Instruction Manual

optek-sensors TF16
optek-Manual--1004-2006-02--TF16-US-2011-06-20
PN: 1004-2006-02 (-52)

optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen

Germany

Phone: +49-(0)201-63409-0
Fax: +49-(0)201-63409-999
E-Mail: info@optek.de
Internet: www.optek.com
 Preface

Preface

This instruction manual is written to assist the user in proper procedures for
trouble-free operation.

It is explicitly pointed out that optek-Danulat GmbH assumes no responsibility for

loss or damage caused due to improper use of this instruction manual or
products described herein.

This manual is protected by copyright. However, the user may produce copies
and translations if required for correct operation of the products.

On request, this manual is available in other languages as well as in digital

format (Acrobat® Reader 7.0 required).

Our products are being continuously improved. Technical data is subject to

change without notice.

Essen, May 2011

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 Table of contents

Table of contents

Preface

1 Using the instruction manual ................................................................................................. 1

1.1 Validity of the instruction manual ......................................................................................... 1
1.2 Pictograms and signal words ............................................................................................... 2

2 Returns and disposal .............................................................................................................. 3

2.1 Declaration of decontamination ........................................................................................... 3
2.2 Disposal .............................................................................................................................. 3

3 Intended use ............................................................................................................................ 4

4 Description of TF16 / TF16-N sensors ................................................................................... 5

5 Technical data and exploded views ...................................................................................... 7

5.1 Exploded view of TF16 / TF16-N sensor............................................................................ 11
5.2 Exploded view of TF16-HT / TF16-HT-N sensor ................................................................ 12
5.3 Exploded view of TF16-PV / TF16-PV-N sensor ................................................................ 13
5.4 Exploded view of TF16-HT-PV / TF16-HT-PV-N sensor .................................................... 14

6 Installation ............................................................................................................................. 15
6.1 Standard sensor bodies — installation instructions............................................................ 15
6.2 Installation of the sensor.................................................................................................... 16
6.3 Air purge............................................................................................................................ 17

7 Connection to converter C4000 ........................................................................................... 18

8 Faults ...................................................................................................................................... 22

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 Table of contents

9 Maintenance ........................................................................................................................... 24
9.1 Preventive maintenance .................................................................................................... 24
9.2 Exchange of the lamp module ........................................................................................... 25
9.3 Exchange of detector module ............................................................................................ 26
9.4 Return to operation after the exchange of lamp module and detector module ................... 27
9.5 Spare parts and accessories ............................................................................................. 28
9.5.1 Lamp modules / detector modules / optics modules ................................................ 28
9.5.2 Standard window ..................................................................................................... 29
9.5.3 Gaskets (not wetted) ................................................................................................ 29
9.5.4 Screw sets ............................................................................................................... 29
9.5.5 Small part sets ......................................................................................................... 30
9.5.6 Installation material .................................................................................................. 30
9.5.7 Accessories cable sets ............................................................................................ 30

10 Declaration of conformity ..................................................................................................... 31

11 Contacts ................................................................................................................................. 32

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 Using the instruction manual

1 Using the instruction manual

1.1 Validity of the instruction manual

This instruction manual is valid for TF16, TF16-N sensors and their variants.
There are the following variants:
• HT
• PV
• HT-PV

Abbreviations mean the following sensor options:

• N near infrared (wavelength range 730 - 970 nm)
• HT high temperature
• PV purge varivent (air purge connections at sensor)

Follow the instruction manual for every operation. If the sensor is not used as
described in this instruction manual, your safety and the sensor function could
be affected.

To keep up reliability of the product, enhance its life cycle and avoid down times,
you have to follow the instructions given in this manual.

Furthermore, please follow the existing accident prevention and environmental

protection instructions, as well as recognized technical instructions for safe and
professional working.

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 Using the instruction manual

1.2 Pictograms and signal words

Important information in this instruction manual is marked with the following pic-
tograms:

Danger!
This pictogram indicates immediate danger to life and health of persons.
The text next to the symbol gives information on how to avoid bodily injuries.

If the possible cause of risk can be specified, the corresponding pictogram pre-
cedes instructions:

Danger!
Electrical voltage.
This pictogram indicates danger due to electrical voltage.

Caution!
This pictogram indicates information on how to avoid material damage.

Note!
This pictogram indicates instructional or general advice.

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 Returns and disposal

2 Returns and disposal

2.1 Declaration of decontamination

For the safety of our employees and because of legal regulations we need a
signed “declaration of decontamination” before your return can be handled.
This signed declaration must be included with the shipping documents on the
outside of the packaging.
Any returns which were exposed to hazardous substances and were not
professionally decontaminated are not accepted and will be sent back on your
cost.

optek’s declaration of decontamination and contact information can be found on

our website www.optek.com.

2.2 Disposal

Special legal regulations apply to the return and disposal of industrial waste
equipment. However, manufacturer and user can contractually agree on which
party is to fulfill these legal obligations.

Observe current national disposal regulations.

To dispose packaging material, please separate materials into the following
groups:

• Paper / paperboard
• Plastic

For disposal, disassemble the system components and separate them

according to different material groups.

Dispose of materials according to national and local regulations.

If no agreement has been made, products may be shipped to optek for disposal.

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 Intended use

3 Intended use

The optek-sensors TF16 and their variants are to be applied only as scattered
light turbidimeters for liquids and gases in inline applications according to the
technical data.

The use of the sensors in hazardous locations is prohibited.

You can purchase flameproof sensors for hazardous locations from optek. For
these sensors, special instruction manuals are delivered with the sensor.

Unauthorized constructional changes, additional fittings or rebuildings regarding

the sensor are prohibited. The only exception are rebuildings into one of the va-
riants listed in the chapter "Validity of the instruction manual". Changes to and
interference with the converter program are prohibited as well.

To lay sensor cables underground without protection is prohibited.

The manufacturer is not liable for damage resulting from misuse.

Following this instruction manual is part of the intended use.

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 Description of TF16 / TF16-N sensors

4 Description of TF16 / TF16-N sensors

The TF16 model is a high precision dual channel scattered light turbidimeter. It
measures direct light and light scatterd from particles in the process medium at
an angle of 11°. The sensor is made entirely of stainless steel and designed for
direct installation into pipelines.

Fig. 1 TF16

The following are the main sensor components:

7 6 2 1 2 3

Fig. 2 Schematic TF16

1. Sensor body
2. Windows
3. Optics module
4. Detector (direct light)
5. Detector (scattered light)
6. Optics module
7. Lamp

Its modular construction offers maximum flexibility in adapting to the process,

without affecting the property of measurement. An appropriately defined light
beam penetrates the process medium. The light scattered from particles in the
process medium, e. g. traces of suspended solids, immiscible liquids or gas
bubbles, is detected by eight hermetically sealed silicon photodiodes at an angle
of 11°. Simultaneously, the unscattered light is detected as direct light by
another photodiode. The receiver optics design guarantees that extraneous
lights created inside the sensor body are not included in measurements.

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 Description of TF16 / TF16-N sensors

Due to the small scattering angle, direct light and scattered light practically travel
the same distance in the process medium. This is why product specific
disturbances such as color or color changes of the carrier medium as well as
soilings on windows may be optimally compensated.

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 Technical data and exploded views

5 Technical data and exploded views

Tab. 1 Technical data TF16

TF16 TF16-PV TF16-HT TF16-HT-PV

Material sensor body made of stainless steel 1.4571, SS 316 Ti (standard)

Special materials 1.4435 (SS 316 L), 1.4539, 1.4462, TFM 4215, Hastelloy® C4, Hastelloy® C22, Titanium,
Tantalum, Monel® 400, Inconel® 625, PP, others on request.
Line size 1/4" to 8", (DN 6 to DN 200)
Connections ASME-Flange, DIN-Flange, Varivent, JIS-Flange, Tri-Clamp, BBS-Clamp, Female Thread NPT,
Female Thread DIN ISO 228/1 G, Sanitary Thread (DIN 11851), others on request
Gaskets Viton®, EPDM (FDA), EPDM (USP Cl. VI), Kalrez®, Chemraz®, Fluoraz®, Buna (NBR), Silicone,
Viton® / FEP (FDA), others on request
Windows Pyrex®, Sapphire
Optical path length 40 mm (1.58 '') standard, others on request
Process pressure 10 mbar to 325 bar, (0.15 psi to 4713 psi),
depending on process connection, material and design
Process temperature Data is only valid for appropriate choice of high temperature version
material of sensor body and gaskets! No ice
formation on sensor!

permanent: permanent:
0 °C bis +120 °C, (+32 °F bis +248 °F) -20 °C to +240 °C, (-4 °F to +464 °F)

peak (15 min/day): periodic 15 min/day:

0 °C bis +150 °C, (+32 °F bis +302 °F) -20 °C to +260 °C, (-4 °F to +500 °F)
Ambient temperature operation:
0 °C bis +40 °C, (+32 °F bis +104 °F)
(When higher or lower ambient temperatures are given, it may be necessary to impose restrictions
on the admissible process temperature!)
transport:
-20 °C to +70 °C, (-4 °F to +158 °F)
Air purge connectors available as standard
Light source incandescent tungsten lamp: 5.0 V DC, 775 mA, typical lamp life 3 to 5 years
Wavelengths 400 nm - 1100 nm
Detector silicon photodiodes, hermetically sealed
Calibration basic calibration in ppm (DE), FTU, EBC
Measuring range any measuring range between
0 - 0.5 to 500 ppm (DE)
0 - 0.2 to 200 FTU
0 - 0.05 to 50 EBC
Resolution < ± 0.05 % of respective measuring range
Repeatability < ± 0.3 % of respective measuring range
Linearity application specific, < ± 1 % standard solution
Protection all optical parts protected according to IP65 if sensor is constructed as intended, valid for
installation of plug or protection cap
Cable lengths standard: 5, 10, 20, 35, 50 m (16, 33, 66, 115, 164 ft.) maximum: 250 m (820 ft.)
non-metallic sheathed cable with finely stranded copper conductor according to IEC 228 CL.5,
Cable material
insulation PVC (-40 °C ... + 70 °C, -40 °F ... +158 °F)
SS-plug-protection special high shielded cable sets, rigid stainless steel plug
Certificates ISO 9001:2000, ATEX, FM, PED, CE, HP0

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 Technical data and exploded views

Tab. 2 Technical data TF16-N

TF16-N TF16-PV-N TF16-HT-N TF16-HT-PV-N

Material sensor body made of stainless steel 1.4571, SS 316 Ti (standard)

Special materials 1.4435 (SS 316 L), 1.4539, 1.4462, TFM 4215, Hastelloy® C4, Hastelloy® C22, Titanium,
Tantalum, Monel® 400, Inconel® 625, PP, others on request.
Line size 1/4" to 8", (DN 6 to DN 200)
Connections ASME-Flange, DIN-Flange, Varivent, JIS-Flange, Tri-Clamp, BBS-Clamp, Female Thread NPT,
Female Thread DIN ISO 228/1 G, Sanitary Thread (DIN 11851), others on request
Gaskets Viton®, EPDM (FDA), EPDM (USP Cl. VI), Kalrez®, Chemraz®, Fluoraz®, Buna (NBR), Silicone,
Viton®/ FEP (FDA), others on request
Windows Pyrex®, Sapphire
Optical path length 40 mm (1.58 '') standard, others on request
Process pressure 10 mbar to 325 bar, (0.15 psi to 4713 psi),
depending on process connection, material and design
Process temperature Data is only valid for appropriate choice of high temperature version
material of sensor body and gaskets! No ice
formation on sensor!

permanent: permanent:
0 °C bis +120 °C, (+32 °F bis +248 °F) -20 °C to +240 °C, (-4 °F to +464 °F)

peak (15 min/day): periodic 15 min/day:

0 °C bis +150 °C, (+32 °F bis +302 °F) -20 °C to +260 °C, (-4 °F to +500 °F)
Ambient temperature operation:
0 °C bis +40 °C, (+32 °F bis +104 °F)
(When higher or lower ambient temperatures are given, it may be necessary to impose restrictions
on the admissible process temperature!)
transport:
-20 °C to +70 °C, (-4 °F to +158 °F)
Air purge connectors available as standard
Light source incandescent tungsten lamp: 5.0 V DC, 775 mA, typical lamp life 3 to 5 years
Wavelengths 730 nm - 970 nm
Detector silicon photodiodes, hermetically sealed
Calibration basic calibration in ppm (DE), FTU, EBC
Measuring range any measuring range between
0 - 0.5 to 500 ppm (DE)
0 - 0.2 to 200 FTU
0 - 0.05 to 50 EBC
Resolution < ± 0.05 % of respective measuring range
Repeatability < ± 0.3 % of respective measuring range
Linearity application specific, < ± 1 % standard solution
Protection all optical parts protected according to IP65 if sensor is constructed as intended, valid for
installation of plug or protection cap
Cable lengths standard: 5, 10, 20, 35, 50 m (16, 33, 66, 115, 164 ft.)
maximum: 250 m, (820 ft.)
non-metallic sheathed cable with finely stranded copper conductor according to IEC 228 CL.5,
Cable material
insulation PVC (-40 °C ... + 70 °C, -40 °F ... +158 °F)
SS-plug-protection special high shielded cable sets, rigid stainless steel plug
Certificates ISO 9001:2000, ATEX, FM, PED, CE, HP0

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 Technical data and exploded views

Fig. 3 Schema for determining dimensions

• A = installation height (in mm)

• B = installation length detector side (in mm)
• C = installation length lamp side (in mm)

Table 3 indicates a part of our extensive range of sensor bodies. Other sensor
bodies with diverse process connections and made of many other materials are
available (see table 1 on page 7 and table 2 on page 8).
Detailed technical information is given in the instruction manual "Sensor bodies
according to Pressure Equipment Directive, Module E1" of the corresponding
sensor body.
Moreover, Varivent adapters are available in different line sizes to allow quick
and easy adaptation to pipelines.

Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

Line OPL A-A*) A B C

Process connection Part.-No. Material Design
size [mm] [mm] [mm] [mm]
NPT Female thread 1.4571 /
0120-1104-03 1" 40 96 160 195
(ASME B1.20.1) SS 316 Ti
Female thread 1.4571 /
0120-1103-03 1" 40 96 160 195
(DIN ISO 228/1-G) SS 316 Ti
Clamp
0120-1102-28 SS 316 L 1" 40 96 160 195
(ISO 2852-1993)
Clamp
0120-1302-28 SS 316 L 1.5" 40 106 160 195
(ISO 2852-1993)
Clamp
0120-0402-28 SS 316 L 2" 40 112 160 195
(ISO 2852-1993)
Sanitary thread SC 1.4571 /
0120-1101-03 welded DN 25 40 125 160 195
(DIN 11851) SS 316 Ti
Sanitary thread SC 1.4571 /
0120-1301-03 welded DN 40 40 125 160 195
(DIN 11851) SS 316 Ti
Sanitary thread SC 1.4571 /
0120-0401-03 welded DN 50 40 125 160 195
(DIN 11851) SS 316 Ti
Sanitary thread SC 1.4571 /
0120-0501-03 welded DN 65 50 140 165 200
(DIN 11851) SS 316 Ti
Sanitary thread SC 1.4571 /
0120-0601-03 welded DN 80 50 180 165 200
(DIN 11851) SS 316 Ti
Sanitary thread SC 1.4571 /
0120-0701-03 welded DN 100 60 200 170 205
(DIN 11851) SS 316 Ti
Flange 1.4571 /
0120-1106-03 welded 1" 40 150 160 195
(ASME B16.5 RF, 150 lbs) SS 316 Ti
Flange 1.4571 /
0120-1306-03 welded 1.5" 40 150 160 195
(ASME B16.5 RF, 150 lbs) SS 316 Ti

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 Technical data and exploded views

Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

Line OPL A-A*) A B C

Process connection Part.-No. Material Design
size [mm] [mm] [mm] [mm]
Flange 1.4571 /
0120-0406-03 welded 2" 40 150 160 195
(ASME B16.5 RF, 150 lbs) SS 316 Ti
Flange 1.4571 /
0120-0606-03 welded 3" 50 225 165 200
(ASME B16.5 RF, 150 lbs) SS 316 Ti
Flange 1.4571 /
0120-0706-03 welded 4" 60 230 170 205
(ASME B16.5 RF, 150 lbs) SS 316 Ti
Flange 1.4571 /
0120-1115-03 welded DN 25 40 150 160 195
(DIN 2633, E) SS 316 Ti
Flange 1.4571 /
0120-1315-03 welded DN 40 40 150 160 195
(DIN 2633, E) SS 316 Ti
Flange 1.4571 /
0120-0415-03 welded DN 50 40 150 160 195
(DIN 2633, E) SS 316 Ti
Flange 1.4571 /
0120-0515-03 welded DN 65 50 150 165 200
(DIN 2633, E) SS 316 Ti
Flange 1.4571 /
0120-0615-03 welded DN 80 50 215 165 200
(DIN 2633, E) SS 316 Ti
Flange 1.4571 /
0120-0715-03 welded DN 100 60 220 170 205
(DIN 2633, E) SS 316 Ti
Clamp 1.4435 /
0120-2918-08 Biotech 1" 40 96 160 195
(TC L14 AM7) SS 316 L
Clamp 1.4435 /
0120-1946-08 Biotech 1.5" 40 106 160 195
(TC L14 AM7) SS 316 L
Clamp 1.4435 /
0120-2914-08 Biotech 2" 40 112 160 195
(TC L14 AM7) SS 316 L

*) Optical path length (OPL) using standard windows model A is given in column
OPL A-A.

For the TF16 sensor, the sensor body and window combination have to be
chosen so that a type A window is installed on the detector side and the optical
path length is 40 mm (1.58 ''). That means, if a sensor body with 50 mm (1.97 '')
OPL A-A is chosen, a type A window has to be installed on the detector side and
a type C window has to be installed on the lamp side.

Tab. 4 Cable weights

Cable Weight

Lamp cable (1.5 mm2) 0.9 kg / 10 m

Lamp cable (2.5 mm2) 1.2 kg / 10 m

Lamp cable (4.0 mm 2) 1.5 kg / 10 m

Detector cable (TF16) 1.2 kg / 10 m

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 Technical data and exploded views

5.1 Exploded view of TF16 / TF16-N sensor

11 10 10 16

20 22

20 21
9 8 7 6 5 4 3 2 1 12 13 14 7 15 9

18 17 7 7 19 18
Fig. 4 Photo and exploded view of TF16 / TF16-N

Tab. 5 Exploded view explanations

No Explanation No Explanation
1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3 O-Ring 25.12 x 1.78, Viton® 14 Detector assembly TF16, 1.4571 (316 Ti)
Lamp adapter TF16, 1.4571 (316 Ti), incl.
4 15 Detector socket, 9-pin
wavelength module (see Table 13 on page 28)
5 O-Ring 31.47 x 1.78, Viton® 16 Detector cable TF16
6 Optical housing OH06, 1.4571 (316Ti) 17 Lamp cable TF16 with SS-plug-protection
4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
7 O-Ring 21.95 x 1.78, Viton® 18
washer
8 lamp module TF16 19 Detector cable TF16 with SS-plug-protection
9 O-Ring 10.10 x 1.60, Viton® 20 O-Ring 4.00 x 1.00 Viton®
10 4 screws M3 x 6 (DIN 7985), 1.4571 (316Ti) 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 Lamp cable TF16 22 Purge connection M5, Ms/Ni

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 Technical data and exploded views

5.2 Exploded view of TF16-HT / TF16-HT-N sensor

20 22

20 21
9 8 7 6 5 4 3 2 1 12 13 14 7 15 9

18 17 7 7 19 18
Fig. 5 Photo and exploded view of TF16-HT / TF16-HT-N

Tab. 6 Exploded view explanations

No. Explanation No. Explanation

1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3 O-Ring 25.12 x 1.78, Viton® 14 Detector assembly TF16-HT, 1.4571 (316 Ti) / PEEK
Lamp adapter TF16-HT, PEEK, incl. wavelength
4 15 Detector socket, 9-pin
module (see table 13 on page 28)
5 O-Ring 31.47 x 1.78, Viton® 16 -
6 Optical housing OH06, 1.4571 (316Ti) 17 Lamp cable TF16 with SS-plug-protection
4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti),
7 O-Ring 21.95 x 1.78, Viton® 18
incl. washer
8 lamp module TF16 19 Detector cable TF16 with SS-plug-protection
9 O-Ring 10.10 x 1.60, VitonÆ 20 O-Ring 4.00 x 1.00 Viton®
10 - 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 - 22 Purge connection M5, Ms/Ni

Note!
For TF16-HT, the cable set always has to be equipped with plug-protection.

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 Technical data and exploded views

5.3 Exploded view of TF16-PV / TF16-PV-N sensor

11 10 10 16

20 22
22 20

21 20 20 21
9 8 7 6 5 4 3 2 1 12 13 14 7 15 9

18 17 7 7 19 18
Fig. 6 Photo and exploded view of TF16-PV / TF16-PV-N

Tab. 7 Exploded view explanations

No. Explanation No. Explanation

1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3 O-Ring 25.12 x 1.78, Viton® 14 Detector assembly TF16, 1.4571 (316 Ti)
Lamp adapter TF16, 1.4571 (316 Ti), incl.
4 15 Detector socket, 9-pin
wavelength module (see table 13 on page 28)
5 O-Ring 31.47 x 1.78, Viton® 16 Detector cable TF16
6 Optical housing OP06 Purge, 1.4571 (316Ti) 17 Lamp cable TF16 with SS-plug-protection
4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
7 O-Ring 21.95 x 1.78, Viton® 18
washer
8 lamp module TF16 19 Detector cable TF16 with SS-plug-protection
9 O-Ring 10.10 x 1.60, Viton® 20 O-Ring 4.00 x 1.00 Viton®
10 4 screws M3 x 6 (DIN 7985), 1.4571 (316Ti) 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 Lamp cable TF16 22 Purge connection M5, Ms/Ni

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 Technical data and exploded views

5.4 Exploded view of TF16-HT-PV / TF16-HT-PV-N sensor

20 22
22 20

21 20 20 21
9 8 7 6 5 4 3 2 1 12 13 14 7 15 9

18 17 7 7 19 18
Fig. 7 Photo and exploded view of TF16-HT-PV / TF16-HT-PV-N

Tab. 8 Exploded view explanations

No. Explanation No. Explanation

1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3 O-Ring 25.12 x 1.78, Viton® 14 Detector assembly TF16-HT, 1.4571 (316 Ti) / PEEK
Lamp adapter TF16-HT, PEEK, incl. wavelength
4 15 Detector socket, 9-pin
module (see table 13 on page 28)
5 O-Ring 31.47 x 1.78, Viton® 16 -
6 Optical housing OP06 Purge, 1.4571 (316Ti) 17 Lamp cable TF16 with SS-plug-protection
4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
7 O-Ring 21.95 x 1.78, Viton® 18
washer
8 lamp module TF16 19 Detector cable TF16 with SS-plug-protection
9 O-Ring 10.10 x 1.60, Viton® 20 O-Ring 4.00 x 1.00 Viton®
10 - 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 - 22 Purge connection M5, Ms/Ni

Note!
For TF16-HT-PV, the cable set always has to be equipped with plug-protection.

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 Installation

6 Installation

6.1 Standard sensor bodies — installation instructions

Installation instructions are provided in the armatures instruction manual.

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 Installation

6.2 Installation of the sensor

Tool • not needed

Install sensor as described below:

Note!
O-Rings are delivered separately and are not installed at delivery.

1. Check that there are O-Rings for the sensor assemblies.

2. Place one O-Ring each into the groove of the window rings (see fig. 8).

Fig. 8 O-Ring at window ring

Danger!
Isopropanol is irritating!
Observe the safety regulations when handling Isopropanol!

3. Make sure that the windows of the sensor body are clean. If not, clean them
with Isopropanol.
4. Check the window ring threads for damage and soiling and clean them if
necessary.
5. Screw on sensor assemblies for detector and lamp sides to the sensor body
hand-tight (right-hand thread, fig. 9). It is recommended to use the supplied
installation paste.

Fig. 9 Installed sensor, example TF16 sensor

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 Installation

6.3 Air purge

Should the temperature of the process medium be too low, the temperature of
the air inside the optical housing might fall below dew point. This leads to
condensation deposits on the window surfaces. For this event, the sensor body
is equipped with an air purge connection on a window ring or the sensor is as
well equipped with one air purge connection on the detector assembly.

Note!
If the product is more than 10 °C (18 °F) cooler than the ambient air of the
sensor, always connect air purge.

Tool • Screw driver

• Wrench 7 mm

At delivery, the drill holes of the air purge connections are sealed with O-Ring
and sealing screws M5 x 6 (DIN 84).
1. Remove the sealing screws and O-Rings.
2. Check if there are O-Rings on air purge connections.
3. Install air purge connections (22, fig. 10) screwing.
4. Place the air purge hoses on the air purge connections (22).

4 22 14 22 22 4 14 22

Fig. 10 Window ring and detector assembly air purge connections (left) as well as optical housing
and detector assembly air purge connections (right)

After connecting the sensor to the power supply and putting it into operation,
rinse it as described below:
1. Loosen lamp adapter (4) and detector assembly (14) turning each 2-3 turns
anticlockwise.
2. Rinse the optical housing by aerating it with dry, oil and dust free air for
approx. 10 minutes at a maximum of 0.5 bar (7.25 psi) gauge pressure.
In case you do not have air purge supply of appropriate quality, you can use
the optek Air Drying System ADS.
3. Reduce air pressure to approx. 0.1 bar (1.45 psi).
4. Retighten lamp adapter (4) and detector assembly (14). Keep up the gauge
pressure. Air consumption in this operational state is minimal.
5. Make sure the O-Rings are fitted correctly.

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 Connection to converter C4000

7 Connection to converter C4000

For connecting the sensor cables, observe the following basic conditions:
• Bring the sensor cable to the cable entry from underneath.
• Form a loop with the sensor cable close to the cable entry.
• Do not lay sensor cables in ducts of current-carrying lines.
• Observe cable specifications (see technical data).
• To lay sensor cables underground without protection is prohibited.

For the connection of the sensor to the converter, there are sensor cables with
plug-protection on the sensor side (17, 19; fig. 11) or without plug-
protection (11, 16).

Connection to the On the sensor side, mixing up sensor cables is not possible, as plugs are
sensor
distinctive:
• 9-pin plug on the detector side (16, 19),
• 4-pin plug on the lamp side (11, 17)

11 17 19 16
Fig. 11 Plug with and without plug-protection

Tool • not needed

Connection of the sensor cable without plug-protection on the detector and lamp
side:
1. Loosen the connection cover of the sensor.
2. Plug in the sensor cable.
3. Screw-tighten the protection cover.

Fig. 12 Connection of the sensor cable without plug-protection

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 Connection to converter C4000

Tool • Screw driver

Connection of the sensor cable with plug-protection on the detector and lamp
side:
1. Loosen the connection cover of the sensor.
2. Ensure there is an O-Ring (7, fig. 13) for plug-protection.
3. Plug in the sensor cable.
4. Fasten each of the four screws of the plug-protection (19) with washer.

7 19

Fig. 13 Connection of the sensor cable with plug-protection

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 Connection to converter C 4000

Note!
Detailed information on the connection of the sensor to a C4000-series
converter is given in the instruction manual of the converter. There you can as
well find the corresponding wiring plans.

Connection to the The following connections are on the back of the converter:
converter

4 - 20 mA 0 / 4 - 20 mA
IN 1, 2 OUT 1, 2 OUT 3, 4
DETECTOR INPUTS
21 40 44
[A] [B]
22 41 45
5 5 115 / 230 V, 50 / 60 Hz, 50 VA 23 42 46
1 1 115 / 230 V, T 1,6 A 24 43 47
!
2 2
A REMOTE IN RELAY OUT LAMP [E]
24 V DC 24 V AC / DC
230V 6
B R1 31 10
V DC
6 acc. to
R2 32 11 7 cable
length
R3 33 12 7

DETECTOR INPUTS
[C] [D]
R4
R5
34
35
13
14
LAMP [F] E
L R6 36 15 6

19
5 5 V DC
PA R7 37 16 6 acc. to
N

20
3 3
PE R8 38 17 7 cable

21
4 4 length
C RR 39 18 7

M6 OPTEK - DANULAT MADE IN GERMANY

F
D

Fig. 14 Detector inputs and lamp outputs of the converter C4422

Letters stand for

• A-D Detector inputs
• E-F Connections for lamp outputs

The connections depend on the equipment of your converter and on how many
sensor you would like to connect.

Note!
Do not use other detector inputs and lamp outputs than given in table 9, even if
in some cases other combinations are possible. Thus, danger of mixing inputs
and outputs up is minimized.

Tab. 9 Connections

Number of Detector input connection of the converters

Lamp
sensors sensor Cable length max.
C4101 C4121 C4201 C4221 C4202 C4222 C4322 C4422 output
type
1 sensor
TF16 A/C A/C A/C A/C A/C A/C E 250 m / 820 ft.
2 sensors
TF16 A/C A/C E
250 m / 820 ft.
AF16 B B F
2 sensors
TF16 A/C A/C E 250 m / 820 ft
AS16 / AS16-BT B B F 50 m / 164 ft.
2 sensors
TF16 A/C A/C E 250 m / 820 ft
AS56 B B F 50 m / 164 ft.

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 Connection to converter C 4000

Tab. 9 Connections

Number of Detector input connection of the converters

Lamp
sensors sensor Cable length max.
C4101 C4121 C4201 C4221 C4202 C4222 C4322 C4422 output
type
2 sensors
TF16 A/C E
250 m / 820 ft
TF16 B/D F
2 sensors
AF26 A/C E
250 m / 820 ft
TF16 B/D F
2 sensors
AF45 A/C E 100 m / 328 ft
TF16 B/D F 250 m / 820 ft
3 sensors
2 x AS56 A/C E 50 m / 164 ft.
TF16 B/D F 250 m / 820 ft

Tool • Screw driver

To be able to allocate the end splices unequivocally to the clamps of the

converter, each end splice is marked with the number of the correct clamp:

Detector cable to sensor

1 = white (A1) 2 = brown (A2) 5 = black (A5)

Detector cable to sensor (reference channel)

3 = white (C3) 4 = brown (C4) 5 = gray (C5)

Lamp cable to sensor

6 = white or blue (6) 7 = brown (7)

Caution!
Lamp voltage must be adjusted to the cable length in order to compensate
voltage loss in the cable. Too low lamp voltage can lead to wrong measuring
results. Too high lamp voltage reduces the life of the lamp module considerably.
Follow the instructions in the instruction manual of the converter. During
operation, voltage at the lamp is 4.8 V.

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 Faults

8 Faults

Among other possibilities, you can detect faults whenever an error message on
the converter appears. Try to clear the fault using the following table and the in-
structions given in the chapter "Software" in the instruction manual of the con-
verter. Should you have any difficulty clearing the fault, feel free to contact our
customer service. To solve the problem efficiently, we ask you to have the sheet
with system data of your sensor or system at hand.

Please find our contact details in chapter 11, page 32.

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 Faults

Tab. 10 Possible faults and remedies

Possible fault Possible remarks Cause Remedy

• Continuity test of lamp cable
• "Lamp failure" LED of conver- Lamp cable between sensor • Exchange lamp cable for new
Failure of and converter defective
ter flashes. one.
lamp module
• Signal loss
Lamp module defective • Exchange lamp module.
• Continuity test of detector
Detector cable between sen- cable
Detector failure - sor and converter defective • Exchange detector cable for
new one.
Detector defective • Exchange detector.
Humidity gets into optical
• Use airpurge,
housing and forms condensa-
chapter 6.3.
Unrealistic, random measuring tion deposits on windows.
Condensate formation
results • Disassemble sensor assem-
O-Ring missing or defective blies and check O-Rings,
exchange if necessary.
• Sensor body windows are
dirty.
• Clean sensor body window.
• Sensor body windows are
• Results are fluctuating. • Exchange sensor body win-
Wrong results corroded.
• Zero point is drifting. dow for sapphire window.
• Lamp module near failure,
• Exchange lamp module.
lamp module near the end of
its life.
• Continuity test of detector
Detector cable between sen- cable
• No function
sor and converter defective • Exchange detector cable for
Connection error • No "Lamp failure" LED mes- new one.
sage
Sensor cable incorrectly con- • Check and revise connec-
nected to converter tions.
• Amplify measuring range.
Measuring range excee- ↑−↑−↑ • If the measuring range cannot
Process conditions
ded Converter indicates flashing be amplified, apply absorption
measurement.
mA-output delivers correct cur-
rent results if measuring results
• Check resistance of wiring.
are low Connected load > 600 ohms
• Use appropriate mA-input.
and too low current results if
mA-signal (output)
measuring results are high.
• Compensation by adjusting
Poor calibration of the receiving
Small deviations given in % calibration of the sending mA-
mA-input
output.
• Compensation by adjusting
Poor calibration of the sending
mA-signal (input) Small deviations given in % calibration of the receiving
mA-output
mA-input.
• Send system (converter and
sensor) to optek for checking
purposes. If necessary, the
None of the above mentioned
Defect of converter - sensor body can remain in
errors can be detected.
the pipeline so that only the
optical arms and the conver-
ter have to be sent.

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 Maintenance

9 Maintenance

9.1 Preventive maintenance

Tab. 11 Preventive maintenance

Component Maintenance activity Maintenance interval Information

Possible damaged sealing faces
as part of standard
inspection with regard of the sensor body can lead to
Wetted parts installation mainte-
to leakages leakages (see instruction manual
nance
of the sensor body).
Operation of the lamp below its
nominal voltage (4.8 V DC
instead of 5.0 V DC) enhances
lamp life. Strong vibrations, high
Lamp temperatures or frequent on and
exchange 1 - 2 years
module off switching of the system can
have negative effects on the ser-
vice life. Statistical service life
amounts to 3 years, for UV
lamps to 1–2 years.

Note!
The used detector is not subjected to measurable aging when used properly.

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 Maintenance

9.2 Exchange of the lamp module

Tool • Screw driver

1. Switch the converter voltage-free.

2. Loosen the sensor cable from the lamp module.
3. Loosen the four screws connecting the lamp module to the stainless steel
housing.
4. Pull out the lamp module (8, fig. 15).
5. Check if there is an O-Ring (7) for the lamp module.
6. Insert the new lamp module into the sensor.
7. Fasten the four screws.
8. Re-connect the sensor cable.
9. Switch on the converter.
10. Follow the instructions given in chapter 9.4, page 27.

8 7

Fig. 15 Exchange of the lamp module

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 Maintenance

9.3 Exchange of detector module

The detector module may only be exchanged at the factory. Please contact your
contact person at optek.

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 Maintenance

9.4 Return to operation after the exchange of lamp module and

detector module

Before return to operation of the entire measuring system, undertake the follow-
ing activities:
1. Switch on the converter.
2. Wait for approx. 15 minutes, until the converter has reached the working
temperature.
3. Check the system's zero-point (see instruction manual of the converter).
4. Document your settings using the form (see instruction manual of the con-
verter).
5. Check measuring results with regard to plausibility.
6. If settings and measuring results are correct, enable measuring.

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 Maintenance

9.5 Spare parts and accessories

9.5.1 Lamp modules / detector modules / optics modules

Tab. 12 Spare parts — lamp module

Name / type Old part number New part number

lamp module TF16 2100-0202-02 1426-3137-1401-01

Tab. 13 Spare parts — wavelength modules

Wavelength module Old part number New part number

wavelength module TF16 old: 2300-0306-00 1430-3137-4000-00
wavelength module TF16-N 1430-3137-7300-00

Tab. 14 Spare parts — detector assemblies

detector assembly TF16

(Choose corresponding wavelength module New part number
from Table 13!)
detector assembly TF16 1421-3700-0000-00
detector assembly TF16-HT 1421-3701-0000-00
detector assembly TF16-PV 1421-3704-0000-00
detector assembly TF16-HT-PV 1421-3709-0000-00
detector assembly TF16-N 1421-3700-0300-00
detector assembly TF16-HT-N 1421-3701-0300-00
detector assembly TF16-PV-N 1421-3704-0300-00
detector assembly TF16-HT-PV-N 1421-3709-0300-00

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 Maintenance

9.5.2 Standard window

Tab. 15 Spare parts — standard window

Sensor type / name Name / type Old part number New part number
® type A 0410-0050-01
Pyrex
type B 0410-0051-01
type C 0410-0052-01
type K 0410-0053-01

standard window** Saphire type A 0410-0050-03

(see corresponding arma- type B 0410-0051-03
ture manual)
type C 0410-0052-03
type K 0410-0053-03
type AM 0410-0056-03
type BM 0410-0057-03
type CM 0410-0058-03

** others on request

Observe that for TF16 sensor and its variants only type A windows may be in-
stalled on the detector side!

9.5.3 Gaskets (not wetted)

Tab. 16 Spare parts — gaskets

Viton® Viton®
Gaskets (4 of each)
Old part number New part number
10.10 x 1.60 0208-4004-02 1203-0004-0008-02
21.95 x 1.78 0208-4001-02 1203-0004-0015-02
25.12 x 1.78 0208-4002-02 1203-0004-0016-02
31.47 x 1.78 0208-4003-02 1203-0004-0018-02
50.52 x 1.78 1203-0004-0021-02

9.5.4 Screw sets

Tab. 17 Spare parts — screw sets

(10 of each) Old part number New part number

M3 x 6 (DIN 7985) 0101-1001-03 1206-0010-0023-03
M3 x 12 (DIN 7985)
0101-1002-03 1206-0010-0077-01
incl. washer M3 (DIN 7980)

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 Maintenance

9.5.5 Small part sets

Tab. 18 Spare parts — small part sets

New part number

set purge connection M5 1201-3131-0001-00

9.5.6 Installation material

Tab. 19 Spare parts — installation material

New part number

set Klüberpaste UH1 96-402 4 x 12 g 1201-3131-0002-00

9.5.7 Accessories cable sets

Tab. 20 Accessories — cable sets standard

Cable sets standard*** New part number

5m 2312-0115-0005-00
10 m 2312-0115-0010-00
20 m 2312-0115-0020-00
30 m 2312-0115-0030-00
40 m 2312-0115-0040-00
50 m 2312-0115-0050-00

Tab. 21 Accessories — cable sets with SS-plug-protection

Cable sets with SS-plug-protection*** New part number

5m 2312-0315-0005-00
10 m 2312-0315-0010-00
20 m 2312-0315-0020-00
30 m 2312-0315-0030-00
40 m 2312-0315-0040-00
50 m 2312-0315-0050-00

*** other cable lengths on request

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 Declaration of conformity

10 Declaration of conformity

Declaration of conformity
in accordance with the

Directive 2004/108/EC relating to electromagnetic compatibility as of 15

December 2004

and the

Directive 2006/95/EC relating to electrical equipment designed for use within

certain voltage limits as of 12 December 2006

Herewith we declare that the measuring systems

each comprising one converter of the series

Control 4000 (C4XXX with X=0..5); Control 8480
Fermenter Control (FCXX with X=0..2);
Haze Control (HC 4XXX, X=0..5)

and one or several sensors of the series

AF16, AF26, AF45, AF46, TF16-N, DTF16, ASD19, ASD25, AS16, AS56,
ACF60

have been developed, constructed and manufactured in conformity with the

mentioned EC directives.

Harmonized standards applied:

• EN 61326:2006 + Corrigendum 1 / June 2008

• EN 61010-1:2001 + Corrigendum 1 / November 2002
+ Corrigendum 2 / January 2004

Manufacturer: optek-Danulat GmbH, Emscherbruchallee 2, 45356 Essen,

Germany

Essen, 2011/05/12

Jürgen Danulat
Managing Director

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 Contacts

11 Contacts

For further inquiry, feel free to contact us or our distributing partners at

any time:

Germany USA
optek-Danulat GmbH optek-Danulat Inc.
Emscherbruchallee 2 N118 W18748 Bunsen Drive
45356 Essen / Germany Germantown WI 53022 / USA
Phone: +49-(0)201-63409-0 Phone: +1 262 437 3600
Fax: +49-(0)201-63409-999 Toll free call: +1 800 371 4288
E-Mail: info@optek.de Fax: +1 262 437 3699
E-Mail: info@optek.com

Netherlands Singapore
optek-Danulat bv optek-Danulat Pte. Ltd.
Grote Brugse Grintweg 12a 25 Int’l Business Park
4005 AH Tiel / Netherlands #05-109-f German Centre
Phone: +31-344-683800 Singapore 609916
Fax: +31-344-653950 Phone: +65 6562 8292
E-Mail: info@optek.nl Fax: +65 6562 8293
E-Mail: info@optek.com.sg

Russian Federation China

optek-Danulat GmbH optek-Danulat GmbH
St.-Petersburg Rep. Office Shanghai Rep. Office
Kolomjazhskij Pr.33-A Room 718 Building 1
Office 911 No. 88 Keyuan Road
197341 St. Petersburg Pudong Zhangjiang
Phone: +7 812 380 72 47 Shanghai, China 201203
Fax: +7 812 380 72 05 Phone: +86 21 2898 6326
E-Mail: info@optek-danulat.ru Fax: +86 21 2898 6325
E-Mail: info@optek-danulat.com

Российская Федерация
Представительство ООО
«оптек-Данулат ГмбХ»
Коломяжский пр-кт, д. 33-A, 88
офис 911 718
197341, г. Санкт-Петербург, :201203
Российская Федерация :+86-21-28986326
Тел.: +7 812 380 72 47 :+86-21-28986325
Факс: +7 812 380 72 05 E-Mail: info@optek-danulat.com
E-Mail: info@optek-danulat.ru

Please visit our website for contacts of our local distributors in other countries.

www.optek.com

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