 Mechanical installation
Endress+Hauser 7
3 Mechanical installation
3.1 Delivery, transport, storage
3.1.1 Delivery
•Is the packaging or content damaged?
•If damaged, contact the transport company.
3.1.2 Transport to measurement point
The measurement station is delivered mounted on a palette. In order to avoid transport
damage, the station is fixed to the pallet in a number of positions. The palette can be
transported using a fork lift truck or crane (min. loading 500 kg) (see Fig. 2 Pos. A and
B). The built-in pump is separately bolted down on the pallet.
The measurement station must be transported upright and secured to prevent tipping
over. Avoid shocks.
Fig. 2: Transport to installation point
Pos. A: Lifting the measurement station with a crane. Fitting correct lifting tackle (see arrow).
Pos. B: Lifting the measurement station using a fork lift truck.
3.1.3 Storage
If the system is to be stored for a longer period (>4 weeks) the following must be taken
care to avoid damage to the unit:
•Completely empty and clean the measurement station. New units are delivered
completely empty
•pH sensor must be stored in the delivered calibration beaker filled with a pH 7 buffer
solution
•When using a peristaltic pump, the pump hose must be removed and stored
according to the respective operating instructions (Section 8 in the ring binder)

Mechanical installation CE 4
8Endress+Hauser
3.2 Installation conditions
•The permitted ambient temperature (see chapter "Technical data") must not be
exceeded both on installation and operation.
•A solid foundation must be available. For dimensions see the foundation plan
(→Chap. 3.2.3)
•Install vertical and level
•Outside installation: Avoid direct sunlight on the front of the unit. If required, fit a sun
protection system (all-weather roof)
•If the water in and outflow pipework is installed in the open air, these should be
protected from frost
•Because the analysis component has to be continuously rinsed with water, it must be
guaranteed that there is always enough water available at the sampling point so that
dry running of the system is avoided (e.g. small weir etc)
The feed hose should therefore be fixed as required
"
Caution!
Dry running and sand grains/particles can shorten the life span of the eccentric pump.
•The outflow hoses must be installed falling away from the unit and with free outlet
•When using the manual or automatic cleaning system, an isolation valve and pressure
reducer must be installed on site
3.2.1 Material resistance of the analysis pipework
The analysis system consists of a PVC pipework system and due to its material
composition is suitable for drinking water and beverages.
General chamical resistance
Resistant: Acids and bases
Non-resistant: Aromatic solvents
Application limits for pressure and temperature
(25-year values with calculated safety factor)
Type used: PVC-PN10
Fig. 3: Application limits pressure and temperature (Source: Georg Fischer +GF+ pipework systems for
industry and supply, 1st edition 1996, Page 5.04)

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3.2.2 Dimensions
The dimensions for the measurement station can be found in chapter "Technical data".
3.2.3 Installation point/foundation plan
Fig. 4: Foundation drawing without water sampler
Pos. A: M8x20 rawl bolts or M8 rawl plugs
Pos. B: In and outflow hoses for the measurement liquid
Pos. C: Water supply
Pos. D: Power cables
Pos. E: Signal cables
Pos. H: Feed pump installation area
Pos. I: Cabinet base
Pos. K: Overflow shaft
Fig. 5: Foundation drawing with water sampler
Pos. A: M8x20 rawl bolts or M8 rawl plugs
Pos. B: In and outflow hoses for the measurement liquid
Pos. C: Water supply
Pos. D: Power cables
Pos. E: Signal cables
Pos. F: Water sampler suction hose
Pos. G: Water sampler overflow and condensation water
Pos. H: Feed pump installation area
Pos. I: Cabinet base
Pos. K: Overflow shaft
100
A
A
A H
I
K
100
84
209
459
568
534
559
240 360 520 620 700
668
0
0
0
184
ø
100
ø50
ø50
ø50
BB
ABCD E
100 350 700 450 800
0
100
668
100
1634
207 567 100
100
134
109
534
500
559
257 377 577 677 930 1234
0
0
0
0
568
0
1534
0
ø100
ø50
ø50
ø50
ø80
ø80
100
250
600
BB
A A
A
A
BCD E F G
HIK

Mechanical installation CE 4
10 Endress+Hauser
3.2.4 Installation point/hose installation
Installation hint
Sampling point
•Medium removal for the pump and the sampling system must be taken from
representative point in the channel, i.e. not on the edge of the channel and not in the
sump or floor of the channel. A point offering a homogeneous mixture should be
selected.
•There should always be enough medium available at the sampling point so that the a
good head of water is always available.
•Suction hose is immersed by using a weight (see "Accessories").
Sampling hose installation
The sampling hose must always be installed with a downward slope from the
measurement station to the sampling point. Depending on the application, some hoses
may require frost protection.
Fig. 6: Sampling hose installation
3.3 Mechanical installation
3.3.1 Tooling
The following tools are required to install the measurement station:
•Electric drill with 12 mm concrete bit
•M8 (4x) V2A rawl bolts
•M8 (4x) V2A nuts and U washers
•13 AF ring spanner
•Screwdriver for power/signal terminals
•Philips screwdriver