-EASURE

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

Instruction Manual

Carbo 510 Smart Sensor

 Instruction 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 © 2013 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: 12.10.2013

Document number C98IB001EN-D.fm

Contents

1 About the Instruction Manual ......................................................................................................... 7

2 Safety Instructions........................................................................................................................... 9
2.1 General Safety Instructions ..................................................................................................... 9
2.2 Warning Signs on the Instrument .......................................................................................... 10
3 Carbo 510 Smart Sensor - An Overview ...................................................................................... 11
3.1 Components of the Carbo 510 Smart Sensor........................................................................ 12
3.2 Measuring Principle ............................................................................................................... 13
3.3 Calculation of the CO2 Content ............................................................................................. 14
3.4 Interfaces ............................................................................................................................... 15
3.5 Dimensions ............................................................................................................................ 16
4 Checking the Supplied Parts ........................................................................................................ 17
5 Installing the Carbo 510 Smart Sensor ........................................................................................ 19
5.1 Installation Requirements ...................................................................................................... 19
5.2 Mounting the Carbo 510 Smart Sensor ................................................................................. 20
5.2.1 Installation in a Horizontal Pipe .............................................................................. 20
5.2.2 Installation in a Vertical Pipe .................................................................................. 20
5.2.3 Installation Sequence and Position ........................................................................ 21
5.3 Optional Cut-off Valve Adapter .............................................................................................. 22
5.3.1 Operating the Cut-off Valve Adapter when Disconnecting and
Connecting the Carbo 510 Smart Sensor .............................................................. 22
5.4 Compressed Air Connection.................................................................................................. 24
5.5 Electrical Wiring ..................................................................................................................... 25
5.5.1 Interface Overview ................................................................................................. 25
5.5.2 Connecting the Power Supply ................................................................................ 26
5.5.2.1 Optional Connector Set 4-pole for Power Supply ................................... 27
5.5.3 Shielding................................................................................................................. 27
5.6 Anton Paar CANopen ............................................................................................................ 28
5.6.1 Wiring of the Anton Paar CANopen........................................................................ 29
5.6.2 Wiring with mPDS 5 ............................................................................................... 30
5.6.2.1 CAN Connection with one Smart Sensor ................................................ 31
5.6.2.2 CAN Connection with more than one Smart Sensor............................... 32
5.6.3 Optional Connector Set CAN ................................................................................. 33
6 Putting the Carbo 510 Smart Sensor into Operation with mPDS 5 .......................................... 34
7 Integrated Self-diagnosis .............................................................................................................. 35
8 Maintenance Work ......................................................................................................................... 36
8.1 Spare Parts List ..................................................................................................................... 37
9 CO2 Concentration Table .............................................................................................................. 38

C98IB001EN-D 5
Appendix A: Technical Data ........................................................................................................... 39
Appendix B: Connectors................................................................................................................. 43
B.1 Connector Set 4-pole .......................................................................................... 44
B.2 Connector Set CAN............................................................................................. 45
Appendix C: CE Declaration of Conformity .................................................................................. 46
Appendix D: Document Numbers ................................................................................................. 47

6 C98IB001EN-D
 1 About the Instruction Manual

1 About the Instruction Manual

This instruction manual informs you about the installation and the safe handling
and use of the product. Pay special attention to the safety instructions and
warnings in the manual and on the product.

The instruction manual is a part of the product. Keep this instruction manual for
the complete working life of the product and make sure it is easily accessible to
all people involved with the product. If you receive any additions or revisions to
this instruction manual from Anton Paar GmbH, these must be treated as part of
the instruction manual.

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.

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.

C98IB001EN-D 7
1 About the Instruction Manual

Typographical conventions

Anton Paar has defined the following typographical conventions:

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.

8 C98IB001EN-D
 2 Safety Instructions

2 Safety Instructions
• Read this instruction manual before using Carbo 510 Smart Sensor.

• Follow all hints and instructions contained in this instruction manual to

ensure the correct use and safe functioning of Carbo 510 Smart Sensor.

2.1 General Safety Instructions

Liability

• The instruction manual at hand does not claim to address all safety issues
associated with the use of the instrument and samples. It is your
responsibility to establish health and safety practices and determine the
applicability of regulatory limitations.

• Anton Paar GmbH only warrants the proper functioning of Carbo 510 Smart
Sensor if no adjustments have been made to the mechanics, electronics,
and firmware.

• Only use Carbo 510 Smart Sensor for the purpose described in this
instruction manual. Anton Paar GmbH is not liable for damages caused by
incorrect use of Carbo 510 Smart Sensor.

Installation and use

• The installation procedure should only be carried out by authorized

personnel who are familiar with the installation instructions.

• The Carbo 510 Smart Sensor impeller is safe to run dry. Regarding a long
service performance the Carbo 510 Smart Sensor should be switched off
when the plant is stopped for longer time.

• Make sure all operators are trained to use the instrument safely and correctly
before starting any applicable operations.

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

• Mechanical knocks and vibrations may damage the Carbo 510 Smart
Sensor. Work on the instrument with care.

• In case of damage or malfunction, do not continue operating Carbo 510

Smart Sensor. Do not operate the instrument under conditions which could
result in damage to goods and/or injuries and loss of life.

• Check the Carbo 510 Smart Sensor for chemical resistance to the samples
and cleaning agents.

C98IB001EN-D 9
2 Safety Instructions

Maintenance and service

• Service and repair procedures may only be carried out by authorized

personnel or by Anton Paar GmbH.

• The Carbo 510 Smart Sensor is typically subject to harsh process conditions
like shock pressure, sudden temperature changes, aggressive samples,
vibrations, etc. Sudden changes of the measurement values or malfunctions
may occur. Check continuously that it is functioning perfectly.

Disposal

• Concerning the disposal of Carbo 510 Smart Sensor observe the legal
requirements in your country.

Returns

• For repairs send the cleaned Carbo 510 Smart Sensor 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 homepage (www.anton-paar.com).

• Make sure you pack the Carbo 510 Smart Sensor securely to prevent
damage occurring during transport. This is especially important if you are
sending back an instrument under warranty. If possible, use the original
packaging.

2.2 Warning Signs on the Instrument

Warning!

• Do not exceed the defined maximum pressure, maximum sample and

maximum CIP temperature (see Appendix A - Technical Data).

• The Cut-off Valve Adapter (optional: Mat. No. 90281) must be closed before
dismantling the Carbo 510 Smart Sensor. (see Chapter 5.3.1 - Operating the
Cut-off Valve Adapter when Disconnecting and Connecting the Carbo 510
Smart Sensor).

• The surfaces of the sample connections and the wetted parts of the Carbo
510 Smart Sensor heat up to the temperature of the sample after a period of
time. The operator is responsible for ensuring protections from burns.

• The compressed air supply for Carbo 510 Smart Sensor must not exceed
7 bar (102 psi) (see Chapter 5.4 - Compressed Air Connection).

10 C98IB001EN-D
 3 Carbo 510 Smart Sensor - An Overview

3 Carbo 510 Smart Sensor -

An Overview
The Carbo 510 Smart Sensor represents the third generation of Anton Paar CO2
analyzers which combines the benefits of the inline measurement with the well-
proven pressure-temperature-impeller method. The new maintenance free
impeller allows very short measuring cycles and has largely improved dry run
abilities (automatic stop in error case). The robust stainless steel construction
meets all requirements of the process environment and is fully CIP capable. All
seals and O-rings are FDA compliant.

Due to the integrated impeller with pump function (0,8 l/min) Carbo 510 Smart
Sensor is the first instrument which is able to measure an accurate CO2 level in
tanks and under stop-and-go conditions.

The Carbo 510 Smart Sensor has integrated self-diagnosis and is connected via
CAN-Bus to the mPDS 5 or Remote Operating Terminal for data transfer.

Fig. 3 - 1 Carbo 510 Smart Sensor with Cut-off valve adapter

C98IB001EN-D 11
3 Carbo 510 Smart Sensor - An Overview

Features and Benefits

• High-precision CO2 measurement with short measuring cycles

• Robust housing made of stainless steel

• Degree of protection IP67

• Safe to run dry

• Impeller with integrated pump function

• Fulfills the NAMUR recommendation NE 107 (self-diagnosis)

• Certified raw materials with material certificates for the metal parts and
O-rings which come into contact with the sample.

• Optional Cut-off valve adapter: service + maintenance every time

• Service-friendly and low maintenance (low running costs)

3.1 Components of the Carbo 510 Smart Sensor

Fig. 3 - 2 Carbo 510 Smart Sensor for installation with Remote Operating
Terminal or mPDS 5

12 C98IB001EN-D
 3 Carbo 510 Smart Sensor - An Overview

3.2 Measuring Principle

The determination of the CO2 content is based on Henry's Law, which defines the
relationship between the concentration of the dissolved gas and its saturation
pressure at a given temperature.

1. The product is flowing through the measuring

chamber. The impeller generates the product
exchange.

2. The valves are closed. A sample of the

product is separate in the measuring chamber.

3. The sample is decompressed (9%) by a

decompression valve. The special Anton Paar
impeller brings the chamber pressure to the
corresponding saturation pressure within a few
seconds. The saturation pressure and
temperature of the sample are measured.

The measurement is repeated every 15 seconds (default setting).

C98IB001EN-D 13
3 Carbo 510 Smart Sensor - An Overview

3.3 Calculation of the CO2 Content

From the saturation pressure and the temperature of the sample the sensor
calculates the content of CO2. The relationship between CO2 content and its
saturation pressure at a given temperature depends on the product composition,
e. g. alcohol content, sugar content, …

The Carbo 510 Smart Sensor has 7 product specific formulas for beer,
beverages, beverages light, wine, mineral water, strong beer, MID. Additionally
one user-defined formula can be created.

In laboratories different tables are used, which usually include the influence of the
head space of bottles. In addition from the online measurement to the bottle the
CO2 content may vary due to loss of CO2 after filling before closing the bottle or
additional carbonisation in the buffer tank of the filler.

14 C98IB001EN-D
 3 Carbo 510 Smart Sensor - An Overview

3.4 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)

C98IB001EN-D 15
3 Carbo 510 Smart Sensor - An Overview

3.5 Dimensions

Dimensions [mm]

16 C98IB001EN-D
 4 Checking the Supplied Parts

4 Checking the Supplied Parts

The Carbo 510 Smart Sensor was tested and packed carefully before shipment.
However, damage could occur during transport.

1. Keep the packaging material (box, foam piece, transport protection) for
possible returns and further questions from the transport- and insurance
company.

2. Check the delivery for completion by comparing the supplied parts to table
below.

3. If a part is missing, contact your Anton Paar representative.

4. If a part is damaged, contact the transport company and your Anton Paar
representative.

Symbol Pcs. Article Description Mat. No.

1 Carbo 510 Smart Sensor 89080
or
Carbo 510 Smart Sensor with Operating 95256
Terminal

1 Instruction Manual
English

Options
1 Remote Operating Terminal 94636

1 Option panel installation for Remote Operating 95150

Terminal

C98IB001EN-D 17
 Symbol Pcs. Article Description Mat. No.
1 Carbo 510 Cut-off valve adapter 90281

1 Power supply DC 24 V 2.5 A 96693

1 Connector set 4-pole 94633

1 Compressed air regulator 6530

1m Hose 4x6 nylon bk 72595

C98IB001EN-D 18
 5 Installing the Carbo 510 Smart Sensor

5 Installing the Carbo 510 Smart Sensor

WARNING
• Installation, putting into operation, maintenance and service work should
only be carried out by trained and authorized personnel.
• Observe the permissible operating and ambient conditions for the Carbo
510 Smart Sensor (see Appendix A - Technical Data).
• Do not exceed the defined maximum pressure, maximum sample
temperature and maximum CIP temperature for the Carbo 510 Smart
Sensor (see Chapter 5.1 - Installation Requirements).

NOTICE • Read this manual carefully before installing the Carbo 510 Smart Sensor.
Incorrect operation can result in damage to the Smart Sensor.
• Mechanical knocks and vibrations may damage the Carbo 510 Smart
Sensor. Work on the instrument with care.

5.1 Installation Requirements

WARNING
Comply with the safety instructions in Chapter 2.2 - Warning Signs on the
Instrument.

Line pressure Max. 10 bar / 145 psi

Sample temperature – 5 °C to + 40 °C
Maximum temperature (CIP) 120 °C (max. 30 min)
Power supply DC 24 V SELV (min. 2 A)
Compressed air supply 4 to 7 bar / 58 to 102 psi

Fig. 5 - 1 Type plate

C98IB001EN-D 19
5 Installing the Carbo 510 Smart Sensor

5.2 Mounting the Carbo 510 Smart Sensor

The Carbo 510 Smart Sensor can be installed in a horizontal or vertical pipe (see
Fig. 5 - 2 - Installation position in a horizontal pipe and Fig. 5 - 3 - Installation
position in a vertical pipe). The flow direction makes no difference in both
installation options.

The impeller of the Carbo 510 Smart Sensor is safe to run dry. Regarding a long
service performance the Carbo 510 Smart Sensor should be switched off when
the plant is stopped for a longer time.

NOTICE With the option Cut-off valve adapter (Mat. No. 90281) the flow direction must be
taken into consideration (see Chapter 5.3 - Optional Cut-off Valve Adapter)

5.2.1 Installation in a Horizontal Pipe

Fig. 5 - 2 Installation position in a horizontal pipe

CAUTION
In a horizontal pipe the Carbo 510 Smart Sensor must be installed horizontal
to the pipe. If the Carbo 510 Smart Sensor is installed vertical (90°) to the
horizontal pipe, air could enter the measurement chamber and a
measurement of CO2 would not be possible.

5.2.2 Installation in a Vertical Pipe

Fig. 5 - 3 Installation position in a vertical pipe

20 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

5.2.3 Installation Sequence and Position

If a SPR(n), DSRn or DPR(n) is also installed, the Carbo 510 Smart Sensor must
be mounted in the production line behind these devices. It is important that the
sample flows through the SPR(n), DSRn or DPR(n) and then through the Carbo
510 Smart Sensor (see Fig. 5 - 4 - Installation sequence - top view - top view).

Flow direction

Fig. 5 - 4 Installation sequence - top view

Fig. 5 - 5 Installation position

C98IB001EN-D 21
5 Installing the Carbo 510 Smart Sensor

5.3 Optional Cut-off Valve Adapter

It is recommended to install the Carbo 510 Smart Sensor with the Cut-off valve
adapter. The Cut-off valve adpater seals with two diaphragms.

With the option Cut-off valve adapter (Mat. No. 90281) the flow direction must be
taken into consideration (see Fig. 5 - 6 - Cut-off valve adapter)

The Cut-off valve adapter offers major advantages for servicing. The Carbo 510
Smart Sensor can be disconnected from and reconnected to the main line during
production, without the need to stop production (see Chapter 5.3.1 - Operating
the Cut-off Valve Adapter when Disconnecting and Connecting the Carbo 510
Smart Sensor).

Fig. 5 - 6 Cut-off valve adapter

5.3.1 Operating the Cut-off Valve Adapter when

Disconnecting and Connecting the Carbo 510 Smart
Sensor

Warning
• The Cut-off valve adapter must be closed before starting disconnecting
the Carbo 510 Smart Sensor.
• Do not exceed the defined maximum pressure and maximum sample
temperature for the Cut-off valve adapter (see Appendix A - Technical
Data)

Disconnecting

1. Turn the locking screws on both sides clockwise until they stop
(see Fig. 5 - 7 - Carbo 510 Smart Sensor with Cut-off valve adapter).

22 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

2. Loosen the “nut 6kt”.

3. Hold the Carbo 510 Smart Sensor with one hand and unscrew the “nut 6kt”
completely.

4. Remove the hinged clamp.

5. Pull the Carbo 510 Smart Sensor out of the Cut-off valve adapter (see
Fig. 5 - 8 - Removing the Carbo 510 Smart Sensor)

NOTICE O-rings 10x2 might fall out.

Connecting

Carry out points 1 to 5 in inverse order.

Fig. 5 - 7 Carbo 510 Smart Sensor with Cut-off valve adapter

Fig. 5 - 8 Removing the Carbo 510 Smart Sensor

C98IB001EN-D 23
5 Installing the Carbo 510 Smart Sensor

5.4 Compressed Air Connection

The Carbo 510 Smart Sensor requires a compressed air supply of 4 – 7 bar
(58 – 102 psi). The compressed air must be free from particles, water and oils.

Connect the compressed air hose to the connector “IN” (see Fig. 5 - 9 -
Compressed Air Connection).

Caution
The compressed air supply for the Carbo 510 Smart Sensor must not exceed
7 bar (102 psi).

The compressed air hose must have an external diameter of 6 mm and an internal
diameter of 4 mm.

The following air quality is required:

Class 5 acc. to DIN ISO 8573-1

• Max. air pressure 7 bar / 102 psi

• Max. particle size 5 μm
• Max. particle density 10 mg/m³
• Max. pressure dew point + 7 °C
• Max. oil content 25 mg/m³

TIP Optionally, the compressed air filter/controller unit (Mat. No. 6530) and the
compressed air hose (Mat. No. 72595) can be ordered.

Fig. 5 - 9 Compressed Air Connection

24 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

5.5 Electrical Wiring

WARNING
The instructions given in this chapter must be followed precisely. Installation
and service work are only allowed to be performed by trained and authorized
personnel.

5.5.1 Interface Overview

DC 24 V Power supply connection

CAN Anton Paar CANopen for communication between
Smart Sensor and mPDS 5.
CAN address Must be set if several Smart Sensors are operated
with one mPDS 5.
Impeller Un/FG/+/- Connection for the impeller
Pressure A/B/+/- Connection for the pressure sensor
Temp Connection for the temperature sensor

Fig. 5 - 10 Carbo 510 Smart Sensor interface

C98IB001EN-D 25
5 Installing the Carbo 510 Smart Sensor

5.5.2 Connecting the Power Supply

TIP The Carbo 510 Smart Sensor must be supplied with SELV DC 24 V (min. 2 A).

Warning
• The connection cables must comply with local regulations and must be
adapted to the local ambient conditions. Also, it is necessary to take
special account of the mechanical load.
• Only shielded cables with double insulation are permitted. The shield must
be connected on sensor side (see Chapter 5.5.3 - Shielding).
• Conductor cross section: min. 1 mm²
• Supply cable: 2-pole shielded cable
• Diameter 4.5 to 10 mm

Recommended cable for the power supply:

• Shielded cable: 2-pole

• Conductor cross section: min. 1 mm²
• The cable diameter must be 4.5 to 10 mm to ensure optimum sealing at the
cable gland.
• Recommended cable type: LiYCY

The wires must be connected acc. to the labeling on the cover plate
(see Fig. 5 - 11 - Carbo 510 Smart Sensor). Make sure the shielding is correct
(see Chapter 5.5.3 - Shielding).

Power supply

Fig. 5 - 11 Carbo 510 Smart Sensor

26 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

5.5.2.1 Optional Connector Set 4-pole for Power Supply

Optionally, it is possible to order the connector set 4-pole (Mat. No. 94633) for a
Smart Sensor. Anton Paar specifies the following cable preparation, installation
and pin assignment for this connector set:

See Appendix B.1 - Connector Set 4-pole

5.5.3 Shielding

Connect the cable shield at the Carbo 510 as shown below:

Fig. 5 - 12 Connecting the cable shield

TIP The shield has to be connected only at the sensor side.

C98IB001EN-D 27
5 Installing the Carbo 510 Smart Sensor

5.6 Anton Paar CANopen

CANopen is a 2-wire bus system to which all participants are connected in parallel
(i.e. short branch lines). To avoid reflections, each end of the bus must be
terminated with a 120 Ohm resistor. This is always necessary, even for very short
lines.

TIP • The maximum cable length of the CANopen bus system is 250 m.
• Optionally, the CAN cable, the CANopen connector for mPDS 5 with
integrated terminating resistor and the terminating resistor for Smart
Sensor can be ordered.
• Each Smart Sensor is equipped with a terminating resistor at delivery.
• The terminating resistor has to be connected between CAN H and CAN L.

Options

Symbol Description Mat. No.

Cable for CAN-BUS 94268
Specifications:
• 2 x 2 x 0.22 mm² twisted pair
• Shielded wire
• Characteristic impedance (1 MHz): 126 ohm
• Conductor resistance 186 ohm/km
• Cable jacket: PVC violet,
external diameter 7.1 mm
• Temperature range – 40 °C to + 70 °C
CANopen connector for mPDS 5 95575
with integrated terminating resistor

Terminating resistor for Smart Sensor 89084

28 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

Fig. 5 - 13 Details of the CANopen Connector (Mat. No. 95575)

5.6.1 Wiring of the Anton Paar CANopen

The Carbo 510 Smart Sensor can be connected to the mPDS 5 evaluation unit or
to the Remote Operating Terminal. The mPDS 5 communicate with one or more
Smart Sensors. The Remote Operating Terminal can communicate with one
Smart Sensor.

All details about the installation of Carbo 510 with the Remote Operating Terminal
see Instruction Manual Operating Terminal / Remote Operating Terminal
Chapter 6 "Electrical Installation".

C98IB001EN-D 29
5 Installing the Carbo 510 Smart Sensor

5.6.2 Wiring with mPDS 5

This chapter explains the wiring of an mPDS 5 with one or more Smart Sensors
and the Anton Paar accessories CAN cable (Mat. No. 94268), CANopen
connector for mPDS 5 (Mat. No. 95575) and terminating resistor for Smart Sensor
(Mat. No. 89084).

TIP • The mPDS 5 has no integrated terminating resistor.

• Each end of the CAN bus system must be terminated with a 120 ohm
resistor.
• Order the optional available CANopen Connector for mPDS 5 with
integrated terminating resistor.

CAN IN

CAN OUT

Fig. 5 - 14 CAN connection at the Smart Sensor

30 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

5.6.2.1 CAN Connection with one Smart Sensor

If you connect one Smart Sensor to the mPDS 5 you have to use the CAN IN at
the CANopen connector for mPDS 5 and CAN IN at the Smart Sensor. At the
CANopen Connector for mPDS 5 you have to switch on the terminating resistor.
You also have to connect the terminating resistor for Smart Sensor at
CAN OUT of the Smart Sensor.

Fig. 5 - 15 CAN connection mPDS 5 and one Smart Sensor

Assignment CAN cable, CANopen connector for mPDS 5 and Smart Sensor:

Cable (94268) CANopen connector mPDS 5 (95575) Smart Sensor

CAN IN CAN OUT CAN IN CAN OUT
Green 6 CANL-IN 3 NC, TR ON CAN L TR
Brown 5 CANGND 2 NC, TR ON CAN GND NC
Yellow 4 CANH-IN 1 NC, TR ON CAN H TR
White Not used

NC ... not connected

TR ... Terminating resistor

C98IB001EN-D 31
5 Installing the Carbo 510 Smart Sensor

5.6.2.2 CAN Connection with more than one Smart Sensor

Fig. 5 - 16 CAN connection mPDS 5 at first position and two Smart Sensors

Assignment CAN cable, CANopen connector for mPDS 5 and Smart Sensor:

Cable CANopen connector for mPDS 5 Smart Sensor Smart Sensor

(94268) (95575) No. 1 No. 2
CAN IN CAN OUT CAN IN CAN OUT CAN IN CAN OUT
Green 6 CANL-IN 3 NC, CAN L CAN L CAN L TR
TR ON
Brown 5 CANGND 2 NC, CAN GND CAN GND CAN GND NC
TR ON
Yellow 4 CANH-IN 1 NC, CAN H CAN H CAN H TR
TR ON
White Not used

NC ... not connected

TR ... Terminating resistor

32 C98IB001EN-D
 5 Installing the Carbo 510 Smart Sensor

Fig. 5 - 17 CAN connection mPDS 5 in the middle and two Smart Sensors

Assignment CAN cable, CANopen connector for mPDS 5 and Smart Sensor:

Cable CANopen connector for mPDS 5 Smart Sensor Smart Sensor

(94268) (95575) No. 1 No. 2
CAN IN CAN OUT CAN IN CAN OUT CAN IN CAN OUT
Green 6 CANL-IN 3 CANL-OUT CAN L TR CAN L TR
Brown 5 CANGND 2 CANGND CAN GND NC CAN GND NC
Yellow 4 CANH-IN 1 CANH-OUT CAN H TR CAN H TR
White Not used

NC ... not connected

TR ... Terminating resistor

TIP • It is necessary to set different CAN addresses for each Carbo 510 Smart
Sensor, if more than one Carbo 510 Smart Sensor is connected to an
mPDS 5.
• Set the CAN address with the switch "CAN address".

5.6.3 Optional Connector Set CAN

Optionally, it is possible to order the connector set CAN (Mat. No. 96554) for a
Smart Sensor. Anton Paar specifies the following cable preparation, installation
and pin assignment for this connector set:

See Appendix B.2 - Connector Set CAN

C98IB001EN-D 33
6 Putting the Carbo 510 Smart Sensor into Operation with mPDS 5

6 Putting the Carbo 510 Smart Sensor

into Operation with mPDS 5
All details about putting the Carbo 510 Smart Sensor into operation with mPDS 5
Evaluation Unit refer to the Instruction Manual mPDS 5. All details about putting
the Carbo 510 Smart Sensor into operation with the Remote Operating Terminal
refer to the Instruction Manual Operating Terminal - Remote Operating
Terminal.

CAUTION
CIP temperature > 80 °C (176 °F) can shorten the lifetime of the diaphragms
(for inlet, outlet and expansion diaphragm). Therefore we recommend
periodical visual check of the diaphragms.

34 C98IB001EN-D
 7 Integrated Self-diagnosis

7 Integrated Self-diagnosis
The Carbo 510 Smart Sensor is equipped with self-diagnosis according to
NAMUR NE 107. This self-diagnosis makes it possible for the Smart Sensor to
switch off automatically in case of an error. The sensor protects itself against
irreparable damage. The error messages are displayed on the mPDS 5 for the
Smart Sensor.

Error messages

Error Explanation / Solution

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

C98IB001EN-D 35
8 Maintenance Work

8 Maintenance Work
For reliable and trouble free operation, it is essential to periodically check and
maintain the Carbo 510 Smart Sensor.

The service and maintenance intervals of the Smart Sensor depend on the
operating conditions. The following service and maintenance work is
recommended:

Every day:

• Check status messages on the display of the Carbo 510 Smart Sensor with
Operating Terminal or on the mPDS 5.

• Process devices like the Carbo 510 Smart Sensor are often exposed to
extreme operating conditions such as pressure shocks, sudden temperature
changes, aggressive samples, etc. which can result in drift or malfunctions.
Therefore, it is absolutely essential to compare the measured results to
reference values and to readjust the measuring system if required.

• Check the displayed product temperature.

• Check the displayed line pressure.

• Check the displayed CO2 concentration.

• If a pressure regulator is installed: Remove any condensation.

Every year:

• Replace the diaphragm and O-rings (this should only be carried out by
trained service personnel). The diaphragm is mechanically stressed as it
typically moves back and forth every 15 seconds.

• Visual check of the impeller. Replace if worn out (to be carried out only by
trained service personnel).

Cleaning the Smart Sensor:

Caution
Stop the Carbo 510 Smart Sensor with Product 0 out of operation. Clean the
Carbo 510 Smart Sensor with warm water.

36 C98IB001EN-D
 8 Maintenance Work

8.1 Spare Parts List

Pcs. Mat. No. Description

1 89076 EPDM diaphragm for decompression (FDA compliant)
2 89078 EPDM diaphragm inflow/outflow (FDA compliant)
1 74911 O-ring 60x3 EPDM 70 (FDA compliant)
2 74012 O-ring 25x2 EPDM 70 (FDA compliant)
2 17521 O-ring 10x2 EPDM 70 (FDA compliant)
1 97031 Pressure/temperature sensor Carbo 510 Smart Sensor
1 89035 Impeller Carbo 510 Smart Sensor
1 89073 Drive for impeller Carbo 510 Smart Sensor
4 95695 O-ring 4.5x1 NBR 70

NOTICE • If your Carbo 510 Smart Sensor requires a repair, please clean it and send
it to your Anton Paar representative.
• Return the Carbo 510 Smart Sensor in its original packaging.

C98IB001EN-D 37
9 CO2 Concentration Table

9 CO2 Concentration Table

CO2 concentration table in (g/l) for water.

38 C98IB001EN-D
 9 CO2 Concentration Table

Appendix A: Technical Data

Carbo 510 Smart Sensor

Carbo 510 Smart Sensor with Operating Terminal

Functional principle
The Carbo 510 Smart Sensor represents the third generation of Anton Paar CO2 analyzers which combines
the benefits of the inline measurement with the well-proven pressure-temperature-impeller method. The new
maintenance free impeller allows very short measuring cycles and has largely improved dry run abilities
(automatic stop in error case). The robust stainless steel construction meets all requirements of the process
environment and is fully CIP capable. All seals and O-rings are FDA compliant.
Due to the integrated impeller with pump function (0,8 l/min) the Carbo 510 Smart Sensor is the first
instrument which is able to measure an accurate CO2 level in tanks and under stop-and-go conditions.
The Carbo 510 Smart Sensor has integrated self-diagnosis and is connected via CAN-Bus to the mPDS 5 or
Remote Operating Terminal for data transfer.

Material numbers

Carbo 510 Smart Sensor 89080

Carbo 510 Smart Sensor with Operating Terminal 95256

Remote Operating Terminal 94636

Options:

Cut-off valve adapter for Carbo 510 90281

Option Front Panel Installation for Remote Operating Terminal 95150

Connector Set 4-pole 94633

Cable Loom for CAN bus 25 m 96512

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C98IB001EN-D 39
Appendix A: Technical Data

Carbo 510 Smart Sensor

Carbo 510 Smart Sensor with Operating Terminal

Operating Conditions

CO2
Measuring range 0 to 20 g/l
Accuracy 0.05 g/l
Repeatability 0.025 g/l
Resolution 0.01 g/l
Temperature
Liquid - 5 to + 40 °C
CIP/SIP + 120 °C (max. 30 min)
Repeatability 0.03 °C
Measuring interval min. 15 sec
Pressure max. 10 bar (145 psi)
Flow rate
Internal pump 0.8 l/min (without Cut-off valve adapter)
Compressed air supply 4 to 7 bar (58 to 102 psi)

Complies with NAMUR

x NAMUR NE 107 compliance (self diagnosis)

Ambient Conditions

Temperature range ambient 0 to + 40 °C

Degree of protection IP 67 (Nema 6)
Humidity 0 to 90 % (non – condensing)

Electrical connections

Power supply SELV DC 24 V (DC 20 to 30 V)

Current consumption max. 2 A
Power consumption max. 48 W
Cable gland M16x1.5 D4.5-10 EMV
Electrical connection Spring-type terminal
Supply cable
Recommended cable type: LiYCY
Cable cross-section 2 x 1 mm² (AWG 17)
Outside diameter 4.5 to 10 mm

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40 C98IB001EN-D
 Appendix A: Technical Data

Carbo 510 Smart Sensor

Carbo 510 Smart Sensor with Operating Terminal

Other

Process connection Tuchenhagen Varivent N

Stainless steel 1.4404* / 1.4571*, ZrO2/MgO – FZM,
Wetted materials
EPDM**
Weight approx. 8 kg

Options

Cut-off valve adapter

Cut-off valve adapter Carbo 510 Mat. No.

Benefit: The main line mustn’t be empty to remove the 90281
Carbo 510 for maintenance or service.

Pressure: max. 10 bar (145 psi)

Wetted materials:
Stainless steel 1.4404 / 1.4571; EPDM 70

Process Connection:
Nominal diameter > DN65, 3” OD, 3” IPS

* Certified raw materials

** FDA compliant

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C98IB001EN-D 41
Appendix A: Technical Data

Carbo 510 Smart Sensor

Carbo 510 Smart Sensor with Operating Terminal

Dimensions [mm]

42 C98IB001EN-D
 Appendix B: Connectors

Appendix B: Connectors

C98IB001EN-D 43
Appendix B: Connectors

B.1 Connector Set 4-pole

94633 CONNECTOR SET 4-POLE

Recommended cable wiring, assembly and
pin assignment

1. Strip measures male cable connector

2. Contact arrangements

1 brown
2 white
3 blue
4 black

4 pole male cable connector 4 pole female socket with wires

(rear view) (front view)

3. Pin assignment

Power supply AO DI/DO

Pin 1 DC 24 V + AO1 + DI
Pin 2 not used AO1 – DO
Pin 3 DC 24 V - AO2 + DIO +
Pin 4 not used AO2 – DIO GND

4. Specifications

Cable connector Socket with wires

Termination Screw connection Wires
Wire gauge max. 0.75 mm² (AWG 20) Wires 0.25 mm² (AWG 24)
Degree of protection IP 67 IP 68
Temperature range - 25 °C to + 85 °C
Rated voltage 250 V
Rated current (40 °C) 4A
Rated impuls voltage 2950 V 2500 V
Cable outlet 6 – 8 mm -

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44 C98IB001EN-D
 Appendix B: Connectors

B.2 Connector Set CAN

96554 CONNECTOR SET CAN

Cable wiring, assembly and pin assignment

1. Strip measures male cable connector

2. Contact arrangements

1 brown
2 white
3 blue
4 black
5 grey

5 pole male cable connector 5 pole female socket with wires

(rear view) (front view)

3. Pin assignment (standardized)

CANopen
Pin 1 Shield
Pin 2 V + (not used)
Pin 3 V – (CAN_GND)
Pin 4 CAN_H
Pin 5 CAN_L

4. Specifications

Cable connector Socket with wires

Termination Screw connection Wires
Wire gauge max. 0.75 mm² (AWG 20) Wires 0.25 mm² (AWG 24)
Degree of protection IP 67 IP 68
Rated voltage 125 V 60 V
Temperature range - 25 °C to + 85 °C
Rated impuls voltage 1500 V
Rated current (40 °C) 4A
Cable outlet 6 – 8 mm -

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C98IB001EN-D 45
Appendix C: CE Declaration of Conformity

Appendix C: CE Declaration of
Conformity

46 C98IB001EN-D
 Appendix D: Document Numbers

Appendix D: Document Numbers

Document No. Date Comment

C98IB001EN-A 14.12.2010 First version
C98IB001EN-B 30.01.2012 Excerption of the chapters concerning
Remote Operating Terminal
C98IB001EN-C 11.04.2012 New specifications.
C98IB001EN-D 10.12.2013 Compressed air supply: new spec. 4-7 bar

C98IB001EN-D 47
Appendix D: Document Numbers

48 C98IB001EN-D