Endress+Hauser OUSAF12 User manual

Products Solutions Services
Operating Instructions
OUSAF12
Optical sensor combined with the OUA260 flow
assembly for absorbance measurement
BA00497C/07/EN/03.21
71538084
2021-07-31

Document information OUSAF12
2 Endress+Hauser
1 Document information
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
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
1.3 Symbols on the product
Reference to device documentation
Do not dispose of products bearing this marking as unsorted municipal waste. Instead, return them to the
manufacturer for disposal under the applicable conditions.

OUSAF12 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 Intended use
The sensor is used to determine the VIS/NIR absorption of a liquid medium. The sensor is
suitable for use in a wide range of applicationsin a variety of industrial sectors , such as:
• Suspended solids measurement
• Pharmaceuticals and biotechnology
• Chemical industry
• Paper and pulp industry
• Interphase detection
• Food and beverage industry
• Chemical industry
• Oil and gas industry
• Centrifuge and separator control
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
Electromagnetic compatibility
• The product has been tested for electromagnetic compatibility in accordance with the
applicable international standards for industrial applications.
• The electromagnetic compatibility indicated applies only to a product that has been
connected in accordance with these Operating Instructions.

Basic safety instructions OUSAF12
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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.
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

OUSAF12 Product description
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3 Product description
3.1 Sensor design
1 12 34
A0014796
 1 Sensor with flow assembly OUA260
1 Cable connector
2 Lamp module
3 Flow assembly OUA260 (depending on version)
4 Detector module
The detector and lamp can vary on account of the individual options ordered.

Product description OUSAF12
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3.2 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 intensity of the light is determined by a photodiode and converted to a photocurrent.
The subsequent conversion to absorbance units (AU, OD) is performed in the associated
transmitter.
2
1OPL 23
4
5
A0029401
 2 Absorption measurement
1 Light source
2 Optical windows (assembly)
3 Detector
4 Measurement filter (depends on sensor, not provided on all sensors)
5 Medium flow

OUSAF12 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/ousaf12
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. Open www.endress.com.
2. Call up the site search (magnifying glass).
3. Enter a valid serial number.

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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 comprises the following, depending on the version ordered:
• Detector and lamp module without flow assembly or
• Detector and lamp module mounted on flow assembly OUA260
• Operating Instructions
‣If you have any queries:
Please contact your supplier or local sales center.
5 Installation
5.1 Installation conditions
5.1.1 Measuring system
An optical measuring system comprises:
• Sensor (photometer) OUSAF12
• Transmitter, e. g. Liquiline CM44P
• Cable set, e. g. CUK80
• Assembly OUA260

OUSAF12 Installation
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1 2
3
7
54
6
 3 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

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5.1.2 Dimensions
A B
C
A0028304
 4 Sensor module
A Dimension of lamp, depends on lamp type → Table
B Dimension of detector → Table
C Assembly, see Technical Information for assembly
Lamp type Dimension A in mm (inch)
High-luminescence lamp or standardincandescent lamp 33.78 (1.33)
Gas-filled lamp 33.78 (1.33)
Collimated incandescent lamp 151.3 (5.96)
Detector type Dimension B in mm (inch)
Standard version with test filter 101.6 (4.0)
Easycal 101.6 (4.0)
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
 5 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.

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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.

OUSAF12 Electrical connection
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6.1 Connecting the sensor
The sensor is connected to the transmitter via the pre-terminated or labeled cable set CUK80
(for connection to CM44P) or OUK10 (for connection to CVM40) . The terminals and labeling
may vary depending on the transmitter in use. The cable set must be ordered separately.
‣Do not shorten or otherwise modify the CUK80 cable!
A B
RD
GY
YE
YE
BK
BK BK
A0028383
 6 OUSAF12 connecting cable
A Light source (lamp) power supply
B Signals of detector
CM44P terminal Cable color Assignment
P+ YE (thick) Lamp voltage +
S+ YE (thin) Detection of lamp voltage +
S- BK (thin) Detection of lamp voltage -
P- BK (thick) Lamp voltage -
A (1) RD sensor measuring detector +
C(1) BK sensor measuring detector -
SH (1) GY Shield
6.2 Lamp voltage
Sensor version Lamp type Lamp voltage [V]
OUSAF12-xxA0x Standard incandescent lamp 3.4 ± 0.1
OUSAF12-xxA1x
OUSAF12-xxA2x
OUSAF12-xxA3x
Standard incandescent lamp 4.9 ± 0.1
OUSAF12-xxBxx Collimated incandescent lamp 4.9 ± 0.1
OUSAF12-xxCxx High-luminescence lamp 4.9 ± 0.1
OUSAF12-xxDxx Gas-filled high-performance lamp 4.9 ± 0.1

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6.3 Versions for use in hazardous areas
Section applies only to measuring points consisting of a photometer, cable set CUK80
and a Liquiline CM44P transmitter.
Safety instructions for electrical apparatus in explosion-hazardous areas, XA01403C
6.3.1 Connecting the detector using a safety barrier
The photometer sensors use silicon photovoltaic cells as detectors which are operated in the
current mode. The detectors are intrinsically safe and can be deployed in Zone 1 and Class I,
Division 1 environments.
The safe area is separated from the hazardous area by one safety barrier MTL7760AC.
105 (4.13)
90 (3.54)
12.6 (0.5)
 7 Safety barrier, dimensions in mm (inch)
The safety barrier may only have a very low leak current since the optical signals from
the sensor can be in the nanoampere range. Therefore, the sensor cable shield is
connected to the ground terminal of the barrier.

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On delivery, the CUK80 detector cable is permanently wired to the safety barrier. All you have
to do is simply connect the individual cable ends to the detector and transmitter.
1. Mount safety barrier including grounding module on a DIN rail.

2. Connect the detector plug of the cable to the detector.
3. Connect the other end of the cable to the transmitter.
RD
BK
3
4
1
2
GY
RD
BK
GY
Transmitter
MTL7760ac
Photometer
(Det.)
A (1)
C (1)
SH (1)
6.3.2 Connecting the hazardous area lamp using a junction box
The hazardous area lamp (EXP-1) must be connected to the transmitter using a certified
junction box.
For versions with FM approval, the junction box is included in the delivery and already
pre-terminated on the lamp side. You simply have to connect the cable of the transmitter
(CUK80) to the terminals of the junction box.
For versions with ATEX approval, the junction box is not included in the delivery and it
and the cable glands required must be provided by the customer at the place of
installation. You must connect the cables entirely on your own (CUK80 of transmitter
and lamp cable of photometer sensor).

Electrical connection OUSAF12
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Transmitter
S-
P+
P-
YE
YE
BK
BK
S+
EXP-1
ATEX II 2G Ex db IIC T5 Gb
FM Cl.1, Div. 1, Groups B, C, D
PE
30
27
A0029440
 8 Connecting the hazardous area lamp to CM44P via a junction box
6.4 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

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6.5 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 OUSAF12
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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.
• D-tryptophan
A protein which is also frequently used for optical calibration. A solution with a
concentration of 100 ppm has an absorbance of around 2.6 OD at 280 nm.
AU = OD*OPL[cm]
AU ... absorbance units, OD ... optical density, OPL .... optical path length
Producing a D-tryptophan parent solution
1. Dissolve 1 g D-tryptophan in a beaker containing 200 ml deionized water by heating (at
30 °C (86 °F)) and stirring (magnetic stirrer).

OUSAF12 Commissioning
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2. While the D-tryptophan is dissolving, add deionized water until the beaker contains an
approximate volume of 450 ml.
3. Continue stirring at 30 °C (86 °F) until the tryptophan is completely dissolved.
4. Dilute the solution to 1000 ml in a volumetric flask.
 You now have a parent solution of D-tryptophan with a concentration of 1000 mg/l
(ppm).
5. Create a series of calibration solutions from the parent solution by diluting, and
determine the absorbance of the solutions at the sensor wavelength using a laboratory
spectrometer.
 Use these value pairs (concentration and absorbance values) in the transmitter for
the data sets for application calibration.
Instead of potassium dichromate or D-tryptophan 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.
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
 9 Filter in "out" position
1 NIST-traceable filter (high)
2 Locking screw
A0033708
 10 Filter in "in" position
3 Positioning pin
4 Lens assembly
The filter(s) is scanned with traceable testing equipment and the actual absorbance at
individual wavelengths is determined.

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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.
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.
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 8000 to 10 000 operating hours (→  35).
• 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.
The only difference is the type of lamp used.
Make sure you use the right spare parts kit.