galvanic MoniTurb-F User manual

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1
MANUAL
MoniTurb Turbidity Sensors
MoniTurb-F 12° Forward Scattered Light
MoniTurb-S 90° Side Scattered Light
MoniTurb-FS 12° / 90° Forward/Side Scattered Light
Version 1.8a
June 11, 2019

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2
Content
Content.......................................................................................................................................................... 2
Copyright ...................................................................................................................................................... 3
Before installation and start-up..................................................................................................................... 4
Installation guidelines ............................................................................................................................... 4
Safety instructions......................................................................................................................................... 5
General .......................................................................................................................................................... 7
What does turbidity mean ? ...................................................................................................................... 7
What causes turbidity ?............................................................................................................................. 7
Measurement of turbidity ?....................................................................................................................... 7
Measurement methods .................................................................................................................................. 8
Context between particle size, measurement method and results................................................................. 9
Typical Measurement units......................................................................................................................... 10
The dependencies on the different measurement units ........................................................................... 10
Typical ranges ............................................................................................................................................. 10
When, which measurement method............................................................................................................ 10
Maintenance ................................................................................................................................................ 11
Replacement of measurement lamp ........................................................................................................ 11
Replacement of gaskets........................................................................................................................... 15
Replacement interval............................................................................................................................... 18
Components model MoniTurb- F (12° scattered light)............................................................................... 19
Spare part list model MoniTurb- F (12° scattered light)............................................................................. 20
Components model MoniTurb- FS (12° / 90° scattered light).................................................................... 26
Components model MoniTurb- FS (12° / 90° scattered light) Ex- version ................................................ 27
Spare part list model MoniTurb- FS (12° / 90° scattered light).................................................................. 28
Connection model MoniTurb-F (12° scattered light) ................................................................................. 30
Connection model MoniTurb-S (90° scattered light) ................................................................................. 32
Connection model MoniTurb-FS (12° / 90° scattered light) ...................................................................... 34
Dimensional drawings................................................................................................................................. 35
Technical data model MoniTurb-F (12° scattered light.............................................................................. 44
Technical data model MoniTurb-S (90° scattered light) ............................................................................ 45
Technical data model MoniTurb-FS (12° / 90° scattered light) ................................................................. 46
Manufacturer’s Warranty Statement........................................................................................................... 46

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Copyright

2008 Galvanic Applied Sciences USA, Lowell, MA
This manual including all of its parts are protected by copyright.
Any further use beyond the copyright laws is not allowed without the approval of Galvanic Applied
Sciences.
There are no further reaching warranty claims to take because of the content of existing document.

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Before installation and start-up
Installation guidelines
•The sensor is manufactured according to the customer’s application (variable line size, flange
type, cleaning jets, gasket material etc.).
•It is recommended to run the calibration of the system before installation of the sensor.
•The location / installation of the sensor should be in a vertical standpipe.
•The process pressure should never exceed the specification of the delivered sensor.
•The process temperature should never exceed the specification of the delivered sensor.
•Avoid air and gas bubbles inside the sensor, they cause disturbances. Air and gas bubbles will
cause noise and drift of the measurement signal. (The air bubbles are not expected at pressures
upwards of 2 bar in aqueous solutions).
•In case the process temperature should fall under the dew point or rise above 85 °C purge the
sensor optic housings with dry instrument air (approx. 10 l/h). Condensed water and excessive
temperatures can damage the sensor and cause inaccurate measurements.
•Due to potential noise problems it is recommended not to extend the sensor cables.
•Due to potential noise problems use original Monitek sensor cables only.
•In case the optional cleaning jets are being used, make sure the pressure of the cleaning fluid is at
least 50% higher than the process pressure.
Danger:
Exceeding the specified maximum pressure and /or the specified maximum temperature
will cause a very high safety risk.
Please read the additional safety instructions before installation and start-up.
Page 5 and page 6 !

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Safety instructions
Pay attention to the following general safety instructions during use and operation of the system.
Ignoring these instructions or special warnings inside of this manual can damage the sensor, cause
inaccurate measurements, and possibly result in unsafe installations. Galvanic Applied Sciences will
not take any responsibility for consequences arising from ignoring the safety instructions and warnings.
Electrical installation
Qualified technical personnel must install the electrical installation of the system.
Hazardous area
DO NOT INSTALL the system in hazardous area without the optional Ex-proof equipment.
Operation of non Ex- proof systems in hazardous area will cause a high risk.
Using the system in hazardous areas (Ex Zone I / Ex Zone II) will only be safe with the
installation of the optional special Ex-proof designs including all required certifications.
Maintenance
Always disconnect the instrument from power during maintenance, replacement of components,
installation of additional components or any other operations at the open instrument.
Only qualified technical personnel must perform this work.
Operating the instrument with open enclosure
Only qualified technical personnel should operate the instrument when the enclosure is open
(e.g. during calibration procedure). Be careful that no moisture enters the enclosure.
Some components inside the instrument are energized with voltages, which can cause lethal shocks
in case of contact. Be careful during installation, handling and operation of the instrument.
Improper installation / operation of the system
Warranty is void if the system is installed improperly, handled improperly, used outside of the technical
specifications (of the instrument), or damaged by gross negligence.

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Storage
Please inspect the instrument immediately after receiving for potential shipping damages.
If the instrument has already been unpacked for inspection or testing, or if the instrument has been
removed from the process and it is not to be installed or reinstalled for more than 1 day, the following
procedure should be observed:
1. If the instrument has been in service, the wetted portion should be thoroughly cleaned (typically
with clean water) and than thoroughly dried.
2. The instrument should be placed in the original packing material.
In case the original packing material is not available place the instrument in a sealed heavy plastic
bag with a desiccant added to assure clean dry storage.
3. The instrument should then be stored in a protected area until time of installation.
Transport damage
Please inspect the instrument immediately after receiving for potential shipping damages.
For any claims to the transportation insurance or warranty repair, it is absolutely required to notify
transportation damages immediately after receiving the instrument. In case of obvious damages of the
outer packaging, the carrier must give a receipt for this damage to make demands for the insurance.
In case of a delayed announcement the insurance will not pay for damages and Galvanic Applied
Sciences will not assume liability for these damages.
Shipment of the instrument
Please clean the instrument carefully before shipment (e.g. for revision / repair). Please use fixed
packaging to protect the instrument against any shipping damages.
If at all possible the original packaging should be used.

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General
What does turbidity mean?
Turbidity is an “appearance” parameter, which describes the characteristic of a transparent product, to
scatter light. Turbidity is a measure of the amount of suspended “particles” in a solution (e.g. water).
Turbidity is the optical property that causes light to be scattered and absorbed rather than transmitted in
straight lines through the sample. A focused light beam will be attenuated and scattered in hazy products.
What causes turbidity?
Turbidity is caused by “particles” in transparent solutions. A particle is defined as something with a
different refractive index as the carrier product. As “particle” concentration increases in a solution, there
is greater the light scattering; this results in a greater turbidity measurement. Some examples of
“particles” are: minerals, clay, yeast cells, metals, oil drops in water, gas bubbles, aerosols, and milk in
water.
Measurement of turbidity?
Turbidity is not an absolute measurement parameter such as temperature or pressure.
For this reason turbidity measurement systems will typically be calibrated by using a reference
suspension standard such as formazin and diatomaceous earth.

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Measurement methods
The typical scattered light turbidity measurement methods are:
•Side scattering
(90°)
The detector is positioned in a right angle (90°) to the light beam.
•Forward
scattering
(12°)
The position of the detector is 12° shifted to the axis of the light.
beam
As shown in the figure above, an intense collimated beam of light is projected through a sample contained
within the sensor. The intensity of this light beam is measured by the direct beam detector, which is
positioned opposite the light source.
A scatter light detector measures the light scattered by the particles in the sample.
Depending on sensor specification, this detector can be located 12° or 90°, displaced from the direct light
axis.
The signals caused by scattered and direct light will be amplified, divided and then processed by the electronics. The result
displayed is the turbidity value.
Turbidity
signallightDirect
signallightScatterd =
The particles inside the flowing liquid decrease the intensity of direct light beam while increasing the intensity of the scattered
light (i.e. the turbidity rises).
Color decreases the intensity of direct and scattered light in the same ratio, therefore the turbidity value is
constant.
Lamp ageing and window coatings are compensated as well by this ratio.
Comparing the different measurement methods
The two different measurement methods (12° forward scattering / 90° side scattering) are not comparable.
Even when you use the same calibration standard to calibrate the systems, different samples will have
different measurement results.
The deviations of the results are caused by the different particle size distributions within different
samples. The measurement methods will respond differently, depending on the current particle
distribution of the actual sample.
Important note:
When comparing measurement results. The same methods must be compared to one another.
For example, 90 vs. 90, 12 vs. 12. Never 90 vs. 12.

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Context between particle size, measurement method and results
The most common Calibration standard for turbidity is based on formazin liquid.
When using formazin as calibration standard, defined formazin suspensions should display identical
measurement results with both methods: 12° and 90°.
During observation of a real sample, such as filtered beer, the different methods will have different
measurement results. The measurement results of the 90° side scatter method are typically a factor of 3 to
10 times greater than the measurement results of the 12° forward scatter method.
There are typically a lot of small particles left inside the filtered beer, such as proteins, etc. This colloidal
turbidity will be overvalued with the 90° method, due to the fact that this method is affected more by the
quantity of the particles rather than the particle size. The 12° forward scatter method is affected more by
particle size.
90° method: small particles and large particles will cause comparable scatter light intensities.
12° method: small particles / low scatter light intensity, large particles / high scatter light intensity.
At a particle size of approx. 0.3 µm (formazin) both methods will have approximately equal scatter light
intensities.
The combination of both measurement results informs about the tendency of the particle size distribution.
Measurement value 90°, greater than the measurement value 12°, average particle size smaller as 0.3 µm
Measurement value 90°, less than the measurement value 12°, average particle size larger as 0.3 µm
Particle size Result 90° scatter light Result 12° scatter
Larger 0.3 µm Lower value Higher value
Smaller 0.3 µm Higher value Lower value
Example filtration control:
90° side scatter:
Small particles (e.g. proteins, colloids, etc.) within the filtered beer will be monitored perfectly by the
using the 90° instrument. Using 90° scatter technology, there will be a delay in detecting a filter
breakthrough, since there will be small number of large particles within the filtrate during the initial
stages of filter breakthrough. The total amount of particles will be raised slightly; therefore the
measurement value will be raised slightly as well.
12° forward scatter:
Small particles (e.g. proteins, colloids, etc.) within the filtered beer can be monitored well by the using
the 12° instrument. The beginning of a filter breakthrough will be monitored immediately due to the large
particles (e.g. DE, yeast cells, etc.) within the filtrate. The few large particles will be monitored
immediately and the measurement value will rise sharply. This is also a mass related measurement
principle, which will allow calibration in mg/l if necessary.

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Typical Measurement units
ppm:
Parts per million
FNU1:
Formazin nephelometric unit
FTU:
Formazin Turbidity Unit
mg/l:
Milligram per liter
TEF:
Trübungseinheiten Formazin (German for
FTU)
gr/l:
Gram per liter
EBC:
European brewery convention
% TS:
Percent total solids
NTU1:
Nephelometric turbidity unit
The dependencies on the different measurement units
1 FTU = 1 TEF = 1 NTU1 = 1 FNU1 = 0,25 EBC
1 Nephelometry describes the method of side scatter turbidity measurement; these units are used at 90° side scatter turbidimeters only.
Based on correlation studies, using a 12° forward measurement system we have found the following
dependencies:
1 FTU = 1 TEF = 0.25 EBC = 2.25ppm = 2.05 mg/l = 0.00205 g/l = 0.00000205 % TS
* At a specific particle weight of 1 kg/dm, 1mg/l particles in 1 kg of water will correspond to 1 ppm.
Typical ranges
The original design of scatter light turbidimeters was used for the detection of low turbidities. The
resolution of these kinds of instruments is suited easily in ranges lower as 0.1 ppm (approx. 0.05 TEF /
FTU / FNU / NTU or approx. 0.01 EBC) and better. The maximum range is 200 ppm (500 ppm for some
applications; there are some systems available with a range of more than 8000 ppm.
Which measurement method to use
The 12° forward scatter method:
The forward scatter method is typically used at low turbidities and produces nearly mass related
measurement results. Main applications are quality control, filtration control, oil in water, etc.
The 90° side scatter method:
The side scatter method is also used at low turbidities. This principle of measurement will produce
measurement results related to the number of particles in the product.
The main application is the observation of small, well-distributed particles e.g. beyond a filter. The
second typical application is the monitoring of potable water as well as wastewater according ISO7027 or
according to the US- FDA requirements.
The measurement results of a 90° scatter light system has to be interpreted carefully, since turbidity
caused by many large particles can show a similar measurement result as a turbidity caused by the same
quantity of small particles.
The combined 12°/ 90° forward- / side- scatter method:
The 12° measurement method has greater sensitivity with large particles. The 90° measurement method has greater sensitivity
with small particles. The most common application for the combined systems is filtration control. A filter break through is
recognized early, with the 12° forward scattered instrument. A small quantity of big particles inside the filtrate will raise the
12° measurement value significant.
The 90° side scattered method exhibits only a small increase of the turbidity measurement values when
some large particles pass the filter. Detection of a filter breakthrough would be delayed, since the number
of particles will not increase significantly when the filter starts to break.
Please note:
The combination of forward- and side- scatter turbidity measurement does not replace a particle size
analysis, but it can provide a tendency of the particle size distribution.

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Maintenance
Replacement of measurement lamp
Introduction
Ignoring of the following hints will cause a loss of warranty
Qualified technical personnel must perform repair and maintenance.
Before beginning any work the sensor must be cleaned and flushed thoroughly. Depending
on customers’ application product residues can be very dangerous (aggressive, poisonous).
Please handle the system very careful due to possible leakage etc.
Avoid pulling and twisting of the lamp cable.
Avoid applying excessive force during assembling and disassembling of the sensor.
Screw in all bolts and cable glands stalwart only.
Please work carefully during the replacement of the measurement lamp.
The lamp replacement should be done in a dry and clean location, to protect the optical
components from dirt.
Please be sure that no dust or other particles penetrates into the optical assembly.
Do not touch the lenses.
In case of dirty component please clean carefully by using fresh water and a cloth (lint-free),
dry all components by using instrument air.
Use suitable tools only.
Required tools:
-Special Monitek lamp spanner wrench
-2 x open end wrench - 22 mm
-Flat blade screwdriver - 2 mm
-Phillips screwdriver – medium size
-Hexagonal spanner – 1.5 mm
-Hexagonal spanner – 2.5 mm
-Needle nose pliers – small
-Small bowl to drop components
Picture 1
The lamp cable is marked with “lamp”
1. Please loose the upper hexagonal nut of the cable gland
by using a 22 mm open-end wrench. Use the second
22 mm open-end wrench to hold the lower hexagonal
nut of the cable gland in position.
This will assure that you do not twist the lamp cable.

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2. Remove Allen screws and / or air purge connectors.
Picture 2
Picture 3
3. Screw off lamp arm.
4. Shift the lamp arm until you have access to the
electrical/cable connections.
Picture 4
5. Loosen all wires of the lamp cable by using the 2 mm
flat blade screwdriver.
Remove lamp arm and cable carefully.
6. Loosen Allen screws (3x) by using the 1.5 mm
hexagonal spanner.
7. Remove lamp assembly carefully.
Important: See Pictures 3, 4 and 5. We recommend removing
the lamp assembly and performing the lamp
replacement procedure in a dry and clean location.
Picture 5
Picture 6
8. Remove screws by using the medium size Phillips
screwdriver.
9. Carefully remove the printed circuit board including
cable and socket from the measurement lamp.
Picture 7

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Picture 8
10. Remove screw joint carefully by using the special
Monitek lamp spanner wrench..
11. Pull out the measurement lamp carefully by using the
small needle nose pliers.
Important: Avoid extreme force in pulling out the lamp.
Picture 9
Picture 10
12. Adjust the pins of the new lamp before installation of
the new measurement lamp by using the lamp socket.
This will allow an easy final assembly of the
components
13. Remove plug from the measurement lamp and push the
lamp into the barrel.
Picture 11
Picture 12
14. Screw in the screw joint and tighten it by using special
Monitek lamp spanner wrench.
15. Push the plug carefully onto the contact pins of the
lamp.
Picture 13

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Picture 14
16. Put the printed circuit board to the barrel and screw on
by using the medium sized Phillips screwdriver.
17. Reconnect the wires of the lamp cable and perform a
lamp test.
Picture 15
Picture 16
Important:Please pay attention to the position of the optical
assembly. The three grooves on the outside of the
barrel must be in line with the three Allen screws.
18. Push the optical assembly into the holder.
19. Tighten Allen screws (3x)
20. Push lamp arm to the thread.
21. Tighten lamp arm.
Picture 17
Picture 18
22. Tighten cable gland
23. Screw in Allen screws and / or air purge connectors
24. Functional test and eventual calibration.
Picture 19

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Replacement of gaskets
Introduction
Ignoring of the following hints will cause a loss of warranty
Qualified technical personnel must perform repair and maintenance.
Before beginning any work the sensor must be cleaned and flushed thoroughly. Depending on
customers’ application product residues can be very dangerous (aggressive, poisonous). Please
handle the system very carefully due to possible leakage etc.
Avoid pulling and twisting of the lamp cable.
Avoid applying excessive force during assembling and disassembling of the sensor.
Screw in all bolts and cable glands stalwart only.
Please work carefully during the replacement of the measurement gaskets.
The lamp replacement should be done in a dry and clean location, to protect the optical
components from dirt.
Please be sure that no dust or other particles penetrates into the optical assembly.
Do not touch the lenses.
In case of any dirty component please clean carefully by using fresh water and a cloth (lint-
free), dry all components by using instrument air.
Use suitable tools only.
Required tools:
-2 x open end wrench - 22 mm
-Flat blade screwdriver - 2 mm
-Hexagonal spanner – 1.5 mm
-Hexagonal spanner – 2.5 mm
-Hexagonal spanner – 3.0 mm
-Small bowl to drop components
Picture 1
1. Please loose the upper hexagonal nut of the cable gland by
using a 22 mm open-end wrench. Use the second
22 mm open-end wrench to hold the lower hexagonal nut
of the cable gland in position. This will assure that you do
not twist the lamp cable.
2. Remove Allen screws and / or air purge connectors.
Picture 2

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Picture 3
3. Screw off lamp / detector arm.
4. Shift the lamp / detector arm until you have access to the
electrical/cable connections.
5. Loosen all wires of the lamp cable by using the 2 mm
flat blade screwdriver.
6. Remove lamp arm and cable carefully.
Picture 4
Picture 5
7. Loosen Allen screws (3x) by using the
1,5 mm hexagonal spanner.
8. Remove lamp assembly carefully.
9. Loosen Allen screws (6pc. M4 x 16 [DIN 912]) by using
the 3 mm hexagonal spanner.
Picture 6
Picture 7
10. Carefully remove sapphire window out of the window
holder.
Important note:
If the window sticks in the holder, remove the holder first
(Step No. 11) after that carefully push the window out of it’s
sealing.
11. Remove the window holder carefully out of the flow cell.
Important note:
If the holder sticks inside the flow cell, please use the mounting
screws to push the holder out of its sealing. Please make sure that
the holder does not tilt during this procedure.
Do not apply excessive force during this procedure; be careful not
to damage the sealing surfaces for the holder or flow cell.
Picture 8

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Picture 9
12. Replace the outer O- ring of the holder.
13. Insert the window holder including the new O- ring into the
flow cell.
14. Adjust the holder so that the mounting holes of the plate
match the mounting threads of the flow cell.
Important note:
Please clean the sealing surfaces carefully before
reassembling the unit. If necessary use lubrication grease to
guarantee proper sealing.
Do not damage or sheer the O- rings.
Picture 10
Picture 11
15. Put the new O- ring into the groove of the window holder.
16. Put the window into the holder.
Picture 12
Picture 13
17. Put a new O- ring into the optic holder.
Important note:
This O- ring does not have a sealing function; it protects
the window against damages.
18. Put the optic holder over the window and screw it by using the
mounting screws.
Picture 14
Important note:
Please make sure that the O- rings stay inside their grooves
during this procedure. We strictly recommend a 30-minute
pressure test under process conditions (without the optical
components) to guarantee proper sealing. This procedure will
avoid possible damages in case of leakage.

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Picture 15
19. Push the optical assembly into the holder.
20. Tighten Allen screws (3x)
Important note:
Please pay attention to the position of the optical
assembly. The three grooves on the outside of the
barrel must be in line with the three Allen screws.
21. Reconnect the wires of lamp / detector cable and perform a
lamp test.
Picture 16
Picture 17
22. Push lamp / detector arm to the thread.
23. Tighten lamp / detector arm
24. Tighten cable gland
Picture 18
Picture 19
25. Screw in Allen screws and / or air purge connectors
26. Functional test and eventual calibration.
Replacement interval
The interval to replace the gaskets depends on the specific application.
The replacement cycle depends on process pressure, process temperature, sealing material and product
characteristics. In worst case (high temperature, high pressure, aggressive medium) the gaskets must be
replaced every month. Under normal conditions the gaskets should be replaced every year. The maximum
lifetime in easy applications can go up to 2 years.
We strictly recommend that the customer establishes a maintenance interval based on local conditions. If
you have any questions or if you require more information contact Metrisa.

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Components model MoniTurb- F (12° scattered light)

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Spare part list model MoniTurb- F (12° scattered light)
Pos.
Item
Bezeichnung
Description
Anz./Sys.
Qty./Sys.
Teile Nr.
Part No.
1
Durchflußarmatur / Body
1
2
Adapterdichtung / Adaptor seal
• O
-Ring / O-ring - [Viton, DIN3771 - 33 x 2] 2 C208-3007-F01
• O
-Ring / O-ring - [EPDM, DIN3771 - 33 x 2] 2 C208-3007-F00
• O
-Ring / O-ring - [Kalrez, DIN3771 - 33 x 2] 2 C208-3007-F02
3
Fenstereinsatz / Window, Adaptor
2 2001-0925-01-1
4
Innere Fensterdichtung / Inner window seal
• O
-Ring / O-ring - [Viton, DIN3771 - 20 x 2] 2 C208-3006-F01
• O
-Ring / O-ring - [EPDM, DIN3771 - 20 x 2] 2 C208-3006-F00
• O
-Ring / O-ring - [Kalrez, DIN3771 - 20 x 2] 2 C208-3006-F02
5
Messfenster, flach (Saphir) / Measuring window, flat (Sapphire)
2 2001-1221-01
6
Äußere Fensterdichtung
/ Back-up window seal
• O
-Ring / O-ring - [Viton, DIN3771 - 20 x 2] 2 C208-3006-F01
7
Federring / Split washer [DIN128
-B4] 12 / 8 C104-1002-00
8
Zylinderschr. m. Innensechsk. / Screw, hex, socket head
- [DIN912-M4x14] 12 C100-1011-00
9
Lampen
- und Optikhalterung / Lamp and optic holder
• mit Luftspülung / with Air Purge
2 2001-0911-19-1
• ohne Luftspülung / without Air Purge
2 2001-0911-19-2
10
Gewindestift m. Innensechskant / Screw, hex, headless
- [DIN 913-M3x3] 6 C100-1001-00
11
Messarmdichtung / Housing seal
• O
-Ring / O-ring - [Viton, DIN3771-50 x 2] 2 C208-3009-01
• O
-Ring / O-ring - [EPDM, DIN3771-50 x 2] 2 C208-3009-00
12
Kabelanschluss mit Grundplatte / Connector, cable, with base plate
•
Detektor / Detector 1 2001-1301-01
• Lampe / Lamp
1 2001-1302-01
13
Federring / Washer, coil spring
- [DIN128-B2,5] 4 C104-1002-00
14
Linsenkopfschr. m. Kreuzs. / Cross recessed raised pan head screw
- [DIN7985-
M2,5x7]
4 C100-1009-00
15
Messarmgehäuse (Standard) / Housing, Arm (Standard)
2 2001-1004-01
16
PG
-Verschraubung VA / Strain relief, cable 2 C305-1003-00