ABB TB404 User manual

—
ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION | OI/TB404-EN REV. B
TB404
Toroidal conductivity sensors
TB404 – perfect for use in standard
to highly corrosive solutions
Measurement made easy
Introduction
TB404 toroidal conductivity sensors expand the
advancements in process conductivity
measurement initiated by ABB with 4-electrode
conductivity measurement. Unlike 4-electrode
sensors, toroidal sensors have no electrodes.
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TB404 conductivity
sensors

For more information
The Data Sheet for the TB404 toroidal conductivity sensors is
available for free download from:
www.abb.com/analytical
or by scanning this code:
Search for or click on:
Data sheet
TB404 toroidal conductivity sensors
DS/TB404-EN

Trademarks and Registrations
Registrations and trademarks used in this document include:
® Mylar
® Viton
® Tri-Clamp
™ PEEK
Registered trademark of E.I. DuPont de Nemours Company, Incorporated
Registered trademark of E.I. DuPont de Nemours Company, Incorporated
Registered trademark of Alfa Laval, Incorporated
Trademark of Victrex plc.

Preface
This publication is for the use of technical personnel responsible for installa-
tion of the ABB Type TB404 Toroidal Conductivity Sensor.
This instruction contains hardware installation instructions only. Wiring pro-
cedures, calibration procedures, etc., are covered in product instructions of
instruments compatible with the Type TB404 sensor.
Some sections of this instruction have been prepared in procedure format.
By treating each task as a separate entity, the procedures provide an easy
method for finding the information needed to perform each task. The proce-
dures can be removed and placed in separate folders or notebooks, or carried
to the job site.
The procedures have check boxes in the margin by each step. When per-
forming a procedure, check each box as each step is completed.
It is important for safety and operation that this instruction be read and
understood before attempting anything related to installation, operation,
maintenance or repair.

List of Effective Pages
Total number of pages in this instruction is 35, consisting of the following:
Page No. Change Date
Preface Original
List of Effective Pages September 11, 2006
iii through vi August 23, 2006
1-1 through 1-6 August 23, 2006
2-1 through 2-3 Original
3-1 Original
4-1 August 23, 2006
PR1-1 through PR1-2 August 23, 2006
PR2-1 through PR2-3 August 23, 2006
PR3-1 through PR3-5 August 23, 2006
PR4-1 through PR4-2 August 23, 2006
PR5-1 through PR5-3 August 23, 2006
PR6-1 through PR6-2 August 23, 2006
Index-1 Original
When an update is received, insert the latest changed pages and dispose of the superseded pages.

Table of Contents
Page
i
SECTION 1 - INTRODUCTION....................................................................................................1-1
OVERVIEW .....................................................................................................................................................1-1
INTENDED USER ...........................................................................................................................................1-1
SENSOR DESCRIPTION ................................................................................................................................1-1
SENSOR APPLICATION................................................................................................................................1-1
INSTRUCTION CONTENT ............................................................................................................................1-2
HOW TO USE THIS INSTRUCTION ............................................................................................................1-2
REFERENCE DOCUMENTS..........................................................................................................................1-2
NOMENCLATURE .........................................................................................................................................1-3
SPECIFICATIONS...........................................................................................................................................1-4
ACCESSORIES................................................................................................................................................1-6
SECTION 2 - INSTALLATION .....................................................................................................2-1
INTRODUCTION ............................................................................................................................................2-1
UNPACKING AND INSPECTION.................................................................................................................2-1
LOCATION CONSIDERATIONS ..................................................................................................................2-1
INSTALLATION PROCEDURES ..................................................................................................................2-3
SECTION 3 - REPAIR AND REPLACEMENT.............................................................................3-1
INTRODUCTION ............................................................................................................................................3-1
SECTION 4 - SUPPORT SERVICES...........................................................................................4-1
INTRODUCTION ............................................................................................................................................4-1
REPLACEMENT PARTS................................................................................................................................4-1
PROCEDURES
PR1 - SUBMERSIBLE ASSEMBLY
PR2 - IN-LINE FLOW ASSEMBLY
PR3 - HOT TAP ASSEMBLIES
PR4 - TWO-INCH SANITARY TRI-CLAMP ASSEMBLY
PR5 - REMOVING SENSOR FROM HOT TAP ASSEMBLIES
PR6 - SENSOR CLEANING
List of Figures
No. Title Page
2-1. Type TB4042 Sensor ................................................................................................................................2-2
2-2. Sensor Orientation Requirements .............................................................................................................2-3
PR1-1 Submersible Assembly ........................................................................................................................PR1-2
PR2-1 In-Line Assembly, Exploded View ......................................................................................................PR2-2
PR2-2 In-Line Assembly in Pipe or Tank Fitting ...........................................................................................PR2-3
PR3-1 Low Pressure Hot Tap Assemblies ......................................................................................................PR3-4
PR3-2 High Pressure Hot Tap Assembly ........................................................................................................PR3-5
PR4-1 Sanitary In-Line Flow Assembly.........................................................................................................PR4-2
PR4-2 Sanitary In-Line Flow Assembly with Tri-Clamp...............................................................................PR4-2
PR5-1 Low Pressure Hot Tap Assemblies ......................................................................................................PR5-2

List of Figures (continued)
No. Title Page
ii
PR5-2 High Pressure Hot Tap Assembly ........................................................................................................PR5-3
List of Tables
No. Title Page
1-1. Reference Documents .............................................................................................................................. 1-2
1-2. Nomenclature........................................................................................................................................... 1-3
1-3. Specifications........................................................................................................................................... 1-4
1-4. Accessories1 ............................................................................................................................................ 1-6
2-1. Installation Procedures............................................................................................................................. 2-3

iii
Safety Summary
SPECIFIC
WARNINGS
Always use the sensor guide when using the high pressure hot tap
assembly. The sensor guide is a tightly toleranced 1½ in.NPT nipple
that prevents adverse play between the insertion rod and the sensor
guide. Adverse play could damage the insertion rod and injure per-
sonnel. (p. PR3-2)
Never stand directly behind the insertion rod upon pressurization. If
the insertion rod is not fully retracted upon pressurization, it could
rapidly reach the blow out protection of the sensor assembly and
severely injure personnel standing too close behind the insertion
rod. (p. PR3-2)
Never exceed the sensor or sanitary clamp temperature and pres-
sure limits. Exceeding these limits can damage the equipment in
such a way as to pose the risk of injury to personnel. (p. PR4-1)
Firmly hold the insertion rod when loosening the compression fitting.
When the compression rod is loosened, the pressure against the sen-
sor assembly will cause the insertion rod to retract from the ball valve
assembly with great velocity. This could injure personnel standing in
the path of the retracting insertion rod. Allow only properly trained
personnel to handle these types of sensor assemblies. (p. PR5-1)
Open one of the flushing ports after the sensor is retracted and the
ball valve is closed. If a continuous stream of liquid exists, damage
to the ball valve or components can occur or may have already
occurred. This condition can cause a hazard to personnel upon
removal of the insertion rod. (p. PR5-1)
Consider the material compatibility between cleaning fluids and pro-
cess liquids. Incompatible fluids can react with each other causing
injury to personnel and equipment damage. (p. PR6-1)
Acids and bases can cause severe burns. Use hand and eye pro-
tection when handling. (p. PR6-1)
Use solvents only in well ventilated areas. Avoid prolonged or
repeated breathing of vapors or contact with skin. Solvents can
cause nausea, dizziness and skin irritation. In some cases, over-
exposure to solvents has caused nerve and brain damage. Sol-
vents are flammable - do not use near extreme heat or open
flame. (p. PR6-1)

iv
Safety Summary (continued)
THIS PAGE INTENTIONALL LEFT BLANK

OVERVIEW
1 - 1
SECTION 1 - INTRODUCTION
OVERVIEW
The Type TB404 Toroidal Conductivity Sensor Series monitors a wide vari-
ety of process liquids. The robust, encapsulated design of the sensor protects
the internal electronics from corrosive process solutions.
This instruction contains information on sensor installation only. For infor-
mation on maintenance, testing, troubleshooting, calibration and repair, refer
to the product instruction of the analyzer or transmitter used with the sensor.
INTENDED USER
This instruction is intended for use by technical personnel responsible for the
installation of the Type TB404 sensor.
SENSOR DESCRIPTION
The Type TB404 sensor employs an encapsulated design that makes it ideal
for aggressive and harsh process streams. The analyzers and transmitters for
which the sensor was designed measure moderate to high conductivity
streams.
The sensor is available with a submersible adapter that accommodates sub-
mersible installations such as tanks and open vessels or waterways. The
in-line flow assembly provides installation capability for pipelines and tanks.
There are also two types of hot tap assemblies available: Low pressure units
with either hand or wrench-tight compression fittings and high pressure
units. The high pressure units can be ordered with ball valves. Ball valves for
low pressure units must be ordered separately. Finally, there is a two-inch
sanitary sensor that provides installation capability for sanitary pipelines and
tanks with two-inch tri-clamp fittings.
SENSOR APPLICATION
The Type TB404 sensor is intended to provide measurements for process
monitoring and/or control applications.
Some typical applications include the measurement for display and control
of the conductivity of process fluid streams, boilers, pulping and sugar
liquor, concentrated chemical streams, clean-in-place systems, food and
pharmaceutical systems, brine, and solutions with heavy solids or high ionic
strength liquids.
INSTRUCTION CONTENT
This instruction consists of four sections and a set of procedures. After
becoming completely familiar with it and the sensor, it can be used as a ref-
erence.