Operating Instructions

Model OUM960 UV Analyzer/
Model OUSAF44 EXP-1 Inline Sensor
Analyzer/Sensor to measure UV Spectral AbsorbanceP/N 71097011 Rev 1
BA925C/07/en/0609

Model OUM960 with OUSAF 44 Inline Sensor

2Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Table of Contents
1.

SAFETY INSTRUCTIONS .................................................................................................................................................. 5

1.1
1.2
1.3
1.4

DESIGNATED USE ........................................................................................................................................................................ 5
INSTALLATION, START-UP AND OPERATION ..................................................................................................................................... 5
OPERATIONAL SAFETY .................................................................................................................................................................. 5
RETURN ..................................................................................................................................................................................... 62.

GENERAL INFORMATION .............................................................................................................................................. 7

2.1
2.2
2.3

HOW THE MODEL 960 UV ANALYZER WORKS ................................................................................................................................ 7
CONCENTRATION AND ABSORBANCE UNITS .................................................................................................................................... 7
EASY INTERFACING ...................................................................................................................................................................... 7

3.

INSTALLATION ................................................................................................................................................................ 9

3.1
3.2
3.3
3.4
3.5
3.6

MODEL OUM960 ANALYZER INSTALLATION .................................................................................................................................. 9
MODEL OUM960 CABLES AND WIRING ...................................................................................................................................... 10
DC INPUT POWER OPTION ......................................................................................................................................................... 11
MODEL OUM960+OUSAF44/EXP-1 WIRING ........................................................................................................................... 13
MODEL OUSAF44 SENSOR INSTALLATION ................................................................................................................................... 14
POST-CONNECTION CHECK ........................................................................................................................................................ 15

4.

OPERATION ................................................................................................................................................................... 16

4.1
QUICK OPERATION GUIDE .......................................................................................................................................................... 16
4.2
DISPLAY AND OPERATING ELEMENTS............................................................................................................................................ 16
4.2.1
Operating Elements ....................................................................................................................................................... 16
4.2.2
Operation Legend .......................................................................................................................................................... 17
4.3
LOCAL OPERATION .................................................................................................................................................................... 17
4.3.1
Measuring Mode............................................................................................................................................................ 17
4.3.2
Configuration Mode....................................................................................................................................................... 19
4.4
REMOTE OPERATION ................................................................................................................................................................. 20
5.

COMMISSIONING.......................................................................................................................................................... 21

5.1
FUNCTION CHECK..................................................................................................................................................................... 21
5.2
SWITCHING ON ........................................................................................................................................................................ 21
5.3
ANALYZER CONFIGURATION AND OPERATION ................................................................................................................................ 22
5.3.1
Factory Default Setting................................................................................................................................................... 23
5.3.2
Sensor Calibration.......................................................................................................................................................... 23
5.3.2.1
Liquid Calibration Procedure...................................................................................................................................... 23
5.3.2.2
EasycalTM Set up and Calibration................................................................................................................................ 25
5.3.3
Change Pathlength Setting ............................................................................................................................................. 28
5.3.4
Setup Output Span......................................................................................................................................................... 28
5.3.5
Output Relay Set Point and Configuration....................................................................................................................... 29
5.3.6
Current Output Calibration ............................................................................................................................................ 31
5.3.7
Date and Time Setting.................................................................................................................................................... 31
5.3.8
Configuration and Use Digital Input ............................................................................................................................... 32
5.3.9
Process Control.............................................................................................................................................................. 33
5.3.9.1
Access of Process Control .......................................................................................................................................... 33
5.3.9.2
Baseline (AutoZero) ................................................................................................................................................... 33
5.3.9.3
Optical Zero .............................................................................................................................................................. 34
5.3.9.4
Lamp Switch ............................................................................................................................................................. 34
5.3.9.5
Optical Check............................................................................................................................................................ 34
5.3.9.6
Password Protection .................................................................................................................................................. 363

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.9.7

Process Value Correlation .......................................................................................................................................... 37

6.

MAINTENANCE ............................................................................................................................................................. 40

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9

MAINTENANCE OUTLINE ............................................................................................................................................................ 40
MERCURY LAMP REPLACEMENT FOR OUSAF44/EXP-1................................................................................................................. 41
OUSAF44/EXP-1 MEASUREMENT DETECTOR/FILTER REPLACEMENT ............................................................................................. 43
MEASUREMENT FILTER REPLACEMENT (EASYCAL™ ASSEMBLY)........................................................................................................ 44
MEASUREMENT FILTER REPLACEMENT (STANDARD AND CAL ROD ASSEMBLIES) .................................................................................. 45
SENSOR WAVELENGTH CHANGE .................................................................................................................................................. 46
SENSOR WINDOW AND GASKET REPLACEMENT .............................................................................................................................. 46
SENSORS WITHOUT PRECISION OPTICAL PATH LENGTH ADJUSTER OPTION ......................................................................................... 47
SENSORS WITH PRECISION OPTICAL PATH LENGTH ADJUSTER OPTION ............................................................................................... 48

7.

REPLACEMENT PARTS LIST.......................................................................................................................................... 52

7.1
7.2

MODEL OUM960 UV ANALYZER ................................................................................................................................................ 52
MODEL OUSAF44/EXP-1 UV INLINE SENSOR............................................................................................................................. 52

8.

TECHNICAL INFORMATION ........................................................................................................................................ 53

8.1
UV ANALYZER OUM960........................................................................................................................................................... 53
8.1.1
Input ............................................................................................................................................................................. 53
8.1.2
Output........................................................................................................................................................................... 53
8.1.3
Power Supply................................................................................................................................................................. 53
8.1.4
Performance .................................................................................................................................................................. 54
8.1.5
Environment.................................................................................................................................................................. 54
8.1.6
Mechanical Construction ............................................................................................................................................... 54
8.2
UV ABSORBANCE SENSOR OUSAF44/EXP-1 ............................................................................................................................... 54
8.2.1
Input and Output........................................................................................................................................................... 54
8.2.2
Mechanic Construction.................................................................................................................................................. 54
8.2.3
Environment.................................................................................................................................................................. 56
8.2.4
Power Supply................................................................................................................................................................. 56
8.2.5
Optical Specifications ..................................................................................................................................................... 56
9.

ORDERING INFORMATION .......................................................................................................................................... 57

9.1
9.2
9.3
9.4

UV ANALYZER OUM960........................................................................................................................................................... 57
UV ABSORBANCE SENSOR OUSAF44........................................................................................................................................... 58
MODEL OUA260 FLOW CELL .................................................................................................................................................... 59
MODEL OUK40 UV SENSOR CABLE SET ...................................................................................................................................... 60

4

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

1.

Safety Instructions

1.1

Designated Use

Safety Instructions

Integra Model OUM960 is an analyzer for determining the UV absorbance of a liquid medium.
The analyzer is particularly suited for use in the following areas:
•
•
•
•
•

Bio-Technology industry
Waste water processing
Chemical processing industry
Food industry
Pharmaceutical industry

Any other use than the one described here compromises the safety of persons and the entire measuring system and is, therefore, notpermitted. The manufacturer is not liable for damage caused by improper or non-designated use.

1.2

Installation, Start-Up and Operation

Please note the following items:•

Installation, electrical connection, start-up, operation and maintenance of the measuring system must only be carried out by
trained technical personnel. The technical personnel must be authorized for the specified activities by the system operator.

•

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 for correctness. Ensure that electrical cables andhose 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 manufacturers or by the service
organization.

1.3

Operational Safety

Relevant regulations and standards have been met. As the user, you are responsible for complying with the following safety conditions:••

Installation instructions
Local prevailing standards and regulations.

EMC
This instrument has been tested for electromagnetic compatibility in industrial use according to applicable standards.
Protection against interference as specified above is valid only for an instrument connected according to the instructions in these
Operating Instructions.

5Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

1.4

Safety Instructions

ReturnIf the device requires repair, please contact your Endress+Hauser representative. Please use the original packaging, if possible.
Notes on safety icons and symbols
Safety icons
Warning!
This symbol alerts you to hazards. They 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.

Electrical symbols
Direct Current (DC)A terminal at which DC is applied or through which DC flows.
Alternating Current (AC)A terminal at which (sine-form) AC is applied or through which AC flows.

Ground connecting
A terminal is already grounded using a grounding system.

Protective earth terminal
A terminal which must be grounded before other connections may be set up.

Alarm relay

Input

Output6

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

2.

General Information

General Information

The Model OUM960 UV analyzer is used in conjunction with a Model OUSAF44/EXP-1 sensor to measure the spectral absorbance ofprocess liquid in the UV region of the electromagnetic spectrum.
Dependent upon the optical pathlength of the connected sensor, the instrument can measure up to 50 Optical Density (OD) units.
The Model OUM960 UV analyzer is manufactured from state of the art digital electronics. Plant interface is through quick disconnect
screw terminals on the back of the module. The user interface is comprised of a 6-button tactile feel keypad and 4 x 20 characteralphanumeric LCD display.

2.1

How the Model 960 UV Analyzer Works

The Model OUSAF44/EXP-1 sensor generates two photocurrent (nA) detector signals based upon the amount of UV energy present at its
lamp source (reference) and measurement point internally. The Model OUM960 unit computes the logarithmic ratio of these two signals
and determines the absorbance of the liquid passing through the sensor. The absorbance value is expressed in optical density units (OD)
and is displayed on the front panel. Two galvanic isolated analog current outputs, proportional to the OD reading, are simultaneouslytransmitted for connection to other instrumentation and recording devices.

2.2

Concentration and Absorbance Units

The concentration of an optically absorbing material in a mixture can be determined since it is related to the amount of light absorbed
from a beam of light passing through it. The absorbance of a substance is directly proportional to the concentration of the material thatcauses the absorption. The Lambert-Beer Law describes this relationship of absorbance (A) to concentration. Essentially, the amount ofradiation transmitted through the absorbing material decreases logarithmically with its increasing concentration.

Where A = log

1
Io
= log
T
Ir

and

T=

Ir
Io

The above assumes that the optical pathlength remains constant. The optical density (OD) however, is defined as Absorption per unit
length. Normalizing to an optical pathlength of 1cm, it follows that:

OD =

Where

2.3

1
( A)
L

OD = Optical Density
A = Absorbance= pathlength in cm

Easy Interfacing

The Model OUM960 UV analyzer incorporates a front panel display and two analog current output signals. The display on the front
panel is an alphanumeric 4 x 20 character LCD. The display may be configured for process variable or analog current output
measurements. Optical Density (OD) readings are normalized to a 1cm pathlength.
There are two analog current outputs from the unit. The range of each can be independently set to be any range within the measurement
range of the instrument. One output is configured to operate with measurement baseline shift commands, while the other tracks fullscale of the instrument.

7Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

General Information

The analog current outputs (4-20mA) will operate with loads up to 750 ohms. These outputs are galvanically isolated and conform to
NAMUR Standard.
Model OUM960 is supplied as standard with four digital inputs and three digital output relays.
The digital inputs can be configured to perform a variety of functions such as baseline and sensor lamp off/on.
The outputs can be connected to a PLC for inclusion in a control scheme, for simple valve operation or for local indication (alarms) andannunciation. Alarm status indication is provided on the front panel display.
All digital inputs are optically isolated.

8Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

3.

Installation

3.1

Model OUM960 Analyzer Installation

Installation

Before starting installation, inspect the analyzer, sensor, and supplied cable set for any signs of shipping damage. Report any visualdamage or discrepancies to Endress+Hauser Conducta and the Shipper immediately.
The Model OUM960 Analyzer is a ¼ DIN enclosure which can be installed in a variety of panels, wall or bench top housings. Refer tofigure 3.1 for mounting dimensions. Mount or install the analyzer into an enclosure or area that is not subject to excessive vibration or
shock and will protect the instrument from materials such as water and chemicals. Allow enough clearance behind it for cable access.

Figure 3.1: Model OUM960 Analyzer Mounting

9Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

3.2

Installation

Model OUM960 Cables and Wiring

All wiring terminals are located on the back panel of the Model OUM960. The analyzer/sensor interconnection cables supplied with thesystem have all been pre-terminated and labeled for ease of installation. The Model OUM960 has two (2) analog current outputs of 4 to
20mA. Both are capable of driving loads up to 750 ohms.
In addition to the analog outputs, three (3) galvanic isolated digital outputs (N.O.) are available. These outputs are rated for both AC andDC voltages up to 280 volts at 125mA. These outputs are intended for dry contact or pilot applications.

Connector
Phoenix Cambion

Insert Terminal
Here

1
2
3
4
5
6
7
8
9
10
11
12

Wire Pin
Terminal

Figure 3.2: Wire Terminal Preparations

Cables installed for signal connection (i.e. analog outputs, lamp fail output) should be shielded twisted pairs.

Warning!
When routing the cables, separate signal cables from power wiring!

Caution!
Use dry contact only when connect digital input to analyzer!
Refer Figure 3.3 for wiring connection.

10Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Installation

Figure 3.3: Model OUM960/OUSAF44/EXP-1 Basic Wiring Diagram (AC Input Version)

3.3

DC Input Power Option

For instruments supplied for 24VDC operation, only the power input connection is changed. Figure 3.4 shows the connection detail for a
24VDC unit.

Input Power+24VDCDC RTN
Ground24 VDC
Figure 3.4: Integra DC Power Connection11Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Installation

Typical Model OUSAF44 Inline Sensor with EXP-1 UV Lamp

Meas.
Det ector

EXP-1 UV Lamp andReference Detector

Meas. Det.
Cable

RED

BLK

SHLD

Attach to Earth Ground

3 4
2 1

Intrinsic Safety Barrier

RED

BLK

Wiring between Sensor and Transmitterto conform with applicable safety standards.
Sealing fittings and conduit supplied by customer.

30
1
27
2
G GRND G
43
43This cable to be run
in conduit

Leads marked with numbers

Attach to Earth Ground

Explosion Proof
Junction Box

Factory Supplied
Cables

White
Green
Red
Black
SHLD GND

22

23

23

24

24

25

25

26

26

Yellow#18 27

27

Yellow 28
Black 29

RELAY 2Signal Inputs

22

RELAY 1

ALARM

LAMP+

28

SENSE+

29

SENSE-

Black#18 30

30

LAMP-

LINE
NEUT
GND

L1

L1

L2

L2

4- 20mA Out

21

Digital Inputs

21

1a
1b
2a
2b
SHLD

1

1

2

2

3

3

4

4

5

SHLD
3a
3b
4a
4b

6
7
8
9
10

11+
22+
COM
1
2
3
4

11
12
13
14
15
16
17
18
19

11
12
13
14

Analog Output 1(4-20mA)
Analog Output 2(4-20mA)

POWER INPUT
100-230 VAC
50/60 HZGRND #8

Figure 3.5: Model OUM960/OUSAF44/EXP-1 EXP-1 UV Lamp Basic Wiring Diagram (ATEX/SIRA) and FM Approved Versions

12

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

3.4

Installation

Model OUM960+OUSAF44/EXP-1 Wiring

THIS SYSTEM IS BEING INSTALLED IN A HAZARDOUS LOCATION AND MUST CONFORM TO ALL LOCALAPPLICABLE SAFETY STANDARDS.
Before installation, plan and select the location of the system components. The Sensor and Ex-Pr, which are located in the
Hazardous area, should be placed such that servicing and wiring are easily done. When routing the cables form the sensor
avoid conduits or wiring troughs that contain high voltage or current wiring.
The OUM960 UV Analyzer and OUSAF44/EPX-1 is configured for either FM or ATEX/SIRA Approved instillations. The
Detector Assembly is intrinsically safe and only requires an Approved Intrinsic Safety barrier be installed in the Safe Area inclose proximity of the OUM960 UV Analyzer.
The Lamp and Reference Detector cable is terminated near the OUSAf44/EXP-1 Sensor in either a FM Approved Class 1,
Division 1, Group B,C, D explosion proof junction box or an ATEX/SIRA equivalent enclosure. The FM Approved EXP-1
Lamp requires that the cable from the lamp housing must be contained in a Flexible Conduit and properly sealed during
installation. The ATEX/SIRA accepts an approved flexible cable and cable gland suitable for Hazardous locations. The cablefrom the lamp housing exits through a sealed gland. Other than this difference, the installation and wiring are identical for
FM and ATEX/SIRA requirements. Refer to Figure 3.5 for system wiring.
All required cables shown in Figure 3.5 are supplied with the system. These cables are terminated, labeled and color coded
for easy installation. After installation check all wiring for proper connection.

13

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

3.5

Installation

Model OUSAF44 Sensor Installation

Figure 3.6: Recommended Orientation for Sensor Installation

Sensors can be installed either directly in a process line or in a by-pass line. They can be mounted either vertically or horizontally. If
mounted horizontally, the sensor lamp and detector housings must be horizontal. This will insure that the optical window surfaces are ina vertical position, which will help prevent build up on the window surfaces. The sensor should be located upstream of pressure
regulators. Operating sensors under pressure will help to avoid the possibility of air or gas bubble evolution, which can cause
measurement noise and error.
When installing, allow adequate space for the connection of cables at the ends of the lamp and detector housings. Access to these areas isalso important for connection/disconnection purposes. Sensor bodies should be supported when in line and care should be taken to
ensure they are protected against damage caused by external forces such as carts on adjacent walkways.

Figure 3.7: Typical OUSAF44/EXP-1/45/46 Sensor With Cables Connected.

14Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

3.6

Installation

Post-Connection Check

After wiring up the electrical connection, carry out the following checks:

Device Status and Specifications

RemarkIs the analyzer or the cable externally damaged?

Visual inspection

Electrical connection Remarks

RemarkAre the installed cables strain-relieved?
No loops and cross-overs in the cable run?
Are the signal cables correctly connected according to the wiring
diagram?
Are all screw terminals tightened?
Are all cable entries installed, tightened and sealed?
Are the PE distributor rails grounded (if present)? Grounding at placeof installation

Grounding at place of installation

Caution!
Improper grounding will lead to unreliable measurement result!

15Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

4.

Operation

4.1

Quick Operation Guide

Operation

User has the following ways of operating the analyzer:••

On site via the keypad
Via the digital input interface to perform process control functions remotely.

4.2

Display and Operating Elements

4.2.1

Operating Elements

Figure 4.1: Operating Controls

1.
2.
3.
4.
5.
6.

i

LED for lamp warning functions and limit relay status.
Menu/ESC key serves two functions. Pressing Menu/ESC will always exit out of a screen and will not save any changes
entered. Pressing Menu/ESC from the main PVi or Output screen will open the Sub-Menu screen.
Ack/ENT key accepts changes in a screen and continue forward through the screen
4 keys navigate the user through the menus and screens.
LC display for displaying the measured values and configuration data LED.
Display of the active contact and key for relay changeover in manual mode.

PV is the Process Value for PV1 and PV2 and corresponds to Output 1 and Output 2 respectively.

16Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

4.2.2

Operation

Operation Legend

In this manual, the following operation legend will be used when describing operation procedure.

Enter/Acknowledge key
Escape/Menu key
Left or Right key
Up or Down key
Figure 4.2: Operation Legend for Operation Instruction

4.3

Local Operation

4.3.1

Measuring Mode

The analyzer normally operates in measuring mode. Here, the relays and alarm LED are triggered by the analyzer according to process
status. The analyzer will take configurable digital input to trigger certain function like BaseLine Zeroii, Optical Zeroiii etc...
During the measuring mode, the LCD screen will display as figure 4.3. The process value, unit and analyzer label will be displayedpermanently. BaseLine, Alarm and Lamp Status will be display when conditions are met.

Figure 4.3: LCD display on measuring mode

ii

iii

BaseLine Zero when enabled offsets the PV to zero. This often used to subtract background absorbance prior to initiating a process.
Optical Zero is established during calibration and the set with a non-absorbing liquid in the flow cell. i.e. de-ionized water.

17

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Operation

Table 4.1 shows the status display description and display condition.

Status Area Name

Displayed symbol

Description and Display criteria

Analyzer Label“xxxxxxxxxxxx”

Editable up to 12 characters for user
analyzer indentification.

Process Unit

“OD”

Display “OD” under normal condition,“xxxxxx”

Displays user configured engineering unit
if PV correlation function is activated.

Over Range Symbol“OVER”

Displays if measurable range is reached.

BaseLine Status“BL OFF”

Displays if BaseLine is not activated.

“BL ON”

Displays if BaseLine function is activated.

“BL SFT”

Displays if BaseLine and BaseLine Shiftfunction are both activated.

Alarm“AL x”

Displays if corresponding relays (1, 2, orboth) are triggered.

Lamp Status“LAMP LOW”

Flash if reference voltage is lower than
80% of initial value.

“LAMP FAIL”

Displays if lamp reference signal is lost.

“LAMP OFF”

Displays if lamp is turned off.

“CABLE FAULT”

Displays if lamp or signal cable has a faulty
connection.

Cable Status

Table 4.1: Operation screen under measuring mode

Figure 4.4: Operations under Measuring Mode

Under measuring mode, press
button will let you enter the process control screen, where user can operate process control
routine. The detail of process control function will be listed in Chapter 6.

18Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

4.3.2

Operation

Configuration Mode

The configuration and calibration functions are arranged as function groups.

•

Use

•

Use

•

Use

•

If a modified setting is confirmed withkey to enter the function group menu from measurement screen.
arrow key to select the group from process set-up, maintenance, or system data.
to confirm the change and input the value.

, the old setting is retained.

Menu
ESC
Ack
ENT
Menu
ESC
Ack
ENT
Menu
ESC
Ack
ENT

Figure 4.5: Diagram of configuration structure

Input data
During the system configuration and set up procedure, user will need to input the data into the screen.
In the data input screen

•

Use

•

To change the decimal point of the input data, place the cursor on decimal point, useto the left or right.

to move the cursor to select the digit to edit.
to move the decimal point

Figure 4.6: Decimal Point Position Placement

19Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

4.4

Operation

Remote Operation

Remote operation function will provide user the ability to use off site dry contact to perform the process control. Short input channel pin
to COMMON pin will trigger the input the channel.
Refer section 5.3.8 to configure and use digital input function for remote control.

Digital Input #Description and Display criteria1Lamp On/Off

2

Enable BaseLine function

3

Update BaseLine value

4

Optical Zero
Hold current process measurement(both display and analog output)
Table 4.2: Digital Input Functions

1-

13

1+ 12
2-

11

Channel 1 & 2
Analog Outputs(4-20 Ma)2+ 14
COM 15
1

16

2

17

3

18

4

19
Dry Contact orPanel Sw itch
Figure 4.7: Typical Digital Input Wiring Diagram

20Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.

Commissioning

5.1

Function Check

Commissioning

Warning!
•
Check all connections for correctness.
•
Make sure that the supply voltage is identical to the voltage written on the technical information!

5.2

Switching On

Familiarize yourself with the operation of the analyzer before it is first switched on. Please refer in particular to the "Safety Instructions"and "Operation" sections. After power-up, the device performs a diagnosis for 30 seconds and then goes to the measuring mode.

Lamp Initial Set-Up

The first time the analyzer is turned on with a new UV lamp, a “LAMP LOW” symbol will be shown on the display screen. The front
LED will be flashing and lamp alarm relay will be toggled. To remove this warning message, the lamp status has to be initialized from thesoftware. The lamp low warning shows as follows:

Figure 5.1: Lamp status during start-up

21

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Reset New UV Lamp

Press

, enter function group selection menu. Move the cursor to

MAINTENANCE and press

Press

to enter.

to navigate to LAMP REPLACE, and press.

The current lamp voltage will be displayed on the right upper corner.
The timer will start counting down once thewarm up the lamp.

is pressed to

Wait 30 minutes until the timer goes to 0:00

The current lamp voltage will be displayed in the first line and lamp
low threshold voltage will be calculated and display on the third line.

Press
to accept the setting and use
to go back tomeasurement screen. The LED and lamp alarm relay will be reset.

5.3

Analyzer Configuration and Operation

After power-up and lamp setting, you must verify analyzer configuration settings which are required for correct measurement.
The analyzer/sensor will be Plug& Play if system was ordered together as a complete solution!
If OUM960 UV analyzer ordered with OUSAF44/EXP-1 UV sensor and OUK40 cable from Endress+Hauser, the factory will perform:•••

New lamp set up
PathLength adjustment in analyzer according to sensor order
Calibrate analyzer with LiquidCal or EasycalTM (if ordered)If application data has been given, factory will perform optical density to engineering unit correlation and deliver correlation data withanalyzer. Span and relay setting also can be performed in factory if requested.
If analyzer ordered separately, the factory default setting will be loaded into the analyzer when analyzer is delivered.

22Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.1

Commissioning

Factory Default Setting
Parameters

Factory Default Value

Measurement Unit

OD

Measurement Pathlength

10mm

Output Span 1

2.0000 OD

Output Span 22.0000 OD

Relay 1 Set Point/Status

1.0000 OD/ Disabled

Relay 2 Set Point/Status

1.0000 OD/ Disabled

Process Value Correlation

Off (Curve #0)

BaseLine

Disabled

Password

Disabled

Table 5.1: Factory Default Setting

5.3.2

Sensor Calibration

Model 960 analyzer supports 2 different calibration procedures: Liquid Calibration and Easycal

TM.

5.3.2.1 Liquid Calibration Procedure
A liquid solution of a known optical density (at the wavelength of the sensor) must be used for instrument calibration. The following
TMprocedure is used in factory when Easycal option is not ordered. Calibration liquid can be chosen by user in field depending on
application.
Potassium Dichromate (K2Cr2O7) is most often used as an optical standard for calibration of UV analyzers. A solution consisting of
182ml of 0.1N K2Cr2O7, diluted with DI water to a 1L volume, has an absorbance of approximately 10 OD at 280 nm. Successive
dilution will provide a series of calibration solutions for sensor calibration at more than one point.
D-Tryptophan is a common protein used for optical calibration of UV analyzers at 280nm. A solution can be made consisting of 1.000
grams of Tryptophan and 200ml of de-ionized water placed in to the beaker and heated on a magnetic stirrer. As the Tryptophan
dissolves add de-ionized water to a volume of about 450ml. The Tryptophan dissolves slowly. Continue the stirring, maintaining atemperature of about 30oC until the Tryptophan is completely in solution. Transfer this solution into a 1000ml volumetric flask anddilute with de-ionized water to a final volume of 1000ml. This is a concentration of 1000ppm D-Tryptophan in water and is used as thebasic standard or mother solution from which successive dilutions can be prepared. A solution diluted to 100ppm is about 2.6 OD at
280nm.
When preparing solutions, it is very important to measure the optical absorbance of every solution prepared (at the wavelength of thesensor) on a certified laboratory spectrophotometer.
The Liquid Calibration screen appears only if an Easycal™ system is not installed and configured in the System Data section.

23

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Liquid Calibration Procedure
Enter MAINTENANCE sub-menu to access
SENSOR CAL function. Press

to ent.

to select LIQUID CAL, Press
Useenter liquid calibration process.

toFill the sensor with a zero fluid.
Press

to record zero point.

Enter the value of the standard solution being used tocalibrate the system. The solution should beapproximately ½ of the full range of the system.
Press

to continue.

Fill the sensor with the standard calibrating solution. Wait
until OD reading increase and stabilize. Press
record the data.

toRemove the calibration solution, and rinse repeatedly
with a zero solution. OD reading should decrease andstabilize. Press

to proceed.

Remove the cover screw on the measurement detector
and install the reference rod. Press

to proceed.

Remove the reference rod and install the cover screw on
the measurement detector. Press
to proceed.
The unit records the values of the calibration solution and
ref rod value and displays these values. The standard
solution is used for calibration, while the ref rod is forchecking calibration. Pressto accept these values.

24Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

5.3.2.2 EasycalTM Set up and Calibration
All OUSAF44/EXP-1 sensors can be fitted with the optional Easycal™ Liquid-Free NIST Traceable Calibration System to allow fast andprecise calibration of the UV system. This option is available in new systems and as a retrofit item for existing units in the field. Check
accessories chapter 7 for retrofit item ordering information.
Each Easycal™ unit contains two traceable filters - a nominal 0.5 AU and 1 AU (Absorbance Unit) - which are placed into the opticalmeasurement path of the instrument either separately or together. These filters are scanned with a traceable source and their actual
absorbance at individual (measurement) wavelengths is ascertained.
The Easycal™ system allows traceable calibration without using liquid standards. It is very important to refer to the actual values of theEasycal™ optical filters as noted on the Calibration Certificate supplied with the unit. These absorbance values should be entered into
the Model OUM960 as part of the configuration setup. The Easycal™ screen appears only if it is installed and configured in the System
Data section.

TM

End View of EasyCal Housing

IN

Hi

Lo

OUT

Air
Purge

Figure 5.2: EasycalTM Housing and Controls25Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

EasycalTM Installation
Enter SYSTEM DATA sub-menu to access
CHANGE EASYCAL CNFG function.
Press

to continue.

Use
to select [YES] or [NO] to decide if theEasycal™ is installed. To install, select [YES] and confirm.

This screen displays the present NIST Filter Absorbanceto change
values and the re-certification date. Pressthe date and filter values starting with the next screen.

Move cursor to edit the day, month and year. Save data
and move to next step.

Refer NIST filter high absorption value listed on NIST filter
certificate delivered with Easycal™. The value should beclose to 1.0000 AU. Press
to continue and use thesame procedure to input the low filter absorption value,
close to 0.5000 AU.

to confirm theAfter put in both filter data use
setting. Easycal™ data installation is finished.

26

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

EasycalTM Calibration Procedure
Enter MAINTENANCE sub-menu to access
SENSOR CAL function. Press
to change.
If Easycal has been installed. Analyzer will automaticallyenter Easycal procedure.
Both high and low NIST filters absorption value will be
displayed in this screen. User set certificate due date isdisplayed also. Press

after review the data.

Assure both high and low filters are in OUT position.
Press

to record zero point.

Move HI filter adjustment screw to IN position.
Press

to record high filter value.

Move LO filter adjustment screw to IN position.
Press

to record HI+LO value.

Move HI filter adjustment screw to OUT position.
to record low filter value and perform
Press
calibration calculation.

The screen then displays the low, high and high+low
readings and % deviation from the certified value of eachvalue. Review the deviation level and press
accept the calibration result.

to27Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.3

Commissioning

Change Pathlength Setting

If sensor pathlength needs to be changed by user, the corresponding change will need to be performed to OUM960 analyzer also.
Refer to Chapter 6 Sensor and Analyzer Maintenance to perform sensor pathlength adjustment. This section only covers corresponding
analyzer setting to match the measurement result.
Pathlength SettingEnter SYSTEM DATA sub-menu to access
PATHLENGTH function. Press

to continue.

to

The FROM value is the present Pathlength Value. Useto select wanted digit. Repeat for
position the cursor andeach digit position. When new Pathlength has been selected, press
to confirm the change.
The SYS DATA: PATHLENGTH is displayed together with the newvalues for pathlength and OD MIN/MAX.

5.3.4

Setup Output Span

The 4~20mA span setting will provide user capability to achieve maximum resolution for preferred measurement range.
Change 4~20mA Output SpanEnter PROCESS SET-UP sub-menu to access OUTPUT SPANS
function. Useto select.

to move the cursor to O1 and press

This screen will display the current output span MIN/MAX span basedon pathlength or process value correlation setting. Presschange the span.

to

In this screen the current value for span is the FROM value. Position
the cursor as done previously and select the number for that position.
Repeat as needed for each digit position. When the new span has beenentered， press

and confirm the sanity check to accept.

Use same procedure above to change Channel 2 output span.

28

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.5

Commissioning

Output Relay Set Point and Configuration

Change Output Relay Set Point
Change Relay Set Point
Enter PROCESS SET-UP sub-menu to access
OUTPUT SPANS function.
Use

to move the cursor to ALx and press

to select.

In this screen the current value for span is the FROM value. Position the
cursor as done previously and select the number for that position.
Repeat as needed for each digit position. When the new relay set point
has been entered， press

and confirm the sanity check to accept.

Configure Output Relays

The Alarm Setup screen allows configuration of PV, Hi/Lo/Off, and NO/NC operation.
is used to change the state. Press

Functions
Trigger Condition

Input Mapping
Relay Operation Mode
Hysteresis
Delay

HIGH
LOW
OFF
PV1
PV2
NO
NC

is used to select the parameter andto continue.

Description
Triggered if process value higher than set point.
Triggered if process value higher than set point.
Relay disabled
Process value #1
Process value #2
Normally open
Normally close
Set relay hysteresis
Delay trigger timer (Sec)Table 5.2: Output Relay Configuration

29

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Configure Output Relay
Enter from MAITENANCE sub-menu. Scroll to the ALARM CONFIG
screen. Useand confirm.

to select the ALx line. Press

to select

The ‘ALARM 1 SETUP’ screen will appear. Select the SOURCE option,
PV1 or PV2.

Next withselect the CONFIG option. Useto select OFF, HIGH and LOW.

Press

to scroll down to ALARM 1 SETUP STATE screen.

selects either normally open (N/O) or normally closed(N/C) alarm state of the relay contacts. Select the N/O option andpress

to accept and confirm.

The CHANGE ALARM 1 DELAY is next displayed. Set the needed
delay. Delay time unit is second. Pressto accept and confirm.

The CHANGE ALARM 1 HYSTS option controls the alarm hysteresis. If
the alarm set point is set 1.00 OD and the hysteresis is 0.100 OD, an
alarm condition exists at 1.00 OD and will stay in alarm until the PV is0.90 OD or less. Hysteresis can be called the deadband between an
alarm on and off condition. Set the hysteresis to 0.100 OD andpress

to accept and confirm.

30Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.6

Commissioning

Current Output Calibration

This function calibrates 4~20mA current output to assure the measurement accuracy.

Calibrate 4~20mA Output
Enter MAINTENANCE Sub-Menu to access
OUTPUT CAL function. Move cursor to OUTPUT 1 and press
select this channel.

toMove the cursor up and down to select the value need to be trimmed.
Use

to trim 4mA or 20mA.

The trimming resolution is 1% per step. Press
confirm the trimming.

to accept andFollow same procedure to trim OUTPUT 2.

5.3.7

Date and Time Setting
Set ClockEnter MAINTENANCE sub-menu to access SET CLOCK function. Useto select the CUR DATE line.

Press

to select the DATE option and then the CHANGE DATE

Screen is displayed with the current date. Use
the cursor andto change the mm/dd/yy numbers. When

the wanted date is entered, press

Press

to position

to accept and confirm.

to select the TIME option and then the CHANGE TIME

Screen is displayed with the current time. Use
the cursor andto position

to change the hh/mm/ss numbers. When

the wanted time is entered, pressto accept and confirm.

31Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.8

Commissioning

Configuration and Use Digital Input
Configure Digital Input
Enter MAINTENANCE sub-menu to access DIGITAL IN function. Press
to continue.

The following screen displays the current configuration of the external
digital inputs. Use theto scroll through the DISABLE andSTANDARD CONFIG When disabled the external digital inputs areinoperative.
When in STANDARD CONFIG, the digital inputs are configured as;
1 Lamp On-Off
2 Baseline On-Off
3 Baseline Update
4 Hold/Optical Zero
Digital Input #4 can be set as Optical Zero function if wanted. Pressto accept and confirm.

32Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

5.3.9

Commissioning

Process Control

From main measurement screen, press

Functions
BaseLine

Lamp Switch
Optical Zero
Optical Checkto enter process control screen.

StatusON
UPDATE
OFF
ON
OFF
-

Description
Enable baseline
Update baseline value
Disable baseline
Turn on lamp
Turn off lam
Make current measurement at 0.
Start sensor check

Remote Trigger
Digital Input 2
Digital Input 3
Digital Input 2
Digital Input 1
Digital Input 1
Digital Input 4-

Table 5.3: Process Control Functions

5.3.9.1 Access of Process Control
The authorization to access the process control functions can be configured in OUM960 analyzer. The access control is password
protected. See 5.3.9.6 for password protection.

Configure Process Control AccessEnter SYSTEM DATA sub-menu to access ACCESS function. Press
to continue.

Select the option to configure.
Note: The Response is in brackets [ ]. With bracketed responses use
for changes. Select ‘YES’ for each option. There are 4
options to configure. When all changes are made, press
and confirm the entries and return to top screen.

to accept

5.3.9.2 Baseline (AutoZero)
To operate the baseline function, the Process Control Screen must be assigned as a privilege for the user. If assigned the privilege, use
to open the Process Control Screen. Useto select baseline and select as follows: To initiate a new baseline
use “On”, to remove an existing baseline use “Off”. To change an existing baseline setting to a new setting use “Update”. If the baseline
was previously “On” when a power interruption occurred, the analyzer will retain its last saved baseline setting and return to that setting
when power is restored, and the analyzer and the baseline control will remain “On”. Baseline function replaced the AutoZero function in
the 600 series analyzer. If a Baseline Shift value has been entered, activating the baseline shift will cause the 4~20mA output channel 2
to “Shift” to the entered % value. Both PV display would indicate “0”. The PV screen will also indicate BL SFT in lieu of BL ON when ashift value has been entered (>0%).

33

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Change BaseLine Shift ValueEnter PROCESS SET-UP sub-menu to access BASELINE SHIFT
function. The current Baseline Shift “%” Percentage value will be
displayed. Press

to continue.

Use
to position the cursor andtoselect wanted number. When the new percentage value has beenentered, presschange and confirm. The channel 2
4~20mA output will “Shift” to the % of full scale selected when
the baseline is activated. Hence, a 0% baseline shift value will
output a 4ma (zero) signal and a 50% baseline shift value will
output a 12ma (midscale) signal.

5.3.9.3 Optical Zero
Optical Zero is a function to provide an over all zero to offset the initial background optical noise in OUSAF44 UV sensor. User can also
use optical zero to setup the process zero (e.g. DI water optical density etc...).

5.3.9.4 Lamp Switch
Use this function to switch lamp on and off.
Note!
Lamp alarm relay status will be affected.

5.3.9.5 Optical Check
Use Cal Rod to check Calibration Reference Rod and Cal Rod Check
A Calibration Reference Rod is supplied with each standard sensor (a sensor without Easycal™) to allow calibration "Check" of the
instrument without requiring the use of calibration solutions. The Reference Rod screws into the detector housing of the sensor,
providing partial blockage of the sensor light path and therefore simulating absorbance in the optical chain. The cross-sectional view of an
OUSAF44/EXP-1 measurement detector shown below illustrates the placement and the blocking effect that the Reference Rod has inrelationship to the sensor's detector. This partial blockage of light to the detector provides an effective, stable and repeatable checking
technique.

34

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Figure 5.3: Cross Sectional view of Detector with Reference Rod

When used in conjunction with an initial liquid standard calibration procedure, the reference Rod can be deemed a secondary standard
for routine system checking. Calibration can be traced to the controlled standard used to verify the original calibration solutions and cantherefore satisfy validation procedures. During initial calibration of a sensor/analyzer pair, liquid standards must be used to calibrate thefull-scale response of the system. After calibration, by filling the sensor with water and ensuring the analyzer reads zero, a value for thereference rod can be obtained by inserting the Reference Rod into the sensor detector housing and noting the analyzer display reading. At
any time in the future, reinserting the reference rod and checking that the analyzer reads the same with the sensor filled with water cancheck the analyzer calibration.

Note!
All analyzers must be re-calibrated with liquid standards if there are any changes made to the optical chain, including replacement ofseals or lamp.

Figure 5.4: Typical Inline UV Sensor with Reference Rod

When not being used, the Reference Rod access hole is plugged with a gasket and stainless steel screw to maintain the environmental
integrity of the detector housing.
All Model OUM960 UV analyzers with standard OUSAF44/EXP-1 sensors (without Easycal™ option) are calibrated at the factory using
liquid standards. Please refer to the Test Sheet accompanying your instrument for the factory determined reference rod value.

35Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

5.3.9.6 Password Protection
OUM960 support the password function to protect the analyzer from unauthorized operation.

Figure 5.5: Password protection level

Password Protection
Enter SYSTEM DATA sub-menu to access PASSWORD function. Press
to continue.

When in the ENTER OLD PASSWORD screen, the CURSOR highlights theleft digit position. Use theto wanted digit position. Use

to scroll thru 0-9 for each digit position. Move the cursor to
the desired digit and enter a number. When the old password number has
been entered, pressto accept.

Note: When “0000” is set a password, the password protection mode isdisabled.

When in the

ER NEW PASSWORD screen, the CURSOR highlights

the left digit position. Use theto wanted digit position. The

scrolls thru 0-9 for each digit position. Move the cursor to
the desired digit and enter a number. Repeat as wanted for each cursor
position. Any password number up to 4 digits can be entered. When the
password number has been selected, press
twice to accept. The
Password for MENU access is now the number entered.

36Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

5.3.9.7 Process Value Correlation
In the OUM960 analyzer software, the user can define and store 3 linearization tables to correlate the optical density measurement tospecified process parameter measurement. Each table supports up to 16 points of measurement value. User can switch correlation curves
to fit different applications.
Caution!
The overall course of the curve must be continuously rising. Horizontal or vertical segments or a zigzagging of the curve are notpermitted.
Data points may be entered into the linearization table randomly; the software performs sorting automatically as needed. It is possible toincrease accuracy in a certain segment of a linearization table later. To do so it is not necessary to enter all data points again, but to enter
only additional data points.

Process Value Correlation Set Up
Enter PROCESS SET-UP sub-menu to access PV CORRELATE
function. Press

to continue.

The next screen asks which curve (1-3) you want to edit and store thecorrelation table. Scroll withPress

to select curve number.

to continue.

If the original sample value is not put in yet. Select SAMPLE IN CELL?
By scrolling withto select. Press

to continue.

The next screen asks if process sample is in the cell and displays
measurement value. If this value is within the Min/Max acceptablepress

to read and store.

The next screen asks if another sample is to be measured. Press
to read another sample, press

if finished all samples.

Confirm the number of point to build correlation curve and press
to store original sample data.

37

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

SAMPLE EDIT is used to put in the target correlation value and unit.
Press

to continue to put in data.

The next screen asks if the user would like to change the original
sample point OD value. If this value needs to be changed, use
andto change value. Presstocontinue.
The next screen is for entry of target correlation values that can be
assigned to the original correlated measured value. i.e. 1.32 measured
units to 9999.9 units. The FROM value is the last entered value on the‘ENTER USER VALUE’ screen. Enter the new value using
andto position the cursor and select the
number for each required position. If a different position is required forthe decimal point, do this first. Press
accept.

twice to change andRepeat above procedure until all correlation points have been entered.

When all the sample points have been edited, the Change Units screen
is next. The engineering unit can be entered is limited to 6 alphanumeric characters.( i.e. gr/l, %, mg/l, cel/cc, etc.). Press
twice to change and accept entry.

The Max/Min values are calculated for entried values and units.
These values are the new limits for output span and relay setting andthe displayed Process Display PV value and units.

38Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Commissioning

Note!
If the OD to correlation unit table is predefined and does not need liquid sampling, use MANUAL EDIT option to enter the table toanalyzer. The procedure is similar to SAMPLE EDIT.

Switch Correlation Curves
Enter PROCESS SET-UP sub-menu to access RUN CAL CURVE
function. Press

to continue.

The next screen asks which curve (0-3) you want to execute. Curve#0 is the default OD measurement. Curves 1-3 are user defined. Scroll
to select curve number. Press
to select andwithconfirm.
NOTE:
Entering a curve with Process Correlate will automatically set it as thecurrent active curve.

39Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

6.

Maintenance

6.1

Maintenance Outline

MaintenanceOnce the unit is in operation, there is no requirement to access the interior of the Model OUM960 UV analyzer housing for normal dayto-day operation and calibration.
Certain maintenance need to be performed for OUSAF44/EXP-1 sensor. The service and maintenance interval time is application
dependant.
Note!
Check list of maintenance!
•
•
•
•
•

Lamp Replacement
O-Ring Replacement
Filter (NIST) Replacement
PathLength Adjustment
Sensor window and gasket replacement

Caution!
The procedures described in this section should only be carried out by qualified maintenance staff.
Model OUSAF44/EXP-1 sensors contain sensitive optical components and should be handled carefully. Particular care must be taken toprevent contamination of these components.
Caution!
Clean all optical components with a suitable lint free lens cleaning tissue and ethanol.

Figure 6.1: Cross-Sectional View of a Typical OUSAF44/EXP-1 UV Sensor

40Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

6.2

Maintenance

Mercury Lamp Replacement for OUSAF44/EXP-1

Caution!
Whenever maintenance is performed on the sensor, remove all cables and power to the sensor. Never view the mercury lamp whenpowered directly without proper eye protection.
To replace the mercury lamp, proceed as follows (Refer to Figure 6.3: Illustrative lamp replacement procedure):
1. Remove the lamp housing from the sensor by unscrewing the housing CCW.
2. Remove the lamp assembly from the housing by unscrewing the lamp assembly CCW. If tight, use the cable connector body flange asa “nut” to gain access.
3. Allow the lamp to cool. Loosen and remove the lamp retaining set-screw.
4. Grip the lamp body in the gap between the lamp power supply and the mirrored reflector. Push the lamp towards to reflector until
the lamp is free of the socket. Grip the glass section of the lamp from the end and remove it through the reflector.
5. With the lamp removed, inspect the lamp assembly for any cable fraying or reflector damage. When cleaning any of the opticalsurfaces use ethanol and soft, lint free tissue.
Caution!
Clean the new lamp and the mirror with ethanol and lens tissue. After cleaning, do not touch these optical surfaces. When handling thelamp, use lens tissue or wear talc-free latex gloves.

Black Anodized
Aluminum
UV Lamp power pins
Figure 6.2: UV Plug-in Lamp OUSAF44/EXP-1/46 Versions

6. The lamp is replaced by inserting it through the reflector and mating it to it’s socket. Make certain that the lamp pins are in line withthe socket connectors. Gently insert the lamp into the socket making sure that it seats completely.
7. After the lamp has been replaced, reinsert the lamp retaining set screw. This screw is just to hold the lamp in place, do not overtighten as the lamp could be damaged or broken.
8. The complete lamp and power supply assembly is now refitted into the lamp housing and onto the sensor.

41

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

MaintenanceStep 1

Removing lamp assemblyfrom sensor
Unscrew CCW

Step 2
Unscrew Lamp
Assembly CCW

Removing lamp
from lamp housing

Remove lamp and power supply
assembly from lamp housing

Lamp Socket

12 VDC/ AC
Lamp Power
SupplyStep 5UV Lamp

Remove Lamp
Set Screw

Grasp Lamp from eachside of body remove
lamp from holder.

Step 3

Step 4

Remove and replace'O' Ring

12 VDC/ AC
Lamp Power
SupplyStep 6
With lamp power pin inline
with lamp socket, insert lamp
as shown until lamp seat in socket.
DO NOT FORCE LAMP

Step 7
Replace set screw.
Do not overtghten

Replacing lamp assembly
into lamp housing

Screw Lamp
Assembly CW

Step 8Screw CW

Replacing lamp assembly
onto sensor

Step 9Figure 6.3: Illustrative Standard Lamp Replacement Procedure42Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

6.3

Maintenance

OUSAF44/EXP-1 Measurement Detector/Filter Replacement

The measurement filter is replaced using the following procedure (refer to figure 6.4 for a view of the assembly):
2-56 X 3/16"

0-ring
INTERFERENCEFILTERTYPICAL VIEW

LAMP HOLDER

Figure 6.4: Reference Detector/Filter Replacement

1. Remove the measurement detector housing from the sensor.
2. Loosen and remove the 4 screws holding the measurement detector back plate onto the back of the measurement detector housing.
Take care to retain all screws, washers and the sealing “O” ring.
3. Withdraw the back plate assembly from the housing.
4. Remove the 2 black anodized screws holding the detector assembly to the back plate and carefully separate, protecting theinterconnecting connecting cable.
5. Remove the 2 screws holding the detector PCB to the back of the filter holder and separate.
6. Remove the two setscrews holding the filters into the holder; turn the filter holder over and drop the filters into your hand.
7. Fit the new filters into the detector/filter holder taking care to ensure that they are installed “shiny” or “mirrored” side towards thelight source and that the correct wavelength value is installed in the correct side. Lightly tighten the retaining setscrews.
8. Clean the detector faces and the filter faces with ethanol and lens tissue. Check and clean all other components as necessary. Installthe detector PCB making sure that the wavelength to channel orientation it is correct.
9. Re-assemble the detector housing in the reverse order, ensuring that the orientation of the detectors is correct to allow use of thereference rod and that all O-Ring seals are correctly fitted and seated.
10. Replace the measurement detector housing onto the sensor.
11. Calibration of the connected analyzers is required after detector replacement.

43Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

6.4

Maintenance

Measurement Filter Replacement (Easycal™ Assembly)

The measurement filter is replaced using the following procedure (refer to figure 6.5 for the exploded-view of the assembly):
1.
2.
3.
4.
5.
6.
7.
8.

Remove the Detector Assembly from the flow cell.
Un-screw the back-plate assembly from the detector housing as shown. If tight, use the cable connector body flange as a “nut”
to gain access.
Remove the four (4) screws form the detector connector and remove the detector as show and remove the detector.
Loosen the measurement filter retaining set screw and with the assembly held vertically, softly tap the assembly until the filter
falls out.
With the assembly still in the vertical position, insert the new filter until it is seated. Lighly tighten the filter retaining set screw
to hold the filter in place. DO NOT OVER TIGHTEN AS FILTER DAMAGE WILL RESULT.
Insert the measurement detector assembly and secure with 3 x M3-08 screws and washers.
Using a fourth M3-08 screw, attach the connector dust cover to the connector flange and Easycal™ back plate assembly.
Refit the detector housing to the assembly.

44

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Maintenance

MEASUREMENTFILTER
DETECTORASSEMBLY

MEASUREMENT FILTERRETAINING PLATEFILTERRETAINING
SCREW

BACK PLATE

Figure 6.5: Easycal™ Measurement Detector Assembly

6.5

Measurement Filter Replacement(Standard and Cal Rod Assemblies)

The measurement filter is replaced using the following procedure (refer to figure 6.5 for a cross sectional view of the assembly):
1. Unscrew and remove the outside casing from the Easycal™ Measurement Detector Housing Assembly. If tight, use the cableconnector body flange as a “nut” to gain access.
2. Loosen measurement filter retaining set-screw.
3. Insert measurement filter, mirror side first, into the housing and locate in the filter retaining plate.
4. Tighten the measurement filter retaining set-screw snug against the filter and ensure the filter is held in place.
5. Insert the measurement detector assembly and secure with 3 x M3-08 screws and washers.
6. Using a fourth M3-08 screw, attach the connector dust cover to the connector flange and Easycal™ back plate assembly.
7. Refit the detector housing to the assembly.

45

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Maintenance

Figure 6.6: Filter/Detector Replacement Standard-Cal Rod

6.6

Sensor Wavelength Change

Should it be required to change the operating wavelength of the sensor, both the measurement and reference filters must be changed.
When changing filter wavelength, follow the same procedures as describe above.

6.7

Sensor Window and Gasket Replacement

Sensor optical pathlength is established by the window type(s) used. Each analyzer-sensor pair is configured for a given pathlength.
Windows must be replaced with the same type to maintain pathlength. The illustration below is a typical flowcell assembly. Figure theavailable window types and possible pathlengths for sensors up to 2" line sizes.
Replacement of windows or window seals, changing window spacing or other maintenance requiring the disassembly of the sensor uses
the following procedure:Note:
To replace and/or change the windows and seals, the sensor must be removed from the process line.

46

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Maintenance

Figure 6.7: Typical Flowcell/Window Replacement

6.8

Sensors without Precision Optical Pathlength Adjuster Option

1. Remove the lamp and the detector housings from the sensor body.
2. Remove the 4 socket head screws from each window retaining ring and remove the rings. Be careful to loosen the screws evenly andalternately around the window retaining ring. If the window is ‘stuck’, apply Acetone to the window seal area and let soak forseveral minutes. This may assist in freeing the windows from the seals.
3. Gently push/ease the windows out of the sensor.
4. Inspect the window area and clean as necessary. Inspect the windows for any signs of abrasive wear or chipping. If any is apparent,
replace the windows. Discard the 'O' rings and replace with new ones of the same material type. Re-assemble the sensor in thereverse order, taking care to cross-tighten the window retaining ring screws evenly to prevent uneven seating. If the sensor
pathlength has been changed, the analyzer module must be configured to reflect the new pathlength. After every re-assembly of an
OUSAF44/EXP-1 sensor, it is necessary to carry out a liquid or Easycal™ calibration with its associated analyzer.
Note!
Upon re-assembly, insure that the lamp assembly is mounted on to the side of the flow cell with the “shorter” length of the two
windows.
5. Remove the lamp and the detector housings from the sensor body.
6. Remove the 4 socket head screws from each window retaining ring and remove the rings. Be careful to loosen the screws evenly andalternately around the window retaining ring. If the window is ‘stuck’, apply Acetone to the window seal area and let soak forseveral minutes. This may assist in freeing the windows from the seals.
7. Gently push/ease the windows out of the sensor.
8. Inspect the window area and clean as necessary. Inspect the windows for any signs of abrasive wear or chipping. If any is apparent,
replace the windows. Discard the 'O' rings and replace with new ones of the same material type. Re-assemble the sensor in thereverse order, taking care to cross-tighten the window retaining ring screws evenly to prevent uneven seating. If the sensor
pathlength has been changed, the analyzer module must be configured to reflect the new pathlength. After every re-assembly of an
OUSAF44/EXP-1 sensor, it is necessary to carry out a liquid or Easycal™ calibration with its associated analyzer.

Note!
Upon re-assembly, insure that the lamp assembly is mounted on to the side of the flow cell with the “shorter” length of the two
windows.

47

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

6.9

MaintenanceSensors with Precision Optical Pathlength Adjuster Option

Systems fitted with an Easycal™ calibration system may also be fitted with pathlength “adjusters” to allow trimming of the optical
pathlength to the exact distance required for measurement. The precision pathlength adjuster is not required for systems being calibratedusing liquid standards.

Figure 6.8: OUSAF44/EXP-1 Sensor with Precision Pathlength Adjuster Option

1. Remove the lamp and the detector housings from the sensor body.
2. Remove the 4 socket head screws from each window retaining ring and remove the rings. Be careful to loosen the screws evenly andalternately around the window retaining ring. If the window is ‘stuck’, apply Acetone to the window seal area and let soak forseveral minutes. This may assist in freeing the windows from the seals.
3. Gently push/ease the windows out of the sensor.
4. Inspect the window area and clean as necessary. Inspect the windows for any signs of abrasive wear or chipping. If any is apparent,
replace the windows.
5. Assemble window actuators into window rings, adjusting to their widest position (rotated all the way into the window ring). Insert
the locking set-screws into the sides of the window rings, but do not tighten.
6. Install a new “O” seal and window into one side of the flow cell.
7. Place the Thrust Washer into its seat in the actuator ring and install the complete window ring onto the flowcell, taking care to alignthe screw holes properly.
8. Install and tighten the four socket head screws to secure the window ring to the flow cell.
9. Repeat the above for the other side.
10. Once both windows are installed and the rings secured, clean and insert the pathlength gauge into the cell down through one of the
tube entries until it is between the window faces.
11. Using the Pathlength Adjusting Tool, narrow the pathlength by carefully screwing in the actuator on each side (in small increments)
until the pathlength gauge just touches both windows. Do not over tighten.
12. Carefully withdraw the pathlength gauge and tighten the locking set-screws to hold the actuator in place.
13. If possible, pressure test assembled flow cell at two times (2X) process pressure. Re-check with pathlength gauge and adjust
pathlength as needed. Pressure testing cycles the compression of the window o-rings and actuator upon assembly. This willcompensate for any initial changes in the pathlength.

Note!
Some window faces may not be parallel to each other. This is normal, especially with fire-polished quartz windows. Take care to ensure
pathlength gauge does not scratch window faces.

48Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

MaintenanceWindow Ring
Window Actuator

Install actuator
for full engagement
Seat Thrust Washer
into Actuator.
Tighten 4 ea. M4 x 10
socket head screws andlock washer onto flowcell(both sides).

Install assembly onto
flowcell w/ windows
and process sealing
o-ring in place.

Window
Process Sealing O-Ring

Figure 6.9: Assembling the Precision Pathlength Adjustment Rings into the Sensor

49Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Maintenance

Pathlength Gauge

Pathlength Adjusting Tool

Tighten Locking Set Screw
after pathlength is adjusted.
Insert gauge in place. Adjust each side in small incrementson alternating sides until gauge just touches windows.

Figure 6.10: Adjusting Pathlength in the Flow cell50

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Maintenance

UV Quartz Windows
0.5mm Pathlength

Type I + B

1mm Pathlength

0.5mm Pathlength

0.5mm Pathlength

1mm Pathlength

1mm Pathlength

Type F + F

Type D + C

Type E + B

2mm Pathlength

Type F + N

Type J + C

2mm Pathlength

Type D + DType E + E

5mm Pathlengthfor use w/ POPL

5mm Pathlengthfor use w/ POPL

Type H + H

Type L + L

Type K + K

5mm Pathlength

5mm Pathlength

5mm Pathlength

Type A + B

1cm Pathlength

Type B + C

1cm Pathlength

1cm Pathlength

Type A + A

2cm Pathlength

2cm Pathlength

2cm Pathlength

Type G + G

Window Selection
for 1/2" and 3/4"
TC sensors

Type M + M

Type B + B

Type C + C

Type A + A

3cm Pathlength

3cm Pathlength

Type G + G

Window Type vs. Length
Type A = 14.0mm
Type B = 19.0mm
Type C = 24.0mm
Type D = 23.0mm
Type E = 18.0mm
Type F = 33.5mm
Type G = 09.0mm
Type H = 31.5mm
Type I = 18.5mm
Type J = 23.5mm
Type K = 16.5mm
Type L = 21.5mm
Type M = 29.0mm
Type N = 34.0mm

Window Selection
for 1" and 1-1/2"
TC sensors

Type B + B

4cm Pathlength

Type A + A

5cm Pathlength

Type G + G

Window Selection
for 2"TC sensors

Figure 6.11: Window Type vs. Sensor Pathlength51

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

7.

Replacement Parts List

7.1

Model OUM960 UV analyzer

DESCRIPTION
Fuse, AC Input 3.15A GDA Ceramic
Fuse, DC Input 1A MST
Fuse, Relays/Alarm 125mA MSF

7.2

Replacement Parts

Reference No.
1678-0017-00
1678-1000-00
1678-0125-00

Part Number
63006917
63006930
63006925

Model OUSAF44/EXP-1 UV Inline Sensor

DESCRIPTION
Replacement Mercury Lamp, Phosphor Coated (276, 280nm)
Replacement Mercury Lamp, Uncoated (254, 295, 302, 313, 365nm)

Reference No.
1415-0150-00
1415-0160-00

Part Number
63006614
63006615

Reference Detector (Pre 1999 units)
Measurement Detector Assembly
Easycal Assembly – 280nm Filter – (cable not included)
254nm Interference Filter
276nm Interference Filter
280nm Interference Filter - Reference
280nm Interference Filter – Measurement
280nm Interference Filter Set (1 reference, 1 measurement)
295nm Interference Filter
302nm Interference Filter
313nm Interference Filter
365nm Interference Filter

1405-0030-00
A012-0760-10
ECAL-H-N - - 1410-0254-00
1410-0276-00
1410-0280-10
1410-0280-20
A003-0280-00
1410-0295-00
1410-0302-00
1410-0313-00
1410-0365-00

63006514
63009331
63011357
63006537
63006540
63006542
63006543
63009149
63006545
63006547
63006548
63006553

Type 'A' Quartz Window
Type 'B' Quartz Window
Type 'C' Quartz Window
Type 'D' Quartz Window
Type 'E' Quartz Window
Type 'F' Quartz Window
Type 'G' Quartz Window
Type 'H' Quartz Window
Type 'I' Quartz Window
Type 'J' Quartz Window
Type 'K' Quartz Window
Type 'L' Quartz Window
Type 'M' Quartz Window
Type 'N’ Quartz Window

1420-0140-01
1420-0190-03
1420-0240-03
1420-0230-03
1420-0180-03
1420-0335-01
1420-0090-01
1420-0315-01
1420-0185-03
1420-0235-03
1420-0165-03
1420-0215-03
1420-0290-01
1420-0340-01

63006635
63006649
63006659
63006654
63006644
63006665
63006630
63006663
63006647
63006657
71000344
63006652
63006662
63006667

Window Gasket Kit, Viton (USP Class VI)
Window Gasket Kit, Kalrez
Window Gasket Kit, EPR(EPDM)
Window Gasket Kit, PTFE Encapsulated Viton

A000-0660-01
A000-0660-04
A000-0660-05
A000-0662-16

63009112
63009113
63009114
63009121

Certified POPL Retrofit Kit for 0.5nm Pathlength
Certified POPL Retrofit Kit for 1nm Pathlength
Certified POPL Retrofit Kit for 2nm Pathlength
Certified POPL Retrofit Kit for 5nm PathlengthA004-4420-00
A004-4420-01
A004-4420-02
A004-4420-05

71000047
63011917
63009163
6300916452

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

8.

Technical Information

8.1

UV Analyzer OUM960

8.1.1

Input
Measured Variable
Range
Digital Input
Keyboard

8.1.2

8.1.3

Technical Information

Dual Channel Current from Model OUSAF44/EXP-1 Inline Sensor
Up to 5 AU/50 OD dependent upon sensor pathlength and sensor type
4 Channels, dry contact
6 push buttons keyboard

OutputCurrent Output

2 channel, 4~20mA NUMAR compatible

Resolution

12bit

Isolation

O1 to PE

500 VDCO2 to PE

500 VDCO1 to O2

500 VDC

Signal on Lamp Alarm

3.6mA or 21.5mA in case of error

Actual Current
Output Range
Load

3.8mA to 20.5mA

Front Panel Display

4x20 Character LC display

Alarm LED

On front Panel, Red LED

General Relay Output

2 Channel, Solid State Relays 250VAC 125mA max.

Relay Operation

Above/Below trigger configurable; NO/NC configurable

Relay Delay

0~60 sec configurable

Lamp Alarm Relay

1 Channel, NC

Lamp Power Supply

12V DC, 1.5A Max.

750 ohm Max.

Power Supply
Supply Voltage
Power Consumption
Mains Fuse

85~265 VAC, 24VDC as option
12 VA Max.
3.15 A

53

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

8.1.4

8.1.5

8.1.6

Performance
Sensor Photo Current Input

1mA to 100pA

Linearity

0.3% Max.

Repeatability

0.3% Max.

Accuracy

0.3% Max.

Initial Drifting<0.5% for first 24 hours

Environment
Temperature(Performance)
Temperature(Operation)
Relative Humidity

0~55°C

Degree of Protection

IP 65 (front panel), IP 30 (housing)

0~70 55°C
95%

Mechanical Construction
Dimensions

L x W x D: 102 x 102 x 177 mm

Weight1.213 kg

Material

Aluminum (polyester coating on front panel)

Degree of Protection

IP 65 (front panel), IP 30 (housing)

8.2

UV Absorbance Sensor OUSAF44/EXP-1

8.2.1

Input and Output

8.2.2

Technical Information

Measured Input Variable

Process UV absorption and optical density

Output Signal

Photo detector current (100pA~ 1uA)

Mechanic Construction
Weight1.225 kg (flow cell not included)

Housing Material

Stainless steel 316L

54

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Technical Information

Figure 8.1: Model OUSAF44/EXP-1 Std. Inline Sensor Dimensions

Connection
Size
1/4" - 3/4"
1" - 1 1/2"
2"

A

B

C

D

E

11.85”(301.0mm)
12.24”(310.9mm)
12.96”(329.2mm)

3.75”(95.3mm)3.94”(100.0mm)
4.31”(109.5mm)

8.10”(205.8 mm)
8.30”(210.8mm)
8.65”(219.7mm)

3.25”(82.5 mm)3.25”
(82.5 mm)3.25”
(82.5 mm)

1.63”
(41.5 mm)
1.63”
(41.5 mm)
1.63”
(41.5 mm)Figure 8.2: Model OUSAF44/EXP-1 NIST Inline Sensor Dimensions

Connection
Size
1/4" - 3/4"
1" - 1 1/2"
2"

A

B

C

D

E

11.85”(301.0mm)
12.24”(310.9mm)
12.96”(329.2mm)

3.75”(95.3mm)3.94”(100.0mm)
4.31”(109.5mm)

8.10”(205.8 mm)
8.30”(210.8mm)
8.65”(219.7mm)

3.25”(82.5 mm)3.25”
(82.5 mm)3.25”
(82.5 mm)

1.63”
(41.5 mm)
1.63”
(41.5 mm)
1.63”
(41.5 mm)55

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

8.2.3

8.2.4

8.2.5

Technical Information

Environment
Temperature

0~55°C

Temperature(Process)
Relative Humidity

0~90 °C Continuous
up to130°C for 2 hours
95%

Degree of Protection

IP 65

Maximum Pressure in Flow
Cell

33 Bar/500 psi.
100 Bar option available

Power Supply
Supply Voltage

12 VDCPower Consumption

4 VA continuous
8 VA start up in-rushOptical Specifications

Wavelengths Available
Filters
Detectors
Lamp

Line
Pathlengths Available
Size
254, 276, 280, 295, 302, 313, 326 and 365nm
Interference filters, 10 nm BW, stray light .01% maximum.
UV enhanced Silicon detectors, hermetically sealed.
Pre-Focused Low pressure Mercury lamp, (2000 hour half life, 3000 hour typical)

56

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

9.

Ordering Information

9.1

UV Analyzer OUM960

Ordering Information

57

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

9.2

Ordering Information

UV Absorbance Sensor OUSAF44

58

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

9.3

Ordering Information

Model OUA260 Flow Cell

59

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

9.4

Ordering Information

Model OUK40 UV Sensor Cable Set

60

Model OUM960 with OUSAF 44/EXP-1 Inline Sensor

Warranty

WARRANTY
Endress+Hauser Conducta Inc., warrants its products to be free from defects in workmanship and material. Endress+Hauser Conducta
Inc liability is limited to replacing the instrument or any part thereof that is returned by the original purchaser, transportation paid, to thefactory within one (1) year after the date of shipment, provided that Endress+Hauser examination shall disclose that a defect existed
under proper and normal use.
Endress+Hauser Conducta Inc. shall not be liable for consequential or incidental damages.

61www.endress.com/worldwide