Berthold InlineSENS Duo Series User manual

InlineSENS - Density Measuring Unit
LB 4700-5x
Operating Manual
56926-5BA2
Rev. No.: 00, 04/2021
Embedded Software as of vers. XX.00.00

BERTHOLD TECHNOLOGIES GmbH & Co. KG
Calmbacher Str. 22
75323 Bad Wildbad, Germany
www.berthold.com
Telephone [phone]
Fax [phone]
industr[email protected]

LB 4700-5x Table of Contents
56926-5BA2, Rev.00, 04/2021 1
Table of Contents
1General Information ........................................................................................... 2
Applicable Documents ................................................................................................. 2
Conformity and Certificates......................................................................................... 2
Symbols Used on the Device ........................................................................................ 2
About this Operating Manual ..................................................................................... 3
Structure of the Operating Manual ............................................................................ 5
Structure of Warnings .................................................................................................. 6
2Safety .................................................................................................................. 7
Dangers and safety measures ...................................................................................... 7
Proper Use ..................................................................................................................... 7
Ambient Conditions during Operation and Storage ................................................. 8
Qualification of the Personnel .................................................................................... 9
Radiation Protection .................................................................................................. 11
Emergency Procedure................................................................................................. 13
Operator's Obligations............................................................................................... 14
3System Description............................................................................................ 15
Overview ..................................................................................................................... 15
Pressure Equipment Directive.................................................................................... 16
Measuring Principle.................................................................................................... 17
Radioactive Source ..................................................................................................... 19
System Components InlineSENS with 241Am ............................................................. 21
System Components InlineSENS with 244Cm.............................................................. 23
4Installation ........................................................................................................ 24
Safety Instructions ...................................................................................................... 24
General Instructions ................................................................................................... 25
Preparing the Installation .......................................................................................... 25
Unpacking / Scope of Delivery................................................................................... 26
Selection of Measuring Site ....................................................................................... 26
Installation instructions for InlineSENS versions with PTFE lining .......................... 27
Installation of the InlineSENS with 241Am ................................................................. 28
Installation of the InlineSENS with 244Cm.................................................................. 28
Installation of the Resistance Thermometer Pt 100 ................................................. 29
Water Cooling............................................................................................................. 29
5Electric Installation ........................................................................................... 31
6Operation.......................................................................................................... 32
Operating Concept..................................................................................................... 32
Detector Code............................................................................................................. 32
Measuring Path........................................................................................................... 32
7Maintenance and Repair................................................................................... 33
Visual Inspection......................................................................................................... 33
Leak Test Source Container ....................................................................................... 34
Checking the Pipe....................................................................................................... 34
Repair .......................................................................................................................... 34
8Decommissioning .............................................................................................. 35
Disposal of radioactive Substances............................................................................ 36
Shipment of radioactive Substances ......................................................................... 36

1 General Information
LB 4700-5x
256926-5BA2, Rev.00, 04/2021
1General Information
Applicable Documents
This manual of the density measuring device InlineSENS contains the following doc-
ument:
•Technical Information, Mat. No. 56926-5TI
This manual applys as an addition to the following documents:
•Safety Manual / Explosion Protection Manual LB 4700, Mat. No. 56926BA26
•Operating Manual LB 4700, Mat. No. 56926BA2
•Technical Information LB 4700, Mat. No. 56926TI
Conformity and Certificates
For the original declaration of conformity and the certificates of the detector,
please refer to the technical information Mat. No. 56926TI and safety manual / ex-
plosion protection manual Mat. No. 56926BA26.
Symbols Used on the Device
Observe the operating manual
Please observe the instructions in this operating manual.
Electrostatic discharge
Please note the handling instructions. Electrostatically endangered compo-
nents. Please observe the instructions in this operating manual.
Protective earth connection
At this position, connect the protective earth conductor (PE).
Equipotential bonding connection
At this position, connect the equipotential bonding conductor.
No domestic waste
The electric product must not be disposed of in domestic waste.
Ionising radiation
The shield is equipped with a radioactive source. Please note the handling
instructions. Please observe the transport instructions in this operating man-
ual.

LB 4700-5x
1 General Information
56926-5BA2, Rev.00, 04/2021 3
About this Operating Manual
The product is handed over to you by the manufacturer BERTHOLD TECHNOLOGIES
GmbH & Co. KG (hereinafter referred to as Berthold) in a complete and function-
ally reliable condition.
This operating manual illustrates how to:
•set up/install the product
•establish the connections to the power supply
•perform measurements
•apply software settings
•carry out maintenance on the product
•fix errors
•disassemble the product
•dispose of the product
Read these instructions thoroughly and completely before working with the prod-
uct. We have tried to compile all information for safe and proper operation for
you.
However, should questions arise which are not answered in this operating manual,
please contact Berthold.
Store the instructions where they are accessible for all users at all times.
Validity of the Operating Manual
The operating manual is valid from the delivery of the Berthold product to the user
until its disposal. Version and release date of this operating manual can be found
in the bottom of each page. Modification service is not performed by the manu-
facturer Berthold.
The manufacturer reserves the right to make changes to this operating manual at
any time without stating reasons.
NOTICE
The current revision of this operating manual replaces all previous versions.
Target Group
This operating manual is directed at qualified specialist personnel who are familiar
with handling electrical and electronic assemblies as well as with communication
and measuring techniques.
Specialist personnel refers to those who can assess the work assigned to them and
recognise possible dangers through their specialist training, knowledge and expe-
rience as well as knowledge of the relevant regulations.

1 General Information
LB 4700-5x
456926-5BA2, Rev.00, 04/2021
Storage Place
This operating manual as well as all product-related documentation relevant to the
respective application must be accessible at all times near the device.
Copyright
This operating manual contains copyright-protected information. None of the
chapters may be copied or reproduced in any other form without prior authorisa-
tion from the manufacturer.

LB 4700-5x
1 General Information
56926-5BA2, Rev.00, 04/2021 5
Structure of the Operating Manual
This operating manual has been divided into chapters. The order of the chapters
should help you to quickly and properly familiarise yourself with the operation.
Symbols Used
NOTICE
If this information is not observed, deterioration in the operation and/or prop-
erty damage may occur.
IMPORTANT
Sections marked with this symbol point out important information on the
product or on handling the product.
Tip
Provides tips on application and other useful information.
General warning symbol
Warning symbol electrical shock
Warning symbol suspended load
Warning of radioactive substances
Wear protective helmet
Wear safety shoes

1 General Information
LB 4700-5x
656926-5BA2, Rev.00, 04/2021
Structure of Warnings
Signal Word
Source and consequence
Explanation, if required
Prevention
In case of emergency
•Warning symbols: (warning triangle) draws attention to the hazard.
•Signal word: indicates the severity of danger.
•Source: specifies the type or source of danger.
•Consequence: describes the consequences of non-compliance.
•Prevention: states how one can avoid the hazard.
•In case of emergency: specifies which actions are required in the event of
the occurrence of risk.
In this manual, warning instructions before instructions for action refer to risks of
injury or damage to property. The hazard-prevention measures described must be
observed.
DANGER
Indicates an
imminent
, major hazard, which will certainly result in serious inju-
ries or even death if the hazard is not avoided.
WARNING
Indicates a
potential
hazard, which can result in serious injuries or even death
if the hazard is not avoided.
CAUTION
Refers to a
potentially dangerous
situation, which can result in medium or mi-
nor physical injuries or damages to property, if it is not avoided.

LB 4700-5x
2 Safety
56926-5BA2, Rev.00, 04/2021 7
2Safety
Dangers and safety measures
•Read these instructions and all applicable documents thoroughly and com-
pletely before working with the product.
•Store the instructions where they are accessible for all users at all times.
Proper Use
The InlineSENS is used along with an appropriate transmitter of Berthold to meas-
ure the radiation intensity as part of a radiometric measurement.
The system was developed for the measurement of the density of liquids, suspen-
sions, turbidity and bulk solids and may be used exclusively for this purpose.
The measuring system InlineSENS contains a radioactive source. The notes on radi-
ation protection contained in the present manual as well as any statutory require-
ments in this respect are to be strictly adhered to.
The following constitutes proper use:
•Strictly adhering to the instructions and procedural sequences and perform no
unauthorised third-party actions that endanger your safety and the functional
efficiency of the measuring system!
•Observing the provided safety instructions!
•Carrying out the prescribed maintenance measures or having them carried out
for you!
Improper Use
•Failing to observe the specified safety instructions and instructions for the op-
eration, maintenance and disposal in the manual.
•Any non-compliance with the present manual for the supplied products.
•Applying conditions and requirements which do not conform to those stated in
the technical documents, data sheets, operation and assembly instructions and
other specific guidelines of the manufacturer.
•Using the product in a damaged or corroded condition.
•Restructuring or changing the system components.
•Using the product with
oopen or not properly closed cover,
oimproperly closed entries,
oinsufficiently tightened or damaged screw connections i.e. cable glands,
adapters or blind plugs1.
•Operation without the safety precautions provided by the manufacturer.
1blanking elements acc. to IEC 60079

2 Safety
LB 4700-5x
856926-5BA2, Rev.00, 04/2021
•Manipulation or avoidance of existing safety equipment.
Berthold shall only accept liability for/guarantee the conformity of the device to its
published specifications.
If the product is used in a way which is not described in the present manual, the
device's protection is compromised, and the warranty claim becomes invalMat.
Ambient Conditions during Operation and Storage
The compliance with the operating conditions specified contributes to guarantee-
ing the permanent functionality of the measuring system and the prevention of
damage (see document “Technical Information”).
Measuring systems containing radioactive substances and sources are to be stored
in a lockable storage room complying with the national requirements as regards
the storage of radioactive substances.
Highly combustible or explosive substances must not be kept in the vicinity of meas-
uring system in order to prevent a fire from spreading to the radioactive sub-
stances.
The measuring system must be stored dry (no condensation), dark (no direct sun-
light) in a clean, lockable room. Furthermore, the ambient conditions in the docu-
ment “Technical Information” Mat. No. 56926-5TI (see appendix) are to be ob-
served.

LB 4700-5x
2 Safety
56926-5BA2, Rev.00, 04/2021 9
Qualification of the Personnel
NOTICE
A minimum requirement for all work on or with the product would be employ-
ees with general knowledge who are instructed by an expert or authorised per-
son.
At different parts in this operating manual, reference is made to groups of people
with certain qualifications who can be entrusted with different tasks during instal-
lation, operation and maintenance.
These three groups of people are:
•Employees with General Knowledge
•Experts
•Authorised Persons.
Employees with General Knowledge
NOTICE
Employees with general knowledge must always be guided by an expert at the
very least. When dealing with radioactive substances, a radiation safety officer
must also be consulted.
Employees with general knowledge are e.g. technicians or welders, who can un-
dertake different tasks during the transportation, assembly and installation of the
product under the guidance of an authorised person. This can also refer to con-
struction site personnel. The persons in question must have experience in handling
the product.
Experts
Experts are persons who have sufficient knowledge in the required area due to
their specialist training and who are familiar with the relevant national health and
safety regulations, accident prevention regulations, guidelines and recognised
technical rules.
Expert personnel must be capable of safely assessing the results of their work and
they must be familiar with the content of this operating manual.
Authorised Persons
Authorised persons are those who are either designated for the corresponding task
due to legal regulations or those who have been authorised by Berthold for par-
ticular tasks. When dealing with radioactive materials, a radiation safety officer
must also be consulted.
Radiation Safety Officer
In order to ensure proper handling and compliance with the statutory require-
ments, the company has to appoint a radiation safety officer in accordance with
the applicable national law (in Germany: Strahlenschutzverordnung [German radi-
ation protection regulation]). The radiation safety officer must implement the stat-
utory radiation protection requirements in order to protect employees against
damage to their health caused by handling radioactive materials.

2 Safety
LB 4700-5x
10 56926-5BA2, Rev.00, 04/2021
NOTICE
Dangerous goods officers must not perform any activities as radiation protec-
tion officers!
Radiation protection officers must have a special training with attendance of
an officially recognized course and appropriate professional experience.

LB 4700-5x
2 Safety
56926-5BA2, Rev.00, 04/2021 11
Radiation Protection
This measuring system uses radioactive sources. The radiation protection infor-
mation in this operating manual and the relevant statutory provisions must be
strictly observed.
Basic Principles and Regulations
The amount of radiation absorbed by the body (exposure to radiation) is deter-
mined by three parameters from which the basic radiation protection regulations
can be derived:
Distance
If work close to equipment containing
radioactive substances is required, the
largest distance possible is to be kept.
In particular, this shall apply for em-
ployees which do not immediately par-
ticipate in such work.
Time
Any work required in the vicinity of ra-
diometric measuring systems is to be
prepared carefully and to be organised
in a way that the work can be executed
as quickly as possible. Here, providing
the correct tools and aids is particularly
important.
Shield
When mounting and dismounting the
shield, it is to be ensured in advance
that the radiation beam outlet is
closed.

2 Safety
LB 4700-5x
12 56926-5BA2, Rev.00, 04/2021
Exposure of Employees to Radiation
Work may only be executed according to the instructions and under the supervision
of the radiation safety officer, who furthermore has to calculate or estimate the
exposure of the employees to radiation in order to ensure that the statutory dose
rate limits are not exceeded.
If a radiometric measuring system is used as intended, the dose rate is so low that
it usually lies below the detection limit of dosimeters. Even if one has to work with
an unshielded source for a short time, the radiation dose can be limited through
good preparation of the work and by keeping a fairly large distance between body
and source, so that the body is exposed to a dose that is only a fraction of the
natural radiation exposure. Nevertheless, one should heed the legislator's require-
ment:
THE RADIATION EXPOSURE WHEN HANDLING RADIOACTIVE MATERIALS MUST BE
KEPT AS LOW AS POSSIBLE.
Theft Protection
Radioactive substances or equipment containing radioactive substances must be
secured in a way that they are protected against access by unauthorized persons.
In the case of firmly installed equipment containing radioactive substances, the
protection against unauthorized access is generally provided by the firmly attached
installation.
Measuring systems with radioactive sources which are decommissioned for a cer-
tain period of time must be dismounted and securely stored in a storage room
complying with the national regulations as regards the storage of radioactive sub-
stances.
Portable measuring systems must never be left unsupervised. When this equipment
is out of use, it is to be protected against access by unauthorised persons.
In the Case of Fire
The shield material can melt and leak from the shield if exposed to very high tem-
peratures for an extended period of time. During and after a fire, there is a risk of
major long-time consequences for your health due to the incorporation of lead as
well as a risk of increased radiation exposure.
When planning the use of radiometric measuring systems, constructional measures
ensuring fire prevention are to be provided.
In the case of fire, these measures limit the access to this area.
Avoid the incorporation by keeping sufficient distance.
Notify Berthold of the situation; you will promptly receive information on im-
mediate measures.

LB 4700-5x
2 Safety
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Emergency Procedure
In case of serious operational trouble, such as fire or explosion, which could ad-
versely affect the radiometric measuring facility, it cannot be ruled out that the
shielding efficiency or the stability of the source capsule have been impaired. In
this case, it is possible that persons in the vicinity of the shielding have been ex-
posed to higher levels of radiation.
If you suspect such a severe malfunction, the Radiation Safety Officer has to be
notified immediately. He will then investigate the situation immediately and take
all necessary provisions to prevent further damage and to avoid more exposure of
the operating staff to radiation.
The Radiation Safety Officer has to make sure that the measuring system is no
longer in operation and then take appropriate steps. He may have to inform the
authorities or contact the manufacturer or supplier of the measuring system.
If adequate know-how as well as suitable instruments are available, emergency
measures may be taken immediately. In this case, proceed as follows:
1. Locate the measuring system.
2. Check the function of the measuring system.
3. Check the efficiency of the measuring system by measuring the dose rate.
4. Secure and label radiation protection areas.
5. Secure the measuring system with source.
6. Document the event and estimate the possible radiation level to which the
persons involved were exposed.
If you suspect any damage to the source capsule, the following points have to be
observed as well:
1. Avoid contamination.
2. Take hold of source using a tool (a pair of pliers or a pair of tweezers) and put
both (source and tool) into a plastic bag.
3. Secure them behind an auxiliary shielding (concrete wall, steel or lead plate).
4. Check if the environment is free of contamination.
5. Make sure the radioactive waste is secured and disposed off in compliance
with the pertinent regulatory requirements.

2 Safety
LB 4700-5x
14 56926-5BA2, Rev.00, 04/2021
Operator's Obligations
The operator of the product must regularly train his personnel in the following
topics:
•Observation and use of the operating manual and the legal provisions.
•Intended operation of the product.
•Observation of the plant security instructions and the operating instructions
of the operator.
•Regular monitoring/maintenance of the product.

LB 4700-5x
3 System Description
56926-5BA2, Rev.00, 04/2021 15
3System Description
Overview
The radiometric density measuring system InlineSENS offers the possibility to meas-
ure the density of
•liquids,
•suspensions,
•slurries and
•bulk goods.
The measurement can be carried out directly in a product line (Fig. 1, Pos.7). The
measurement is independent of variations in pressure or viscosity, and on the flow
rate of the product.
1
2
3
Transmitter LB 474
Connection cable
Scintillation detector
4
5
6
7
Resistance thermometer Pt 100 (optional)
Implemented measuring pipe
Radioactive source
Product line
Fig.
1 Exemplary measuring arrangement
Specific device configurations and calculations allow you to adapt the InlineSENS
to local conditions and the conditions of the product being measured.

3 System Description
LB 4700-5x
16 56926-5BA2, Rev.00, 04/2021
The measuring device comprises the following components:
•the InlineSENS with
-radioactive source
-pipe for the product to be measured
-detector
•the transmitter
•the connection cable
•the resistance thermometer Pt 100 (optional)
The detector's supply voltage, the measurement signal and important information
(high voltage setting, detector temperature, product temperature with connected
Pt 100, etc.) are transmitted from the detector to the transmitter via connection
cable.
Pressure Equipment Directive
Pressure Equipment Directive 2014/68/EU
The InlineSENS is manufactured and put on the market in accordance with the Pres-
sure Equipment Directive 2014/68 / EU. Due to its design (DN 65, DN 50 and DN 40)
the InlineSENS falls under Article 4 (3) of the Pressure Equipment Directive. The
device can only be used for measurements of liquids.
•The maximum operating pressure is 10 bar
•The maximum operating temperature is 100°C
•The maximum product temperature for the version without lining is 120°C
•For the version with polypropylene lining, observe the temperature / pressure
table (see document “Technical Information”)
Since different liquids, such as acids, alkalis, aggressive and abrasive media, are to
be measured, different linings (PTFE, rubber) are available to protect the imple-
mented product pipe. Observe the lower max. product temperatures in the docu-
ment "Technical Information". The responsibility of choosing the right lining lies
with the operator.
The InlineSENS is pressurized twice. The leak test is carried out with 2 bar air. To
improve the detectability of leaks and to protect personnel, the test is carried out
under water. The actual pressure test is carried out with 15.3 bar water.
As standard, the InlineSENS is equipped with water cooling. The connection of the
water cooling has the size R ¼". The maximum operating pressure is 6 bar. Only
clean cooling water may be used so that blockage or obstruction of the water cool-
ing can be excluded.
On request, material certificates according to EN 10204 3.1 and pressure test cer-
tificates can be issued.