ABB AP100 Series User manual

AnalyzeIT
pH/Redox (ORP) Cartridge Sensors
with Water-Wash Option
AP100 Series
Instruction Manual
IM/AP100_1

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.
Use of Instructions
Warning.
An instruction that draws attention to the risk of injury or
death.
Caution.
Aninstruction that drawsattentiontotheriskofdamageto
the product, process or surroundings.
✶
Note.
Clarification of an instruction or additional information.
Information.
Further reference for more detailed information or
technical details.
Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage,
it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded
process system performance leading to personal injury or death.Therefore, comply fully with all Warning and Caution notices.
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
Marketing Communications 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. Chemicalsmustbestoredawayfromheat,protectedfromtemperatureextremesandpowderskeptdry.Normalsafehandlingprocedures
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
R
E
G
I
S
T
E
R
E
D
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No.9/90A
0255
Stonehouse, U.K.

1
CONTENTS
1 INTRODUCTION ............................................................. 2
1.1 Purpose ............................................................... 2
1.2 Cartridges and Cartridge Systems ...................... 2
2 INSTALLATION............................................................... 4
2.1 Typical Installation ............................................... 4
2.2 Water Supply for Water Wash Systems .............. 5
2.3 Preparing the Electrode Cartridge....................... 6
2.4 Installing the Electrode Cartridge ........................ 6
2.4.1 In-line pH Systems .................................. 6
2.4.2 Submersible Systems (pH and Redox) ... 7
2.4.3 Dip Systems (pH and Redox).................. 8
2.4.4 Cable Termination ................................... 9
3 CALIBRATION ................................................................ 9
4 MAINTENANCE ............................................................ 10
4.1 General Cleaning .............................................. 10
4.2 Liquid Junction and Electrolyte Level ................ 10
4.2.1 Replacing Liquid Junction ..................... 10
4.2.2 Checking Electrolyte Level .................... 10
4.3 Storage of the Electrode.................................... 10
5 SPARES ........................................................................ 11

2
1 INTRODUCTION
1.1 Purpose – Figs. 1.1 and 1.2
This instruction manual describes the installation and
maintenance of the AP100 Series Industrial pH and Redox
(ORP) Electrode Cartridge Systems.
A – Electrode In-line System C – Offset Ported Flowcell System
1.2 Cartridges and Cartridge Systems
Fig. 1.1 shows schematic layouts for in-line and dip systems.
Fig. 1.2 shows unit dimensions and identifies cartridge system
installations.
epyTegdirtraC 101PAdehcatedelbaC,tenoyaB
201PAdehcattaelbaC,tenoyaB
301PAdehcatedelbac,ni-wercS
401PAelbisrembuS
sepyTrosneS 1/X01PA001ot0,ssalgdradnatS °Hp41ot0,C
2/X01PA001ot0,ssalgdradnatS °hsaWretaWsulpHp41ot0,C
3/X01PA07ot0,ssalgecnatsiserwoL °Hp11ot0,C
4/X01PA07ot0,ssalgecnatsiserwoL °hsaWretaWsulpHp11ot0,C
5/X01PA)PRO(xodeR
6/X01PAhsaWretaWsulp)PRO(xodeR
Fig. 1.1 System Schematics
Support Chain
Mains in
Current Output
Relays
Relays
Current Output
Mains in Mains in
Current Output
Relays Mains in
Current Output
Relays
Relays
Current Output
Mains in
Tube not supplied.
Water
Wash
from
Solenoid
Valve
D –Submersible System E –Typical Water Wash System
B –Electrode Dip System

3
…1 INTRODUCTION
Fig. 1.2 Overall Dimension in mm (in)
Ø 48 (1.875)
200 (7.875)
See note
176 (7)
86 (3.375)
See note
Ø 48
(1.875)
75 (3)
102 (4)
Note.Allow an additional 130 (5.125) for connectors
and cartridge removal.
1/2" BSPT
Female Thread
1" BSP or 1" NPT
Female Thread
AP101/2/3 –In-Line Flow System
Dimension A
(Overall Length)
Ø 63 (2.5)
Dimension A
7674 – 1060 (41.75)
7675 – 2060 (81.10)
7676 – 3060 (120.50)
AP103 –Dip System
Cable
Anchor point for
additional support
(light chain or
flexible cable)
Ø 48 (1.875)
176
(6.92)
101
(3.97)
Ø 27.9
(1.10)
AP104 –Submersible System
IN
OUT
3
/ 8 " NPT
Male Stud
Couplings
(not supplied)
40 (1.57) 62 (2.44)
115 (4.53)
216 (8.50)
Ø 65 (2.56)
AP101/2 –Offset Port In-Line System

4
2 INSTALLATION
2.1 Typical Installation
A typical installation is shown in Fig. 2.1, with offset ported
flowcell arrangements illustrated in Fig. 2.3. A recommended
installation for samples which may have entrained air or are
subject to intermittent flow is shown in Fig. 2.2.
Fig. 2.3 Installation of Offset Ported Flowcell Assembly
IN
OUT
3
/ 8 in NPT
Male Stud Couplings
(not supplied)
Clamp (Optional)
Recommended clamps
(not supplied)
Fig. 2.1 Typical Installation
To ensure that the cartridge
is always in solution.
To prevent spillage
when cartridge is
removed.
Sample Flow
Drain
Fig. 2.2 Recommended Installation for Samples with Entrained Air or Intermittent Flow
To prevent spillage when
cartridge is removed.
B
Approximately 15°
Vent
A
Point B must be lower than point A
to ensure that the cartridge is always
in solution. Drain

5
2 INSTALLATION…
Fig. 2.5 Location of Water Wash Nozzle
Sensor
Water Wash
Nozzle
Liquid
Junction
Note. It is advisable to use a
suitable hose clamp.
Fig. 2.4 Installing the Water Wash Water Supply
Install a suitable solenoid valve to
the mains water supply feed.
Connect a suitable length of 1/4in. i.d. p.v.c. tube to the outlet of the
solenoid valve. This tube terminates at the electrode installation point. Push the quick-fit
connector supplied, onto
the free end of the tube.
Note that the quick-fit
connector incorporates a
cut-off valve.
To water supply – see
Important Note and
Caution, above.
Suitable Solenoid Valve (user supplied)
2
1
3
2.2 Water Supply for Water Wash Systems –
Fig. 2.4 and 2.5
✶
Important Note. Installation must only be carried
out in accordance with the local water authority and
council bylaws.
Caution. The maximum water pressure at the
electrode should not exceed 4 bar.At NO time should the
sample pressure be allowed to exceed that of the water
wash water supply. Fit a non return valve if this possibility
exists.
Information. As all quick-fit connectors used in
Water Wash systems incorporate cutoff valves, tubes
may subsequently be disconnected on operational
equipment without sample loss or water wash discharge.
✶
Note. For optimum performance of the Water Wash
function in flow systems, the sample pressure should be
at least 2 bars lower than that of the water wash water
supply.
Thewatersupplyforthewaterwashsystemmustcomefrom a
suitable supply via a solenoid valve. The general specification
for the solenoid valve is:
Brass body: 2/2, NC
Orifice size: 3.0 / 4.0 mm
Port size: 1/8" – 1/4" BSP
Pressure: 0 to 6 bar
Coil: 110/115 V a.c. or 230/240 V a.c. 50/60 Hz
Before fitting the electrode cartridge system, install the water
supply as shown in Fig. 2.3.
Note. See Fig. 2.4 for recommended tubing.

6
2.3 Preparing the Electrode Cartridge –Fig. 2.6
✶
Important Note. Before preparing the electrode
cartridge, read through Section 2.4 to become familiar
with the appropriate installation procedure.
The procedure in Fig. 2.6A is appropriate for both pH and
redox (ORP) electrode cartridges. The cartridge is supplied
with a protective cap filled with a 7 pH buffer solution and
should not require pre-conditioning; it is ready for immediate
use.
…2 INSTALLATION
2.4 Installing the Electrode Cartridge –Fig. 2.6
Caution
• Ensure an ‘O’ ring is fitted to seal each cable connector.
• Tighten each plug to ensure a good seal. It is vital that
the terminations are kept dry at all times.
• Ensure the cable is fed through the dip system tube
beforethe cable isconnected.Toavoid theriskofdamp/
corrosive air damaging the cable plugs, connect to the
electrodes as soon as possible.
2.4.1 In-line pH Systems
a) Fit the flow cell into the pipeline observing all safety
precautions. Fit isolating valves where necessary to
enable safe access to the sensor for maintenance
purposes.
b) Ensure that all connections are tight.
c) Connectthetaggedend ofthecable tothe4600 SeriespH/
Redox meter – see Fig. 2.7 and Table 2.1.
Grey
Blue
Red White
Measuring
Electrode
Reference
Temp.
Comp.
Measuring
Electrode
Reference
Grey
Co-ax Inner
Co-ax Inner
A –pH Systems
B –Redox (ORP) Systems
Black
Fig. 2.7 Cable Termination –4600 Transmitters
Fig 2.6 Removing the Protective Cap
✶
Note. Retain protective cap and tape for future use.
Fit cartridge –
see Section 2.4.
5
6
Calibrate –
see Section 3.
3
Rinse with
demineralised
water.
Unwind adhesive tape.
Pull off
protective
cap.
12
Shake gently
to dislodge air
bubbles.
4

7
2 INSTALLATION…
elbaCmetsyS 40364653
gnirusaeM edortcelE )xaocforenni( 211
ecnerefeR )kcalb( 49
.pmoC.pmeT )der( 67
.pmoC.pmeT )etihw( 58
.pmoC.pmeT )der( 76
Table 2.1 Series 4600 Connection Equivalents
d) For cable detached versions
Fit the cable connector plugs to the matching colour
sockets – blue to blue, red to red, as appropriate. See Fig.
2.8 inset for tightening and releasing the connector plug.
e) Calibrate (pH only) – see Section 3.
f) For water wash versions
Snap on the water feed pipe from the solenoid valve – see
Fig. 2.9, and visually check water cleaning action by
switching on the water wash option on the 4600
transmitter. There should be a vigorous jet of water
sprayed across the glass membrane (pH), or platinum
(redox) .
g) Ensure that all pipeline connections are securely fitted.
Apply PTFE tape to the threads of the 1" NPT cartridges to
effect a water tight seal, and check that the ‘O’ ring and
sealing area are clean on bayonet cartridge versions.
h) Fittheelectrode cartridge totheflowcell (screw orbayonet
action) – see Fig. 1.2.Avoid excessive twisting of the cable
on screw-type cartridges by disconnecting the cable from
the electrode before screwing it into the flow cell.
Fit connector plug on completion.
2.4.2 Submersible Systems (pH and Redox)
a) Connect the tagged end of the cable to the 4600 Series pH
transmitter – see Fig. 2.8 and Table 2.1.
✶
Note. It is strongly recommended that a supporting
chain is attached to the anchor point to remove any strain
on the signal cable.
b) Calibrate (pH only)– see Section 3.
c) Immerse electrode into the solution to be measured.
1
Push on firmly
to connect.
To release, press
the metal catch
and the connector
is ejected.
2Quick-fit
Connector
Tube to
solenoid
valve
Fig. 2.9 Water Wash System –Quick-fit Connection
Fig. 2.8 Cable Termination –Electrode Connections
Red Measuring Electrode
Blue Temperature Compensator
Red Electrode
Push
down
firmly
One full turn
clockwise
to tighten
To Connect To Disconnect
One full turn
counter
clockwise to
slacken Pull
Off
2
1
1
2
A –pH Electrode Cable Termionation
B –Redox (ORP) Cable Termionation

8
2.4.3 Dip Systems (pH and Redox) –Fig. 2.10
…2 INSTALLATION
Fig. 2.10 Dip System Assembly
e. Push the end cap 6into the dip tube firmly,
tighten the gland nut !, and connect the cable
to the 4600 Series pH/redox transmitter (see
Fig. 2.8 and Table 2.1).
f. If a water wash system is fitted:
i) snap the quick-fit connector protruding from
the bottom of the dip tube, onto the cartridge
connector £. Also, snap on the water feed
pipe 7from the solenoid valve onto the
connector at the top of the dip tube.
ii) Visually check the water cleaning action by
switching on the water wash option on the
4600 transmitter. There should be a vigorous
jet of water sprayed across or onto the glass
or platinum.
iii) Also ensure that no leaks occur at the tube
connectors as they could cause damage to
the system.
g. Push the adaptor 4into the end of the dip
tube 0firmly to ensure a good seal.
h. Calibrate (pH only) – see Section 3.
a. Pull out the 'O' ring sealed end cap
6
from the dip
tube (If water wash has been ordered, there will be a
water wash tube connected to the connector insert @
in the cap.
b. Pull out the 'O' ring sealed adaptor 4from the other
end of the dip tube, and using PTFE tape on the
threads of the cartridge, screw the cartridge 1fully
into the adaptor 4.
Caution. It is essential that PTFE tape is used
around the thread on the cartridge to ensure a watertight
seal.
c. Fit the cable connector plug(s) 3to the matching
colour electrode socket(s) – blue to blue, red to red,
as appropriate – see Fig. 2.7A for pH and Fig. 2.7B
for Redox. See Fig. 2.7 inset for tightening and releasing
the connector plug(s).
d. Loosen the gland nut !in the end cap 6, and after
feeding the water wash tube (if fitted) down the dip
tube, thread the other end of the cable through the
dip tube and end cap cable gland 5.
Electrode Cable to
Transmitter
Water Wash Feed Pipe
from Solenoid valve
7
12
6
11
5
2
9
8
13
1
4
3
10
Note. The Water Wash delivery tube
9is supplied fitted to the connector insert
@. The tube also has hose clamps at both
ends.

9
…2 INSTALLATION 3 CALIBRATION
35mm (1.4")
Blue
Grey
35mm (1.4")
35mm (1.4")30mm (1.2")
Co-ax Inner
6 mm i.d Heat
Shrink Sleeving
3.2 mm i.d Heat Shrink Sleeving
Screen Trim back black conductive
layer to here
Co-axial Cable Preparation
Wire, 16/0.2, PVC covered,
soldered to screen
Fig. 2.11 Cable Preparation
When the electrode system has been correctly connected and
all electrical connections made to the associated pH
transmitter, the system is ready for calibration by either
immersing the electrodes (using suitably sized beakers):
a) in a calibration solution (buffer) of known pH value for
a single-point calibration,
or b) in two separate calibration solutions of known pH
values for a two point calibration.
For electrode systems in use:
1) Remove the electrode from the process or sample.
2) Wash the visible electrode surface with demineralised
water.
3) Proceed as described in the paragraph above.
Refer to the instruction manual for the pH transmitter for full
details of the calibration procedure.
Warning. Before removing any electrode from a
flowline,ensurethat anyisolating valveshave beenclosed.
Caution. It is important when buffering to ensure
thatthevisible surface of theelectrodeshasbeen cleaned
using demineralised water. Also ensure when moving
from one buffer solution to the next to wash the electrodes
and dry them carefully using a soft tissue.
✶
Note. For AP102 Series Cable Attached, and
AP104 Series Submersible cartridges, note the cable
colours and respective sleeves before proceeding.
If the provided standard length cable requires shortening, the
recommended preparation is as shown in Fig. 2.11.
Stripbacktheoverallcablesheathtomeasurementsasshown
andfitsuitablesoldertagsandsleevestotheendsofallleads,
for connection to the transmitter.
2.4.4 Cable Termination –Fig. 2.11

10
4 MAINTENANCE
Remove the liquid junction
using the key provided.
Screw in the old/new liquid
junction firmly.
Electrolyte
level
(bottom of
junction
thread)
O-Ring
1
2
Note. After removing
the liquid junction ensure that
the O-ring is still in place in the
filling hole before fitting the
liquid junction. If the O-ring is
missing, leakage of electrolyte
will occur.
Fig. 4.1 Removing/Replacing the Liquid Junction
4.2.2 Checking Electrolyte Level –Fig. 4.1
Periodicallycheck the levelofelectrolyte (approximatelyevery
three months) as follows:
a) Remove the electrode cartridge from the system.
b) Use the procedure in 4.2.1 to remove the liquid junction
observing necessary cautions and notes.
c) View the electrolyte level through the liquid junction hole
and top up to the bottom of the junction thread, if
necessary, using the pipette and electrolyte provided with
the replenishment kit.
d) Fit the liquid junction, or replace with a new one if
necessary, and install the electrode.
4.3 Storage of the Electrode
Caution. Failure to ensure the glass membrane
and reference element do not dry out may irreversibly
affect the response of the electrode.
If it is necessary to remove the electrode from the sample line,
fill the retained protective cap (see Fig. 2.6) with water and
cotton wool, or equivalent, and fit it to the cartridge.
4.1 General Cleaning
Warning. Before removing any electrode from a
flow line, ensure that any isolating valves have been
closed.
To ensure accurate monitoring, keep the electrodes free of
contaminants by periodic cleaning, the frequency of which
depends on the particular application.
4.2 Liquid Junction and Electrolyte Level
The procedures in this section are appropriate for both pH and
redox (ORP) electrode cartridges.
4.2.1 Replacing Liquid Junction –Fig. 4.1
Caution. Carry out the following procedure with
the cartridge inverted, as shown in Fig. 4.1, to prevent
spillage of the electrolyte.
✶
Note.
A tool for removing and fitting liquid junctions is provided
in the electrolyte replenishing kit (part no. 7670 088).

11
5 SPARES
Table 5.1 Spares List
metI.oNtraP dlOtraP.oN
segdirtraCtenoyaB
Hpssalgdradnats–001/101PA1010767
Hpssalgecnatsiserwol–003/101PA5010767
xodeR005/101PA1120767
Hpssalgdradnats–hsawretawhtiw002/101PA1030767
Hpssalgecnatsiserwol–hsawretawhtiw004/101PA5030767
hsawretawhtiwxodeR006/101PA1130767
segdirtraCniwercS
Hpssalgdradnats–001/301PA2010767
Hpssalgecnatsiserwol–003/301PA6010767
xodeR005/301PA2120767
Hpssalgdradnats–hsawretawhtiw002/301PA2030767
Hpssalgecnatsiserwol–hsawretawhtiw004/301PA6030767
hsawretawhtiwxodeR006/301PA2130767
segdirtraCdehcattAelbaC
ertem3–Hp301/201PA3070767
ertem5–Hp501/201PA5070767
ertem01–Hp011/201PA0170767
ertem3–xodeR305/201PA
ertem5–xodeR505/201PA
ertem01–xodeR015/201PA
segdirtraCelbisrembuS
ertem01–Hp011/401PA0060767
ertem03–Hp031/401PA4060767
ertem01–xodeR015/401PA0260767
ertem03–xodeR035/401PA4260767
serapSelbamusnoC rebmuNtraP
tnemhsibrufeRsgnir'O':gnisirpmoctiKM5.3,
,ettepip,etylortcelelCK&noitcnujdiuqil
yeknoitcartxe 8800767
serapSmetsyS
rotpadAtenoyaBdewercS3600767
tenoyaB–llecwolF1400767
dewercS–llecwolF2400767
)tenoyaB(gniR’O‘edortcelE0801120
gniR’O‘llecwolF7321120
gniR’O‘rotpadA9221120
gniR’O‘rotcennoCgulP2601120
tresnIenilepiP
1
/ 2 TPSB"0241067
tresnIenilepiP
1
/ 2 TPN"0341067
)lateca(llecwolFdetroPtesffO0710767
)leetssselniats(llecwolFdetroPtesffO0810767
)llecwolFdetroPtesffO(pmalClanoitpO5615120
seilbmessAelbaCdehcateD
ertem3–Hp3000767
ertem5–Hp4000767
ertem01–Hp5000767
ertem3–xodeR3100767
ertem5–xodeR4100767
ertem01–xodeR5100767
Table 5.2 Additional Spares for Water Wash
Systems Only
metI yfitnediot01.2.giFotrefer( )stekcarbnisrebmuntnenopmoc .oNtraP
rotcennoCenil-nItif-kciuQpaCdnE –)7(
1
/ 4 brab" 2156120
tresnIrotcennoCtif-kciuQpaCdnE tnuomlenaP–)21(
1
/ 8 brabesoh" 3156120
rotcennoCenil-nItif-kciuQegdirtraC –)8(
1
/ 8 brab" 4156120
3ro2,1:htgnelyficeps–)9(gnibuT sertem 1412120
evoba)9(gnibutrofpmalcesoH3615120

12

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Customer Support
We provide a comprehensive after sales service via a
Worldwide Service Organization. Contact one of the following
offices for details on your nearest Service and Repair Centre.
United Kingdom
ABB Limited
Tel: [phone]
Fax: [phone]
United States of America
ABB Inc.
Tel: [phone]
Fax: [phone]
Client Warranty
Prior to installation, the equipment referred to in this manual
must be stored in a clean, dry environment, in accordance with
the Company's published specification.
Periodic checks must be made on the equipment's condition. In
the event of a failure under warranty, the following
documentation must be provided as substantiation:
1. A listing evidencing process operation and alarm logs at time
of failure.
2. Copies of all storage, installation, operating and maintenance
records relating to the alleged faulty unit.

IM/AP100 Issue 1
ABB Limited
Oldends Lane, Stonehouse
Gloucestershire
GL10 3TA
UK
Tel: [phone]
Fax: [phone]
ABB Inc.
2175 Lockheed Way
Carson City
NV 89706
USA
Tel: [phone]
Fax: [phone]
ABB has Sales & Customer Support
expertise in over 100 countries worldwide
www.abb.com
The Company’s policy is one of continuous product
improvement and the right is reserved to modify the
information contained herein without notice.
Printed in UK (03.04)
© ABB 2004