ABB AP200 Series User manual

Rugged pH/Redox (ORP) Sensor Systems with
Rapid Temperature Response
for Critical Processes
AP200 Series
User Guide
IM/AP200_12

ABB
The Company
We are an established world force in the design and manufacture of instrumentation for industrial
process control, flow measurement, gas and liquid analysis and environmental applications.
As a part of ABB, a world leader in process automation technology, we offer customers
application expertise, service and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled
service and support.
The quality, accuracy and performance of the Company’s products result from over 100 years
experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.
The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants operated
by the Company, and is indicative of our dedication to quality and accuracy.
Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for
any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the
Technical Publications Department.
Health and Safety
To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the
information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/
or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures
must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be
obtained from the Company address on the back cover, together with servicing and spares information.
EN ISO 9001:2000
Cert. No. Q 05907
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No. 9/90A
0255
Stonehouse, U.K.

1
1DESCRIPTION .................................................................2
1.1 Introduction ..............................................................2
1.2 Systems....................................................................2
1.2.1 Typical Systems ...........................................2
1.2.2 AP120 Series Electrodes
Used with Holders .......................................2
2MECHANICAL INSTALLATION ....................................... 3
2.1 Installing the Systems ...............................................3
2.1.1 Model AP201 Insertion System ....................3
2.1.2 Model AP202 Inline System .........................4
2.1.3 Model AP203 Flanged Dip (Immersion)
System ........................................................5
2.2 Removing the Sensor Holder .................................... 6
2.2.1 Models AP201 Insertion and AP202 Inline
Systems.......................................................6
2.2.2 Model AP203 Flanged DIp (Immersion)
System ........................................................7
2.3 System Assembly ..................................................... 8
2.4 Jetwash System .......................................................9
2.5 Jetwash System Assembly .....................................10
3ELECTRICAL INSTALLATION ....................................... 11
3.1 Analyzer Connections ............................................. 11
3.2 Shortening the Connection Cable ........................... 11
3.3 Extending the Connection Cable .............................12
3.4 Jetwash System Connections .................................12
4CALIBRATION ...............................................................13
4.1 Method ...................................................................13
4.2 Buffer Solutions ...................................................... 13
4.3 Redox (ORP Sensor) ...............................................13
5MAINTENANCE .............................................................14
5.1 General Cleaning .................................................... 14
5.1.1 General Sludge and Loosely
Adhering Matter ......................................... 14
5.1.2 Heavy, Non-Greasy Deposits .....................14
5.1.3 Greasy or Organic Deposits ....................... 14
5.2 Fault Finding ........................................................... 14
5.3 Storing the Electrode .............................................. 14
6SPECIFICATION ............................................................15
7SPARES .........................................................................16
7.1 Model AP201 Insertion System ...............................16
7.2 Model AP202 Inline System ....................................17
7.3 Model AP203 Flanged Dip (Immersion) System ) ..... 18
CONTENTS

2
Dip (Immersion) System – AP203
In-line System – AP202
Insertion System – AP201
1DESCRIPTION
Fig. 1.1 System Schematics
1.2.2 AP120 Series Electrodes Used with Holders
AP121/11000 General process 0 to 14 pH, 0 to 100°C
AP121/21000 High temperature 0 to 14 pH, 0 to 130°C
AP121/31000 Low temperature 0 to 10 pH, –5 to +50°C
AP121/60000 Redox(ORP) platinum 0 to 100°C
See Section 6 – SPECIFICATION for full details
1.1 Introduction
This manual describes the installation and maintenance of the
AP200 Series Process pH and Redox (ORP) Electrode Holder
Systems.
1.2 Systems – Fig. 1.1
1.2.1 Typical Systems
•AP201 Insertion system
•AP202 In-line, flow-through system
•AP203 Dip (immersion) system

3
Fig. 2.1 Model AP201 Insertion System
Pipe-Mount System Tank-Mount System
ø50
327
(12.87)
100
(3.94)
15°min. from horizontal
Angled-Weld Socket
Allowable Mounting Position
15°min.
15°min.
90
(3.54)
G 1
1
/ 4
G 1
1
/ 4 G 1
1
/ 4
R 1
1
/ 4
ø25
50
(1.97)
40
(1.58)
ø25
ø36
ø25
ø36
1 in. NPT
or R 1in.
20
(0.78)
Mounting Adaptors
18
(0.71)
G 1
1
/ 4
or
1
1
/ 4 NPT
18
(0.71)
50
(1.97)
50
(1.97)
7690 130
PPS Ryton R1
1
/ 4 in. Adaptor
+
7690 134
PP 1
1
/ 4 in. NPT Adaptor
+
7690 129
PP R1
1
/ 4 in. Adaptor
7690 131
1in. NPT Stainless Steel
Mounting Adapter
+
7690 128
R1in. Stainless Steel
Adaptor
7690 132
DN25 Straight-Weld Socket
(316 SS)
7690 133
DN25 Angled-Weld Socket
(316 SS)
2MECHANICAL INSTALLATION
Note. When installing the Model AP201 insertion system,
ensure that the electrode is fully immersed in sample
under all operating conditions.
Dimensions in mm (in.)
2.1 Installing the Systems
2.1.1 Model AP201 Insertion System – Fig. 2.1
This system is designed to mount directly into a pipeline or tank. Mounting adaptors are available:
7690 130 PPS Ryton™ R 11/4in. adaptor 7690 128 R 1in. Stainless Steel adaptor
7690 134 Polypropylene 11/4in. NPT adaptor 7690 132 DN25 Straight-weld socket
7690 129 Polypropylene R 11/4in. adaptor 7690 133 DN25 Angled-weld socket
7690 131 1in. NPT Stainless steel adaptor

4
To ensure electrode
is always in sample
Isolating
Valve
Isolating
Valve
ø50
Rp 1 in.
Female Threads
Typical Installation
314
(12.36)
95
(3.74)
100
(3.94)
147
(5.79)
To prevent spillage
when system
is removed
90
(3.54)
76
(3)
(Polypropylene
versions only)
(Stainless Steel
versions only)
100
(3.94)
Minimum
clearance
required
Fig. 2.2 Model AP202 Inline System
…2 MECHANICAL INSTALLATION
2.1.2 Model AP202 Inline System – Fig. 2.2
This system is supplied with an inline tee-piece for mounting the system directly into a pipeline. Allow sufficient height above the
system to enable the sensor to be withdrawn from the tee-piece.
Dimensions in mm (in.)
Note. Refer to Section 6 – SPECIFICATION
for information about the different versions.

5
2.1.3 Model AP203 Flanged Dip (Immersion) System – Fig. 2.3
This system is designed to be installed over an unpressurized tank or channel. A sliding flange is supplied to enable adjustment of the
immersion depth. A suitable mounting bracket or support must be supplied by the user.
Fig. 2.3 Model AP203 Flanged Dip (Immersion) System
Typical Installation
Dimensions
Mounting Flange
100
(3.94)
90
(3.54)
1, 2 or 3 m
(39.37, 78.74, 118.11)
74
(2.91)
ø50
ø56
Mounting bracket
supplied by user
Thumb-screws
(see Note below)
Insert
2MECHANICAL INSTALLATION…
Note. Ensure the thumb-screws compress the
insert when clamping the flange to the dip tube.
Dimensions in mm (in.)

6
2.2 Removing the Sensor Holder
2.2.1 Models AP201 Insertion and AP202 Inline Systems – Fig. 2.4
…2 MECHANICAL INSTALLATION
Twist cable shroud
counter-clockwise
and remove
Unscrew sensor holder retaining
nut and remove sensor holder
from in-line adaptor
Check O-ring is in position,
located on underside of
electrode holder
AP201 AP202
1
Open cover and detach
cables and jetwash
tubing (if fitted) from cap
3
4
2
Fig. 2.4 Models AP201 and AP202 – Removing the Sensor Holder

7
2.2.2 Model AP203 Flanged DIp (Immersion) System – Fig. 2.5
2MECHANICAL INSTALLATION…
Open cover and detach
cables and jetwash tubing
(if fitted) from cap
Unscrew sensor guard
from dip tube (
see Note below )
2
1
3
Remove the sensor holder from the dip tube using the
sensor guard as a tool. Engage the sensor guard lugs in
the sensor holder slots. Twist the sensor holder
counter-clockwise to disengage the bayonet lugs from
the slots in the dip tube and withdraw the sensor holder.
Ensure the O-ring remains clean.
Fig. 2.5 Model AP203 – Removing the Sensor Holder
Notes.
•Before refitting the sensor
guard, clean and regrease
the threads and O-ring.
•Do not overtighten the
sensor guard.

8
…2 MECHANICAL INSTALLATION
11
Close cover
Locate cable shroud over
sensor holder and twist
clockwise to engage
bayonet lugs in slots
9
Clip cables and jetwash tube
(if required) into slots in
protective cover
1
Route cables and jetwash tube
(if required) through cable shroud
Tighten
Locate sensor
cable connector
over keyway
Connect earth
(ground)
terminal
to rod
8
Connect jetwash
supply tube
(if required –
see Section 2.5)
and tighten to
recommended
torque value of
60cNm
Ensure support washer
and O-ring are fitted to
electrode
2
4
6
3
Insert sensor in holder
Tighten to
recommended
torque value of
125cNm
7
5
10
Fig. 2.6 System Assembly
Note. Model AP201 shown. When
assembling Models AP202 and AP203,
refit the Tee piece to the sensor holder
(AP202) or the sensor guard to the dip
tube (AP203) – see Figs. 2.4 and 2.5.
2.3 System Assembly – Fig 2.6