-EASURE

WHAT IS MEASURABLE
AND MAKE MEASURABLE
THAT WHICH IS NOT
'ALILEO 'ALILEI  

Smart Sensor
Carbo 510
Service Manual
Service Manual

Carbo 510
Smart Sensor
Anton Paar GmbH assumes no liability for technical or printing errors or omissions in this document.

Nor is any liability assumed for damages resulting from information contained in the document.

Anton Paar GmbH reserves the right to content changes. This also extends to changes to delivery
volumes or any features of delivered parts.

All rights reserved (including translation). This document, or any part of it, may not be reproduced,
changed, copied, or distributed by means of electronic systems in any form (print, photocopy, microfilm
or any other process) without prior written permission by Anton Paar GmbH.

Trademarks, registered trademarks, trade names, etc. may be used in this manual without being marked
as such. They are the property of their respective owner.

Published by Anton Paar

Printed: Anton Paar, Austria
Copyright © 2011 Anton Paar GmbH, Graz, Austria

Address: Anton Paar GmbH

Anton-Paar-Str. 20
A-8054 Graz / Austria – Europe
Tel: +43 316 257-0
Fax: +43 316 257-257

E-Mail: info@anton-paar.com
Web: www.anton-paar.com

Date: 13.04.2012

Document number C98IB002EN-B

Contents

1 About the Service Manual ............................................................................................................... 7

2 Safety Instructions........................................................................................................................... 8
2.1 Warning Signs on the Instrument ............................................................................................ 9
3 Carbo 510 Smart Sensor - System Description .......................................................................... 10
3.1 Terminals of the Carbo 510 Smart Sensor..............................................................................11
4 Service and Maintenance of the Carbo 510................................................................................. 12
4.1 Service Parts ......................................................................................................................... 12
4.2 Required Tools and Equipment.............................................................................................. 13
4.3 Service Settings and Parameters .......................................................................................... 13
4.4 Interfaces ............................................................................................................................... 15
5 Disconnecting the Carbo 510 ....................................................................................................... 16
5.1 Disconnecting the Carbo 510 electrically............................................................................... 16
5.1.1 Disconnecting the Compressed Air Supply ............................................................ 17
5.2 Disconnecting the Carbo 510 mechanically........................................................................... 18
5.2.1 Disconnecting the Carbo 510 with Cut-off Valve Adapter....................................... 18
5.2.2 Disconnecting the Carbo 510 without Cut-off Valve Adapter.................................. 19
6 Carbo 510 Smart Sensor - Check and Change............................................................................ 21
6.1 Diaphragms ........................................................................................................................... 21
6.1.1 Replace the Diaphragm for Decompression .......................................................... 21
6.1.2 Replace the Inlet / Outlet Diaphragms ................................................................... 23
6.2 Solenoid Valves ..................................................................................................................... 25
6.2.1 Parts Description .................................................................................................... 26
6.2.2 Check the solenoid valves...................................................................................... 26
6.2.3 Replace the solenoid valves................................................................................... 27
6.3 Impeller .................................................................................................................................. 28
6.3.1 Check during Operation ......................................................................................... 28
6.3.2 Replace the impeller............................................................................................... 28
6.3.3 Parts description..................................................................................................... 29
6.4 Impeller Drive......................................................................................................................... 30
6.4.1 Check the impeller drive......................................................................................... 30
6.4.2 Replace the Impeller Drive ..................................................................................... 30
6.4.3 Parts Description .................................................................................................... 31
6.5 Temperature Sensor .............................................................................................................. 33
6.5.1 Check the Temperature Sensor.............................................................................. 33
6.5.2 Check the Temperature Sensor during Production ................................................ 33
6.5.3 Replace the Temperature Sensor........................................................................... 34
6.5.4 Parts Description .................................................................................................... 34
6.5.5 Check the Temperature Sensor when it is not mounted......................................... 35
6.6 Pressure Sensor .................................................................................................................... 36

C98IB002EN-B 5
 6.6.1 Check the Pressure Sensor ................................................................................... 36
6.6.2 Replace the Pressure Sensor ................................................................................ 37
6.6.3 Parts Description .................................................................................................... 37
6.7 Printed Circuit Boards............................................................................................................ 39
6.7.1 Parts Descriptiton Carbo 510 Smart Sensor .......................................................... 40
6.7.2 Parts Description Carbo 510 Smart Sensor with Operating Terminal .................... 40
6.7.3 Change the printed circuit boards .......................................................................... 41
6.8 Service Menu......................................................................................................................... 42
7 Integrated Self-Diagnosis.............................................................................................................. 43
Appendix A: Menu Tree................................................................................................................... 44
Appendix B: Document Numbers .................................................................................................. 47

6 C98IB002EN-B
 1 About the Service Manual

1 About the Service Manual

This service manual informs you about repair work and maintenance procedures
on the instrument. Make sure that the service manual is easily accessible to all
personnel involved with servicing the instrument. Pay special attention to the
safety instructions and warnings in the manual and on the instrument.

Conventions for safety messages

The following conventions for safety messages are used in this instruction
manual:

WARNING
Warning indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Caution indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

Hot surface
This symbol calls attention to the fact that the respective surface can get
very hot. Do not touch this surface without adequate protective measures.

NOTICE Notice indicates a situation which, if not avoided, could result in damage to
property.

TIP Tip gives extra information about the situation at hand.

Typographical conventions

The following typographical conventions are used in this instruction manual:

Convention Description
<key> The names of keys and buttons are
written inside angle brackets.
"Menu Level 1 > Menu Level 2" Menu paths are written in bold, inside
straight quotation marks. The menu
levels are connected using a closing
angle bracket.

C98IB002EN-B 7
2 Safety Instructions

2 Safety Instructions
• This service manual does not claim to address all of the safety issues
associated with the service and operation of the Carbo 510 and samples. It
is the service technician’s responsibility to ensure all health and safety
regulations are met for the persons concerned prior to starting service and
maintenance work.

• Before servicing the Carbo 510, read this manual completely.

• Anton Paar GmbH only warrants the proper functioning of the Carbo 510 if
no unauthorized adjustments have been made to mechanical parts,
electronic parts and software, and the following points are adhered to.

• Follow all hints, warnings and instructions in the manual to ensure the
correct and safe functioning of the Carbo 510.

• Do not handle the Carbo 510 other than described in the manual. Anton Paar
GmbH is not liable for damages caused by incorrect handling of the Carbo
510.

• Do not use any accessories other than those supplied or approved by Anton
Paar GmbH.

• The installation procedure should only be carried out by authorized

personnel who are familiar with the installation instructions.

• Do not operate the Carbo 510 if a malfunction is suspected, or damages,

injuries or loss of life cannot be excluded under all circumstances.

• The Carbo 510 is not an explosion-proof instrument and therefore must not
be operated in areas where there is a risk of explosion.

• Use only original spare parts and parts explicitly indicated as parts for repair.
Service or repair work must only be carried out by qualified personnel,
authorized service centers, professional workshops or by Anton Paar GmbH.

• Use only recommended and appropriate tools.

• Service and/or maintenance procedures which involve removing outside

covers and working with the power switched on may only be performed by
authorized service personnel.

• Ensure that all operators are fully trained to use the Carbo 510 correctly and
safely.

• Due to the nature of the measurement, the measuring results not only
depend on the correct use and functioning of the Carbo 510, but may also be
influenced by other factors. We therefore advise that the analysis results are
plausibility tested before consequential actions are taken.

8 C98IB002EN-B
 2 Safety Instructions

• Repair and service procedures may only be carried out by authorized

personnel or by Anton Paar GmbH.

• If the safety appliances of the Carbo 510 are opened, changed or interrupted
during the service, a safety check must be performed after the repair.

• Dispose of the Carbo 510 according to the country-specific legal

requirements.

• Never install the Carbo 510 and the evaluation unit in areas where strong
electromagnetic fields are present.

• Before carrying out any service procedures, the Carbo 510 must be
disconnected from the mains, product line, compressed air and from the
evaluation unit.

• The Carbo 510 contains electrostatically sensitive devices. When handling

modules/components of the instrument they must be protected from
electrostatic discharge. Use a grounded wristband when handling these
components. If you return modules for repair, use appropriate packaging
which protects these modules from electrostatic discharge.

• For repairs send the cleaned transducer unit to your Anton Paar
representative. Only return the instrument together with the filled out
"Maintenance/Error Report" and the "Standard Maintenance Contract". Find
the applicable forms on the Anton Paar hompage (www.anton-paar.com).

2.1 Warning Signs on the Instrument

Warning
Risk of injury! Before working on areas which are marked with this symbol,
first read the instruction manual.

C98IB002EN-B 9
3 Carbo 510 Smart Sensor - System Description

3 Carbo 510 Smart Sensor - System

Description

10 C98IB002EN-B
 3 Carbo 510 Smart Sensor - System Description

3.1 Terminals of the Carbo 510 Smart Sensor

Fig. 3 - 1 Terminals

DC 24 V Power supply connection

CAN Anton Paar CANopen for communication between
Smart Sensor and mPDS 5 or Remote Opterating
Terminal
CAN address Must be set if several Smart Sensors are connected to
one mPDS 5
Impeller Un/FG/+/- Connection for the impeller
Temp Connection for the temperature sensor
Pressure A/B/+/- Connection for the pressure sensor
ETH/PB/DN Connection for fieldbus
DI Digital input for start/stop or freezing of the measuring
value
DO Digital output for error status or limit value monitoring
DO+ / DIO GND Power supply for digital output
AO +/- Analog output
Display Connection for Operating Terminal

C98IB002EN-B 11
4 Service and Maintenance of the Carbo 510

4 Service and Maintenance

of the Carbo 510
To ensure reliable and trouble-free operation, the Carbo 510 must be checked,
serviced and cleaned periodically.

Process sensors like the Carbo 510 are often exposed to extreme working
conditions such as pressure shock, sudden changes in temperature, aggressive
samples, etc. which may cause drifts or failure. Therefore, it is essential to
periodically check the measured results to reference values and re-adjust the
measuring system if required.

The maintenance intervals of the Carbo 510 depend on the operating conditions.
The following is recommended as a general maintenance procedure.

Daily check:

• the error messages on the display of the mPDS 5, the Remote Operating
Terminal or the Operating Terminal

• the displayed temperature of the product

• the displayed line pressure

• the displayed CO2 concentration

4.1 Service Parts

These are the most important service parts that should be at hand on-site.

Part Mat. No. Replacement pcs

Interval
Diaphragm EPDM for decompression 89076 yearly 1
Diaphragm EPDM for inlet/outlet 89078 yearly 2
O-ring 25x2 EPDM (impeller drive) 74012 yearly 1
O-ring 25x2 EPDM (pressure and temperature sensor) 74012 yearly 1
O-ring 60x3 EPDM 70 (measuring chamber) 74911 yearly 1
O-ring 4.5x1 NBR 70 (compressed air junction) 95695 yearly 4
O-ring 10x2 EPDM 70 17521 yearly 2
(in combination with the cut-off valve adapter)
Pressure Sensor / Temperature Sensor 97031 - 1
Impeller 89035 - 1
Drive for impeller 89073 - 1

12 C98IB002EN-B
 4 Service and Maintenance of the Carbo 510

Cleaning the Smart Sensor:

WARNING
Stop the Carbo 510 by using "Product 0 Out of Operation"

Clean the Carbo 510 with warm water.

4.2 Required Tools and Equipment

Flat wrench with wrench size 10 mm:
Flat wrench with wrench size 20 mm:
Torx screwdriver
Small slotted screwdriver:
Universal pliers:
DC 24 V power supply:
for the hexagon nut at the hinged
clamps
to open the cable glands at the
electronic housing
for the spring-tpye terminals
to replace the diaphragm for
decompression
for testing the Smart Sensor

4.3 Service Settings and Parameters

The service password for the Operating Terminal is 1922. To log on as a service
user at the mPDS 5 refer to the Carbo 510 and the mPDS 5 instruction manuals.

TIP If you are logged on as a service user you can read or write the diagnosis values
and settings. For more information refer to the Carbo 510 and the mPDS 5
instruction manuals.

Next maintenance

The Carbo 510 calculates the time to the next service itself. If this time is
exceeded, the warning message "Maintenance Request" appears in the status
area of the evaluation unit mPDS 5 or Operating Terminal.

TIP If a warning message appears on the display, the relay contact of the DO opens.
The digital output of the Operating Terminal can be used for error monitoring. This
means whenever an error occurs, the digital output switches. It has to be
configurated to the error (default setting) or warning status.

C98IB002EN-B 13
4 Service and Maintenance of the Carbo 510

At delivery the parameter "Next maintenance" is set to 2,000,000 measuring

cycles. This complies with a period of one year continuous operation. One
measuring cycle takes 15 seconds (7 seconds cycle time plus 8 seconds
measuring time). After every service a new value for the parameter "Next
maintenance" has to be set.

Follow the menu tree down to "Diagnose settings" and enter the new value.
The new value is the measuring cycles shown on the display plus 2,000,000.

If the new value for "Next maintenance" is set, the Carbo 510 has to be
restarted. After the restart the Carbo 510 calculates the days to the next service.
The days are shown in the menu item "Diagnose values".

14 C98IB002EN-B
 4 Service and Maintenance of the Carbo 510

4.4 Interfaces

Product matrix

Carbo 510 Smart Sensor

Material number
89080 (Carbo 510 Smart Sensor)
79233 (mPDS 5)

Carbo 510 Smart Sensor with

Operating Terminal

Material number
95256 (Carbo 510 Smart Sensor with
Operating Terminal)

Carbo 510 Smart Sensor with Remote

Operating Terminal

Material numbers
89080 (Carbo 510 Smart Sensor)
94636 (Remote Operating Terminal)

Carbo 510 Smart Sensor with

Remote Operating Terminal
for panel installation

Material numbers
89080 (Carbo 510 Smart Sensor)
94636 (Remote Operating Terminal)
95150 (Option Panel Installation)

C98IB002EN-B 15
5 Disconnecting the Carbo 510

5 Disconnecting the Carbo 510

WARNING

• Inform the responsible person on site that you will stop the Anton Paar
Smart Sensor.

• Stop the Smart Sensor by selecting "Product 0 Out of Operation" at the

mPDS 5 or the Operating Terminal.

• Turn off the DC 24 V power supply.

5.1 Disconnecting the Carbo 510 electrically

NOTICE Before disconnecting the connection cables, the power supply of the evaluation
unit and of the Carbo 510 must be turned off. Please write down the pinning.

1. Open the 4 Torx screws M5x12 to remove the cover of the electronic
housing.

2. Disconnect the cables for power supply, CAN bus (at the Carbo 510 with
mPDS 5 or the Remote Operating Terminal) and of the fieldbus (if there is a
fieldbus system).

3. Open the cable glands and pull out the cables.

4. Check the gasket of the cable glands. If a gasket is worn out, change the
cable gland (Mat. No. 90711).

5. Mount the cover with the 4 torx screws M15x12 again to avoid pollution
inside the electronic housing.

16 C98IB002EN-B
 5 Disconnecting the Carbo 510

Fig. 5 - 1 Front View of the Carbo 510 Smart Sensor

5.1.1 Disconnecting the Compressed Air Supply

Close the ball valve at the compressed air hose and disconnect the hose at the
compressed air connection "IN" of the Carbo 510.

Fig. 5 - 2 Compressed Air Supply

C98IB002EN-B 17
5 Disconnecting the Carbo 510

5.2 Disconnecting the Carbo 510 mechanically

WARNING

• Inform the responsible person on site that you will stop the Anton Paar
Smart Sensor.

Hot surface

• Do not disconnect the Smart Senor if the main line is hot.

• Do not disconnect the Smart Sensor directly after CIP-cleaning as it may

be hot.

TIP The sample connection and parts of the measuring chamber assume the sample
temperature at their surface. The respective surface can get very hot (over 70 °C
with CIP). Do not touch this surface without adequate protective measures.

5.2.1 Disconnecting the Carbo 510 with Cut-off Valve

Adapter

1. Close the locking screws at the Cut-off Valve Adapter.

2. Hold the Carbo 510 with one hand and open the hexagon nut at the hinged
clamp.

3. Remove the hinged clamp.

4. Pull the Carbo 510 out of the Cut-off Valve Adapter.

5. Check the O-rings 10x2 EPDM (Mat. No. 17521) between the Cut-off Valve
Adapter and the Carbo 510 and replace them if they are worn out.

18 C98IB002EN-B
 5 Disconnecting the Carbo 510

Fig. 5 - 3 Carbo 510 with Cut-off valve adapter

5.2.2 Disconnecting the Carbo 510 without Cut-off Valve

Adapter

WARNING

• Do not disconnect the Carbo 510 if the main line is under pressure.

• Before opening the main line the product must be drained off.

C98IB002EN-B 19
5 Disconnecting the Carbo 510

1. Hold the Carbo 510 with one hand and open the hexagon nut at the hinged
clamp.

2. Remove the hinged clamp.

3. Pull the Carbo 510 out of the main line.

Fig. 5 - 4 Carbo 510 without Cut-off valve adapter

20 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6 Carbo 510 Smart Sensor - Check and

Change

6.1 Diaphragms

As the diaphragms move up and down every 15 seconds they are mechanically
stressed. Due to this, they get worn out and should be replaced regularly, on
average once a year. Always replace all three diaphragms at the same time. If the
inlet / outlet diaphragms do not close the measuring chamber correctly or the
decompression diaphragm does not work, the error message "Valve error"
appears in the status area of the mPDS 5 or the Operating Terminal.

CAUTION
CIP temperature > 80 °C (176 °F) can shorten the lifetime of the diaphragms.
Therefore we recommend periodical visual check of the diaphragms.

WARNING

• Stop the Smart Sensor by selecting "Product 0 Out of Operation" at the

mPDS 5 or of the Operating Terminal.

• Disconnect the compressed air supply.

• The Carbo 510 measuring chamber has to be empty and pressureless

before the diaphragms can be replaced.

6.1.1 Replace the Diaphragm for Decompression

Parts Description

C98IB002EN-B 21
6 Carbo 510 Smart Sensor - Check and Change

Fig. 6 - 1 Diaphragm for Decompression

1. Loosen the cable glands of the impeller drive and the temperature/pressure
sensor. Pull both cables out of the housing so that you can put it down safely.

2. Open the hexagon nut at the hinged clamp.

3. Remove the hinged clamp.

4. Pull down the electronic housing carefully. Hold it with one hand.

5. Remove the diaphragm for decompression (Mat. No. 89076) by unscrewing

the diaphragm counterclockwise. If it is too tight, use pliers for removal.

6. Check the two O-rings 4.5x1 NBR between the measuring chamber and the
electronic housing.

7. Replace the O-rings 4.5x1 NBR (Mat. No. 95695) if they are worn out.

Fig. 6 - 2 O-rings between measuring chamber and electronic housing

22 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

8. When reassembling the system make sure to tighten the diaphragm and the
screws.

C98IB002EN-B 23
6 Carbo 510 Smart Sensor - Check and Change

6.1.2 Replace the Inlet / Outlet Diaphragms

TIP The inlet and outlet valves and diaphragms are identical.

Parts Description

Fig. 6 - 3 Inlet / Outlet Diaphragms

1. Open the eight screws M5x35 at the Inlet and Outlet Valve and remove all
valves from the measuring chamber of the Carbo 510.

Fig. 6 - 4 Remove Inlet/Outlet Valve

2. Remove the cover with a small slotted screwdriver.

3. Check the O-ring 32x2.5 EPDM in the groove of the cover.

4. Replace the O-ring 32x2.5 EPDM (Mat. No. 47645) if it is worn out.

24 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

5. Press the piston with your fingers into the actuator and hold the position
while you unscrew the old diaphragm counterclockwise.

Fig. 6 - 5 Piston: Front View and Cross Section

6. The piston falls out of the actuator.

7. Check the seal on the piston.

8. Replace the piston seal (Mat. No. 89154) if it is worn out.

Piston seal

Fig. 6 - 6 Piston Seal

9. Check the O-rings 4.5x1 NBR (Mat. No. 95695) between the measuring
chamber and the actuator.

10. Replace the O-rings 4.5x1 NBR (Mat. No. 95695) if they are worn out.

11. When reassembling the system make sure you tighten the diaphragms and
the screws.

C98IB002EN-B 25
6 Carbo 510 Smart Sensor - Check and Change

6.2 Solenoid Valves

The inlet/outlet valves and the decompression valve are controlled by 2 solenoid
valves. If the inlet/outlet and decompression valve do not work correctly, the error
messsage "Valve error" appears in the status area of the evaluation unit
mPDS 5 or Operating Terminal. The solenoid valves are connected with the
sensor board.

WARNING

• In case of malfunction the electronic housing might be under pressure

and/or filled with the product. Wear protective goggles and clothing!

Fig. 6 - 7 Solenoid Valves Carbo 510

TIP The inlet/outlet solenoid valve moves the inlet and outlet valve. The
decompression solenoid valve moves the decompression valve. The
decompression solenoid valve is marked with the label "EXP".

26 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6.2.1 Parts Description

Fig. 6 - 8 Electronic Boards and Solenoid Valves of the Carbo 510

6.2.2 Check the solenoid valves

1. Open the 4 M5x12 screws and remove the cover

2. Open the 3 M3x8 screws and remove the cover plate.

3. Open the 3 M3x25 screws and take out both electronic boards.

4. For the manual valve check, press the blue button at the front of the valve in
the direction of arrow. It is easier to use a small slotted screwdriver.

Fig. 6 - 9 Manual valve check

5. If the solenoid valves are ok, refit the parts in reverse order.

C98IB002EN-B 27
6 Carbo 510 Smart Sensor - Check and Change

6.2.3 Replace the solenoid valves

WARNING

• Stop the Smart Sensor by selecting "Product 0 Out of Operation" at the

mPDS 5 or the Operating Terminal

1. Disconnect the compressed air supply and exhaust the system.

2. Disconnect the Carbo 510 electrically and mechanically from the main line
(see Chapter 5.1 - Disconnecting the Carbo 510 electrically and Chapter 5.2
- Disconnecting the Carbo 510 mechanically).

3. Open the 3 M3x8 screws and remove the cover plate.

4. Open the 3 M3x25 screws and take out both electronic boards.

5. Open the 4 screws at the old solenoid valves.

6. Disconnect the solenoid valves from the electronic board.

Fig. 6 - 10 Solenoid Valves

7. Check the seals of the new solenoid valves.

Fig. 6 - 11 Seals of the Solenoid Valves

28 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

8. Mount the new solenoid valves and refit the parts in reverse order.

6.3 Impeller

The impeller is mounted in the measuring chamber below the impeller drive. The
impeller accelerates until it reaches the equilibrium pressure for the CO2
measurement.

Notice The impeller of the Carbo 510 is save to run dry. If the plant is stopped for a longer
time, the Carbo 510 should be switched off by "Select product 0" in order to
prevent it from wear and tear.

6.3.1 Check during Operation

The impeller is turned off in the "Product 0 out of Operation" mode and turned
on when a product is chosen.

If the impeller fails, the mPDS 5 or the Operating Terminal shows the message
"impeller error". This message is shown in the status area of the mPDS 5 or the
Operating Terminal.

If you are not sure that the impeller is running or not, disconnect the cable
"Impeller +" of the impeller drive and check the change of the CO2 value. The
error message "Degassing error (Impeller devective)" appears in the status
area. When the impeller is disconnected, the CO2 value must be 30% - 50% of
the standard value. If there is only minor change, the impeller is defective.

6.3.2 Replace the impeller

WARNING

• Stop the Carbo 510 by selecting "Product 0 Out of Operation" at the

mPDS 5 or the Operating Terminal.

• Before replacing the impeller, the measuring chamber of the Carbo 510
must be empty and pressureless.

C98IB002EN-B 29
6 Carbo 510 Smart Sensor - Check and Change

6.3.3 Parts description

Fig. 6 - 12 Impeller and Impeller Drive

Notice The impeller drive and the impeller are magnetically coupled. Be careful when
changing the impeller. The bearing is made of ceramic.

1. Open the three screws M5x8 and pull the impeller drive.

2. Remove the old impeller from the impeller drive.

3. Check the O-ring 25x2 EPDM (Mat. No. 74012) on the impeller drive.

4. Replace the O-ring 25x2 EPDM (Mat. No. 74012) if it is worn out.

5. Mount the new impeller (Mat. No. 89035) carefully on the impeller drive.

6. Refit the parts.

30 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6.4 Impeller Drive

The impeller drive uses a BLDC motor to drive the impeller. Impeller and impeller
drive are magnetically coupled. The impeller drive is connected with the
connector board inside the electronic housing.

6.4.1 Check the impeller drive

Follow the menu tree on the mPDS 5 or the Operating Terminal down to
"Diagnose values". Check the current consumption of the impeller drive. The
current consumption must be 100 mA to 2 A. Typically the current consumption
under normal conditions is 400 mA to 1 A (depending on the viscosity and
temperature of the product).

TIP If the temperature in the measuring chamber is higher than 100 °C, the impeller
drive will be switched off automatically. If the temperature goes back below 90 °C,
the impeller drive will be switched on again.

6.4.2 Replace the Impeller Drive

WARNING

• Stop the Carbo 510 by selecting "Product 0 Out of Operation" at the

mPDS 5 or the Operating Terminal.

• The measuring chamber of the Carbo 510 must be empty and

pressureless before the impeller drive can be replaced.

C98IB002EN-B 31
6 Carbo 510 Smart Sensor - Check and Change

6.4.3 Parts Description

Fig. 6 - 13 Impeller and Impeller Drive

1. Open the 4 screws M5x12 to remove the cover of the electronic housing.

Fig. 6 - 14 Front View of the Carbo 510

2. Disconnect the impeller drive from the connector board.

TIP Refer to the labelling of the cover plate to disconnect the cables.

3. Open the cable gland and pull out the cable of the impeller drive.

32 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

4. Check the gasket of the cable gland. If the gasket is worn out, change the
cable gland (Mat. No. 90711).

5. Open the three screws M5x8 and pull out the impeller drive.

6. Remove the impeller from the old impeller drive.

7. Mount the impeller on the new impeller drive (Mat.No. 89073).

8. Refit the parts in reverse order.

9. Use a flat wrench to tighten the cable gland correctly.

C98IB002EN-B 33
6 Carbo 510 Smart Sensor - Check and Change

6.5 Temperature Sensor

The temperature sensor measures the temperature of the sample in the

measuring chamber. It is located in the pressure and temperature sensor of the
Carbo 510. The temperature is measured with an NTC temperature sensor. The
resistance of the sensor is converted to a temperature value.

Fig. 6 - 15 Pressure/Temperature sensor Carbo 510

6.5.1 Check the Temperature Sensor

If the temperature sensor is devective, the error message "Temp. sensor

failure" appears in the status area of the evaluation units mPDS 5 or the
Operating Terminal.

If the temperature sensor is defective, the Carbo 510 stops.

6.5.2 Check the Temperature Sensor during Production

1. Make sure that the product is running through the production line.

2. Check the line temperature in the production line on a temperature gauge

and note down the reading.

3. Check the reading with the temperature on the Carbo 510. The temperature
of both readings should be more or less the same.

34 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6.5.3 Replace the Temperature Sensor

WARNING

• Stop the Carbo 510 by selecting "Product 0 Out of Operation" at the

mPDS 5 or the Operating Terminal.

• The measuring chamber of the Carbo 510 must be empty and

pressureless before the temperature sensor can be replaced.

6.5.4 Parts Description

Fig. 6 - 16 Temperature/Pressure sensor

1. Open the 4 screws M5x12 to remove the cover of the electronic housing.

Fig. 6 - 17 Front View of the Carbo 510

C98IB002EN-B 35
6 Carbo 510 Smart Sensor - Check and Change

2. Disconnect the pressure/temperture sensor from the connector board.

TIP Refer to the labelling of the cover plate to disconnect the cables.

3. Open the cable gland and pull out the cable of the pressure/temperature
sensor.

4. Check the gasket of the cable gland. Change the cable gland (Mat. No.
90711) if the gasket is worn out.

5. Open the screws M5x12 and pull out the pressure/temperature sensor.

6. Check the O-ring 25x2 EPDM (Mat. No. 74012) and replace it if it is worn
out.

7. Mount the new pressure/temperature sensor (Mat. No. 97031)

8. Refit the parts in reverse order.

9. Use a flat wrench to tighten the cable gland correctly.

6.5.5 Check the Temperature Sensor when it is not mounted

Temperature [°C] Resistance [k

0 29.49
2 26.89
4 24.55
6 22.43
8 20.52
10 18.79
12 17.22
14 15.79
16 14.50
18 13.33
20 12.27
22 11.29
24 10.41
25 10.00
26 9.61
28 8.87
30 8.19
32 7.58

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 6 Carbo 510 Smart Sensor - Check and Change

6.6 Pressure Sensor

The pressure sensor measures the absolute pressure in the measuring chamber.
It is located in the pressure and temperature sensor Carbo 510.

Fig. 6 - 18 Pressure/Temperature Sensor Carbo 510

During normal operation the pressure sensor is checked by the software. If the
pressure sensor is defective, the error message "Pressure sensor failure"
appears in the status area of the evaluation unit mPDS 5 or Operating Terminal.

Due to different process conditions a misunderstanding of the error message is

possible. Berfore replacing the pressure sensor you have to make sure that the
message comes from the sensor and not from the process conditions.

TIP If the liquid temperature is higher than 90 °C, the sensor will be switched off
automatically. If the temperature is below 90 °C, the sensor will be switched on
automatically.

6.6.1 Check the Pressure Sensor

1. Make sure that the product in the production line is carbonated.

2. Check the line pressure in the production line on a pressure gauge and write
down the value.

3. Check P-line and P-gas value. The P-Line value should be similar
(+/- 0.5 bar) to the reference value. P-gas is always lower than P-line.

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6 Carbo 510 Smart Sensor - Check and Change

Failure possibility for the pressure sensor:

It is possible that the P-line value is higher as the value of the pressure gauge.
This would mean that the pressure sensor got a pressure shock and the
membrane is damaged.

Change the pressure sensor or set a pressure offset. Follow the menu tree to
"Diagnosis settings" for the offset.

6.6.2 Replace the Pressure Sensor

WARNING

• Stop the Carbo 510 by selecting "Product 0 Out of Operation" on the

mPDS 5 or the Operating Terminal.

• Before replacing the the pressure sensor, the measuring chamber of the
Carbo 510 must be empty and pressureless.

6.6.3 Parts Description

Fig. 6 - 19 Temperature/Pressure Sensor

1. Open the 4 screws M5x12 to remove the cover of the electronic housing.

38 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

Fig. 6 - 20 Disconnect the temperature/pressure sensor cable

2. Disconnect the pressure/temperature sensor from the connector board

TIP Refer to the labelling of the cover plate to disconnect the cables.

3. Open the cable gland and pull out the cable of the pressure/temperature
sensor.

4. Check the gasket of the cable gland. Change the cable gland (Mat. No.
90711) if the gasket is worn out.

5. Open the screws M5x12 and pull out the pressure/temperature sensor.

6. Check the O-ring 25x2 EPDM (Mat. No. 74012) and replace it if it is worn
out.

7. Mount the new pressure/temperature sensor (Mat. No. 97031)

8. Refit the parts in reverse order.

9. Use a flat wrench to tighten the cable gland correctly.

C98IB002EN-B 39
6 Carbo 510 Smart Sensor - Check and Change

6.7 Printed Circuit Boards

The Carbo 510 Smart Sensor has two printed circuit boards:

• Sensor board: the solenoid valves are connected to the sensor board.

• Connector board: the power supply, CAN bus, pressure/temperature

sensor, impeller drive and interface modules are connected to the connector
board.

WARNING

• Stop the Carbo 510 by selecting "Product 0 Out of Operation" on the

mPDS 5 or the Operating Terminal.

• Turn off the power supply of the Carbo 510.

1. Close the Cut-off Valve Adapter (if you service a Carbo 510 with a Cut-off
Valve Adapter).

2. Make sure that the product line is empty (and not under pressure: see
Chapter 5 - Disconnecting the Carbo 510) if you service a Carbo 510 without
a Cut-off Valve Adapter.

3. Disconnect the compressed air supply.

4. Disconnect the cables for power supply and CAN bus if it is necessary.

5. Unscrew the nut of the hinged clamp by using a flat wrench 10 mm.

6. Take off the Carbo 510 from the product line and close the line with a
blanking plate Tuchenhagen Varivent.

40 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6.7.1 Parts Descriptiton Carbo 510 Smart Sensor

Fig. 6 - 21 Parts Description of a Carbo 510 without Operating Terminal

6.7.2 Parts Description Carbo 510 Smart Sensor with

Operating Terminal

Fig. 6 - 22 Parts Description of a Carbo 510 with Operating Terminal

C98IB002EN-B 41
 6.7.3 Change the printed circuit boards

TIP • Do not keep the detached printed circuit boards in places with high humidity.
The boards will be destroyed.

• Do not put the detached printed circuit boards in polluted places.

1. Open the 4 screw M5x12 to remove the cover of the electronic housing.

2. Open all existing cable glands

3. Disconnect all cables from the connector board with a small slotted
screwdriver.

4. Pull the cables out of the electronic housing.

5. Check the gasket of the cable gland. Change the cable gland (Mat. No.
90711) if the gasket is worn out.

6. Open the screws to get to the right printed circuit board.

7. Change the defective board.

8. Refit the parts in reverse order.

9. Us a flat wrench to tighten the cable gland correctly.

42 C98IB002EN-B
 6 Carbo 510 Smart Sensor - Check and Change

6.8 Service Menu

Service

Only authorized and well-trained persons are allowed to use this menu item. You
must be logged on as "service user" to use all features and parameters.

System information

The menu item "System information" informs you about firmware version, serial
number and hardware version of the Smart Sensor and the Operating Terminal.

Restore factory settings

The Smart Sensor will be set back to its factory settings. All products, product
type settings and user settings will be deleted.

TIP The Carbo 510 should only be set back to its factory settings after consultation
and agreement with the Anton Paar headquarter.

Diagnosis

The diagnosis menu item is divided into the diagnosis settings and diagnosis
values item.

Diagnosis settings: the parameters off-set, gain factor, filter, next maintenance,
rinse and measuring time can be set.

Diagnosis values: the operating period, measuring cycles, case temperature,

data about current consumption of the Smart Sensor and the impeller drive are
displayed.

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 7 Integrated Self-Diagnosis

The Carbo 510 Smart Sensor is equipped with self-diagnosis according to

MAMUR NE 107. This means that the Smart Sensor switches off automatically in
case of an error and the sensor protects itself against irreparable damage. The
error messages are displayed on the mPDS 5 for the Smart Sensor and directly
on the display for the Smart Sensor with Operating Terminal.

Error messages

Error Explanation / Solution

Alarm Limit high!
Alarm Limit low!
Watchdog error!
Motor current too low!
Motor current too high!
Voltage too low!
Voltage too high!
Chip temp. too high!
Liquid temp. too high!
Liquid temp. too low!
Impeller defective!
Valve error!
Temp. sensor failure!
Pressure sensor failure!
Line pressure too high!
Line pressure too low!
Gas bubbles in measuring
chamber!
CANopen Error!
Unspecified error!
Upper limit value exceeded: Product
outside of specification!
Lower limit value exceeded: Product
outside of specification!
Contact Anton Paar Service!
Check wires and impeller!
Check for short circuit or change motor!
Check power supply (min. DC 20 V)!
Check power supply (max. DC 30 V)!
Contact Anton Paar service!
Sensor in cleaning mode!
Liquid temp. below - 5 °C: Out of
measuring range!
Check impeller and impeller drive!
Gas bubbles in measuring chamber or
valves defective!
Check wires or change sensor!
Check wires or change sensor!
Line pressure above 10 bar!
Pipe pressure below 1 bar!
Measuring values incorrect!
Check of CAN wiring and terminating
resistors.
Error! Contact Anton Paar Service!

44 C98IB002EN-B
 Appendix A: Menu Tree

Appendix A: Menu Tree

Adjustment Product selection Value selection (only Offset
adjustable values)
Gain

Product settings Add new product Product name

Product number
Product type
Lower alarm
Upper alarm

Copy product Product selection Product name

Product number
Product type
Lower alarm
Upper alarm

Edit product Product selection Product name

Product number
Product type
Lower alarm
Upper alarm

Delete product Product selection Security query

Product type settings Product type selection Display layout Display line 1
Display line 2
Display line 3
Display line 4

Hardware AO1 assignment

configuration
AO1 scaling (4 mA)
AO1 scaling (20 mA)
AO2 assignment
AO2 scaling (4 mA)
AO2 scaling (20 mA)
Alarm assignment
Digital output
Digital input

C98IB002EN-B 45
Appendix A: Menu Tree

Setup Display brightness

Change PIN codes User selection

Language selection Language selection

Service System information Operating terminal Sensor name

FW version
HW version
Bus address
Serial no.

Smart Sensor Sensor name

FW version
HW version
Bus address
Serial no.

Diagnosis Diagnosis settings Offset press.

Gain press.
Offset temp.
Gain temp.
Rinse time
Measuring time
Impeller check rate
Next maintenance
Median filter size
Average filter size

46 C98IB002EN-B
 Appendix A: Menu Tree

Diagnosis values Operating time [days]

Power up counter
Measuring cycles
Next maint. [days]
Supply voltage [V]
Motor current [mA]
State
Case temp. [°C]
Gas pressure [bar]
Gas temperature [°C]
CO2 [g/l]
Sample temp. [°C]
Line pressure [bar]
CO2 pressure [Pa]
Pressure [bar]
Start/Stop

Restore factory settings Security query

C98IB002EN-B 47
7 Integrated Self-Diagnosis

Appendix B: Document Numbers

Document number Date Comment
C98IB002EN-A 28.04.2011 First release
C98IB002EN-B 13.04.2012 New specifications of the impeller
drive and the P/T sensor.

48 C98IB002EN-B