Optek AS56 Series User manual

Phone: [phone]
E-Mail: [email protected]
Internet: www.optek.com
optek-Danulat GmbH
Emscherbruchallee 2
D - 45356 Essen
Instruction Manual
optek-sensors AS56
optek-Manual--1004-2011-02--AS56-US-2017-06-28
PN: 1004-2011-02 (-52)

Preface
Preface
This instruction manual is written to assist the user in proper procedures for
trouble-free operation.
It is explicitly pointed out that optek-Danulat GmbH assumes no responsibility
for loss or damage caused due to improper use of this instruction manual or
products described herein.
This manual is protected by copyright. However, the user may produce copies
and translations if required for correct operation of the products.
On request, this manual is available in other languages as well as on a digital
medium (Acrobat® Reader 7.0).
Our products are being continuously improved. Technical data is subject to
change without notice.
Essen, December 2015
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Table of contents
Table of contents
1 Using the instruction manual ............................................................................................... 1
1.1 Validity of the instruction manual............................................................................................. 1
1.2 Pictograms and signal words................................................................................................... 2
2 Returns and disposal ............................................................................................................ 3
2.1 Declaration of decontamination ............................................................................................... 3
2.2 Disposal................................................................................................................................... 3
3 Intended use........................................................................................................................... 4
4 Description of AS56-F / AS56-N sensors ............................................................................ 5
5 Technical data and exploded views..................................................................................... 7
5.1 Dimensions AS56-F / AS56-N sensor ..................................................................................... 9
5.2 Accessories weld-in port AS25................................................................................................ 10
5.3 Accessories Varivent adapter port AS25-G60......................................................................... 12
5.4 Accessories Clamp adapter port AS25-G60............................................................................ 13
5.5 Accessories optek T-pieces for pipe DIN 11850 ..................................................................... 14
5.6 Accessories optek T-pieces for pipe OD ................................................................................. 15
5.7 Accessories sealing flange AS25 ............................................................................................ 16
5.8 Exploded view of AS56-F / AS56-N sensor............................................................................. 17
6 Installation.............................................................................................................................. 18
6.1 General installation instructions............................................................................................... 18
6.2 Installation of the sensor.......................................................................................................... 20
6.3 Airpurge ................................................................................................................................... 22
7 Wiring...................................................................................................................................... 23
8 Faults ...................................................................................................................................... 24
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Table of contents
9 Maintenance........................................................................................................................... 27
9.1 Preventive maintenance .......................................................................................................... 27
9.2 Exchange of lamp module ....................................................................................................... 28
9.3 Return to operation after the exchange of lamp module ......................................................... 31
9.4 Spare parts and accessories ................................................................................................... 32
9.4.1 Lamp modules .......................................................................................................... 32
9.4.2 Installation Kit............................................................................................................ 32
9.4.3 Gaskets (not wetted)................................................................................................. 32
9.4.4 Gaskets (wetted)....................................................................................................... 32
9.4.5 Screw sets ................................................................................................................ 32
9.4.6 Accessories – cable sets stainless steel connector .................................................. 33
9.4.7 Accessories – process adapter................................................................................. 34
9.4.8 Accessories – T-piece for AS16 / AS56 - DIN 11850 ............................................... 35
9.4.9 Accessories – T-piece for AS16 / AS56 - OD (BS 4825-1)....................................... 35
10 EU declaration of conformity................................................................................................ 36
11 Contacts ................................................................................................................................. 37
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Using the instruction manual
1 Using the instruction manual
1.1 Validity of the instruction manual
This instruction manual is valid for the following sensors:
AS56-F, AS56-N.
Abbreviations mean the following sensor options:
• F: color sensor (wavelength application specific)
• N: near infrared sensor with range of wavelengths 730 – 970 nm
Follow the instruction manual for every operation. If the product is not used as
described in this instruction manual, your safety and the product function may be
affected.
To keep up reliability of the product, enhance its life cycle, and avoid down times,
follow the instructions given in this manual.
Furthermore, please follow the existing accident prevention and environmental
protection instructions, as well as recognized technical instructions for safe and
professional working.
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Using the instruction manual
1.2 Pictograms and signal words
Important information in this instruction manual is marked with the following
pictograms:
Danger!
This pictogram indicates immediate danger to life and health of persons.
The text next to the symbol gives information on how to avoid bodily injuries.
If the possible cause of risk can be specified, the corresponding pictogram
precedes instructions:
Danger!
Electrical voltage.
This pictogram indicates danger due to electrical voltage.
Attention!
This pictogram indicates information on how to avoid material damage.
Notice!
This pictogram indicates instructional or general advice.
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Returns and disposal
2 Returns and disposal
2.1 Declaration of decontamination
For the safety of our employees and because of legal regulations we require a
signed "declaration of decontamination" before your return can be handled.
This signed declaration must be included with the shipping documents on the
outside of the packaging.
Any returns which were exposed to hazardous substances and were not
professionally decontaminated are not accepted and will be sent back at your
cost.
optek's declaration of decontamination and contact information can be found on
our website www.optek.com.
2.2 Disposal
Special legal regulations apply to the return and disposal of industrial waste
equipment. However, manufacturer and user can contractually agree on which
party is to fulfill these legal obligations.
Observe current national disposal regulations. For disposing of packaging
material, please separate materials:
• paper/cardboard
• plastic
For disposal, disassemble the system components and separate them according
to different material groups.
Dispose of materials according to national and local regulations.
If no agreement has been made, products may be shipped to optek for disposal.
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Intended use
3 Intended use
The sensor and its variants are to be applied only as absorption sensors for
liquids and gases in inline applications according to the technical data.
Use in hazardous locations is prohibited.
You can purchase flameproof sensors for hazardous locations from optek. For
these sensors, special instruction manuals are delivered with the sensor.
Unauthorized constructional changes, additional fittings or rebuildings regarding
the sensor are prohibited. The only exception are rebuildings into one of the
variants listed in the chapter "Validity of the instruction manual". Changes to and
interference with the converter program are prohibited as well.
Burying sensor cables underground without protection is prohibited.
The manufacturer is not liable for damage resulting from use contrary to the
intended use.
Following this instruction manual is part of the intended use.
The content of all serial number plates on optek products is model-specific and
refers to the time of delivery.
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Description of AS56-F / AS56-N sensors
4 Description of AS56-F / AS56-N sensors
This sensor is a high precision absorption sensor designed for direct installation
into pipelines and vessels. It is of compact and robust construction with a
measuring segment optimized with respect to flow and sterile requirements. Two
different optical path lengths in combination with an extensive range of
accessories offer maximum flexibility for adaptation to the process.
Fig.1: AS56
The following are the main sensor components:
22 4 315
Fig.2: Schematic AS16 / AS56
1 Optical path length (OPL) 2 Sapphire window
3 Lamp 4 Optics module with filter
5 Detector
The process medium is penetrated by a precisely focused, constant light beam.
A hermetically sealed silicon photodiode measures intensity of incoming and
optically filtered light and supplies the converter with it in form of photocurrent.
Attenuation of light intensity, as a result of absorption and/or scattering of
substances in the process medium, is described by the Lambert-Beer Law. It
states that the logarithm of the transmission loss is proportional to the
concentration of the substance. This is true for dissolved substances and
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Description of AS56-F / AS56-N sensors
undissolved material. Depending on the particular material properties,
concentrations can be detected in ppm as well as in %.
According to this law, the extinction coefficient, defined through ingredient and
wavelength, affects the logarithm of the transmission loss, too. Therefore, the
choice of wavelength or range of wavelengths is of decisive importance for the
measurement and is defined for each measurement type with the help of optical
filters.
The third factor of influence in the Lambert-Beer Law is the path length of light
passing through the process medium. Equally proportional, the path length, too, is
an important aspect with regard to specification of a photometer. The distance to
be covered by light is defined through the optical path length (OPL), that is the
distance between the windows in the measuring segment of the sensor. The OPL
of your sensor is given on its serial number plate.
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Technical data and exploded views
5 Technical data and exploded views
Tab.1: Technical data AS56-N/-F (subject to changes) *
Technical data AS56-N AS56-F
Measurement
Measurement principle: 1- Channel Absorption of light
Measurement
wavelength(s): 730 nm - 970 nm 430 nm
Detector: 1 silicon photodiode (hermetically sealed)
Measuring range:
With converter C4000:
any measuring range between
0 - 0.05 to 4 CU
With converter 156:
any measuring range between
0 - 0.5 to 4 CU
With converter C4000:
any measuring range between
0 - 0.05 to 1.5 CU
With converter 156:
any measuring range between
0 - 0.5 to 1.5 CU
Optical path length: 5 or 10 mm
Calibration: CU (concentration units)
application specific calibration
Light source: special incandescent tungsten lamp 5.0 V DC, 450 mA
typical life span: 3 to 5 years (25,000 to 40,000 hours)
Resolution: < ± 0.5 % of respective measuring range
Repeatability: < ± 1 % of respective measuring range
Linearity: < ± 2 % of respective measuring range (specific to application)
Type of protection: all optical parts have an IP rating of IP65 or higher
Process adaption
Material:
wetted parts:
stainless steel 1.4435 (SS 316L)
surface: electro-polished Ra < 0,8 μm
housing: stainless steel 1.4571 (SS 316 Ti)
Port connection:
thread G1-1/4 in., ISO 228/1
for port AS25 (similar Ingold-port)
diameter: 25 mm ( D= 25 H7)
O-ring groove for 30 mm and for 60 mm port length
Port gasket: O-ring 18.64 x 3.53 mm EPDM (FDA / USP Class VI)
Insertion depth: 35 mm (1.38 in) + OPL
at a port length of 60 mm (2.36 in)
Process pressure:
PN10 test pressure PT 15 bar (217.6 psi)
10 mbar to 10 bar (0.15 psi to 145 psi) for 0 - 90 °C (32 - 194 °F)
10 bar (145 psi) up to 90 °C (194 °F)
8 bar (116 psi) up to 100 °C (212 °F)
Windows: sapphire (seal-less)
Window gaskets: n/a
Weight: probe: approx. 2.0 - 2.5 kg, depending on model
Airpurge: connectors available as standard, air purge pressure 0.5 bar max.
Installation accessories: weld-in ports, Varivent adapter (50.00), clamp adapter (1.5 and 2.0 in.)
optek T-pieces DIN 11850 (DN50 - DN100), optek T-pieces OD (BS4821-1) (2.0 - 4.0 in.)
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Technical data and exploded views
Technical data AS56-N AS56-F
Temperature ratings
Process temperature: permanent: 0 - 90 °C (32 - 194 °F)
peak 60 min/day: 0 – 100 °C (32 – 212 °F)
Ambient temperature: operation: 0 - 40 °C (32 - 104 °F)
transport: -20 – 70 °C (-4 – 158 °F)
Cables
Cable length: standard: 2, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 m
(7, 10, 16, 33, 49, 66, 82, 98, 115, 131, 148, 164 ft.)
Cable material: non-metallic sheathed cable with finely stranded copper conductor according to IEC 228 CL.5,
insulation PVC (-40 °C … +70 °C, -40 °F ... +158 °F)
Plug connection: SS plug protector
Cable weights: probe cable: 1.5 kg / 10 m
Cable diameter: approx. 9.5 mm / approx. 11 mm with shrink hose
Certificates
ISO 9001:2015, PED, CE, HP0
* Pressure and temperature ratings specified herein may be subject to limitations.
The appropriate choice of material for all wetted parts is the sole responsibility of
the user.
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Technical data and exploded views
5.1 Dimensions AS56-F / AS56-N sensor
28.8mm [1.13"]
Ø19mm [0.75"]
58.8mm [2.31"]
74.5mm [2.93"]
OPL
OPL + 95mm [3.74"] max. 210mm [8.27"]
OPL + 305mm [12.01"]
Ø60.3mm [2.37"]
1
2
3
4
5
6
7
Fig.3: Dimensions AS56-F / AS56-N sensor
1 OPL (optical path length, measuring gap) 2 Lower O-ring groove (with approx. 60 mm port
length)
3 Upper O-ring groove (with approx. 30 mm port
length)
4 Swivel nut G 1-1/4" ISO 228/1
(short, approx. 19mm)
5 Orientation mark for measuring gap 6 Probe head with optics and lamp module
7 Airpurge connection
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Technical data and exploded views
5.2 Accessories weld-in port AS25
The AS56 sensor is designed for port connections (similar to Ingold Port) with a
25H7 inside diameter, a nominal length of 60 mm (2.36'') and a G1-1/4''
ISO 228/1 connection thread. The AS25-GS60 port is prepared in a way that the
straight (0°) AS25-G60 port as well as the angular (15°) AS25-S60 port are easy
to realize at the site. The port may as well be welded in at an angle smaller than
15°, because it is provided with the corresponding cone. The three weld-in ports
are available as accessories.
Ø27mm [1.06"]
Ø24.7mm [0.97"]
50mm [1.97"]
58.3mm [2.3"]
G1¼"A-ISO 228/1
30°
Ø42mm [1.65"]
15mm [0.59"]
70mm [2.76"]
1
2
3
69.6mm [2.74"]
58.3mm [2.3"]
15mm [0.59"]
50mm [1.97"]
G1¼"A-ISO 228/1
Ø27mm [1.06"]
Ø25mm [0.98"] H7
15°
Ø27mm [1.06"]
G1¼"A-ISO 228/1
Ø25mm [0.98"] H7
60mm [2.36"]
50mm [1.97"]
Fig.4: Weld-in port
1 Weld-in port AS25-GS60 2 Weld-in port AS25-S60
3 Weld-in port AS25-G60
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Technical data and exploded views
Notice!
After welding, distortion at the weld-in port has to be corrected!
Modify the interior drill hole of Ø24.7mm to obtain the nominal diameter
Ø25 H7 (Ø25.0-Ø25.021mm) before installing the probe!
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Technical data and exploded views
5.3 Accessories Varivent adapter port AS25-G60
The adapter allows sensor installation with Varivent inline housings. The adapter
may be installed on all housings instead of a closing plate Ø 68 mm (2.68'')
(TUno.221-144.02, optekFH50-99). The adapter made of high-quality bulk
material 1.4435 (SS 316 L) combines Varivent inline housings with the AS25-G60
weld-in port.
Varivent hinged clamp (TU no. 701-075), nut M6 (TU no. 912-035) and gasket
Ø60x3, EPDM FDA (TU no. 930-144) are parts included in the Varivent inline
housing scope of supply. As standard, the adapter is delivered without these
parts.
The sensor is inserted into the pipeline to a different degree depending on the
applied optical path length and the variant:
Tab.2: Varivent adapter port AS25-G60
OPL
[mm]
AS56
(L = 35 mm + OPL)
insertion depth max.
[mm]
5 40
10 45
G1¼''A-ISO 228/1
60mm [2.36"]
50mm [1.97"]
Ø68mm [2.68"]
Ø25mm [0.98"] H7
Ø27mm [1.06"]
15mm [0.59"]
Fig.5: Varivent adapter port AS25-G60
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Technical data and exploded views
5.4 Accessories Clamp adapter port AS25-G60
The adapter allows sensor installation with T-pieces with clamp 1.5" or 2.0"
L14AM7 (Tri-Clamp).
The adapter made of high-quality bulk material 1.4435 (SS 316 L) combines
Clamp technology with the AS25-G60 weld-in port.
As standard, the adapter is delivered without hinged clamp and gasket.
The sensor is inserted into the pipeline to a different degree depending on the
applied optical path length (OPL):
Tab.3: Clamp adapter port AS25-G60
OPL
[mm]
AS56
(L = 35 mm + OPL)
insertion depth max.
[mm]
5 40
10 45
50mm [1.97"]
52mm [2.05"]
58.33mm [2.3"]
6.33mm [0.25"]
Ø25mm [0.98"] H7
Ø30mm [1.18"]
Ø63.9mm [2.52"]
Ø56.5mm [2.22"]
Ø27mm [1.06"]
G1¼''A-ISO 228/1
15mm [0.59"]
Fig.6: Clamp 2.0" adapter port AS25-G60
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Technical data and exploded views
5.5 Accessories optek T-pieces for pipe DIN 11850
T-pieces for pipelines according to DIN 11850 are tubing within the meaning of
the PED for liquids and gases of fluid group 1 and 2.
Tab.4: optek T-pieces for pipelines according to DIN 11850
Material: T-piece made entirely of stainless steel 1.4435 (SS 316 L)
Line sizes: DN 50 - DN 100 (2.0" - 4.0")
Process connection: pipe according to DIN 11850
Port connection:
thread G1-1/4'', ISO 228/1
for port AS25 (similar to Ingold port)
diameter: 25 mm (0.98'') (D = 25 H7)
O-ring groove for 30 mm (1.18'') and for 60 mm (2.36'') port length
Admissible pressure PS: 10 mbar - 16 bar for TS -40 °C / +120 °C (-40 °F / +248 °F)
Admissible pressure at
increased temperature
TS [°C] ≤ 120 150 200 (248, 302, 392 °F)
PS [bar] 16 14 13
Tab.5: Dimensions for optek T-pieces for pipelines according to DIN 11850
Line size
Length
L
[mm]
Pipe size
diameter x S
[mm]
Inside
diameter D
[mm]
Height
H
[mm]
Depth
H1
[mm]
Maximum
OPL
[mm]
DN 50 150 53,0 x 1,5 50.0 94.5 120 20
DN 65 150 70,0 x 2,0 66.0 103.0 136 20
DN 80 150 85,0 x 2,0 81.0 110.5 151 40
DN 100 250 104,0 x 2,0 100.0 120.0 170 40
L
G1¼"A-ISO 228/1
Ø25mm [0.98"]
H
50mm [1.97"]
58.3mm [2.3"]
H1
70mm [2.76"]
S
ØDI
Fig.7: optek T-pieces for pipe DIN 11850
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Technical data and exploded views
5.6 Accessories optek T-pieces for pipe OD
T-pieces for pipelines OD according to British Standard BS 4825 Part 1 are tubing
within the meaning of the PED for liquids and gases of fluid group 1 and 2.
Tab.6: optek T-pieces for pipe OD
Material: T-piece made entirely of stainless steel 1.4435 (SS 316 L)
Line sizes: DN 50 - DN 100 (2.0" - 4.0")
Process connection: pipe OD according to BS 4825-1
Port connection:
thread G1-1/4'', ISO 228/1
for port AS25 (similar to Ingold port)
diameter: 25 mm (0.98'') (D = 25 H7)
O-ring groove for 30 mm (1.18'') and for 60 mm (2.36'') port length
Admissible pressure PS: 10 mbar - 20 bar for TS -40 °C / +120 °C (-40 °F / +248 °F)
Admissible pressure at
increased temperature
TS [°C] ≤ 120 150 200 (248, 302, 392 °F)
PS [bar] 20 18 16
Tab.7: Dimensions for optek T-pieces for pipe OD
Line size
Length
L
[mm]
Pipe size
diameter x S
[mm]
Inside
diameter D
[mm]
Height
H
[mm]
Depth
H1
[mm]
Maximum
OPL
[mm]
2.0" 150 50,8 x 1,65 47.5 93.5 117 20
2.5" 150 63,5 x 1,65 60.2 100.0 130 20
3.0" 150 76,2 x 1,65 72.9 106.0 142 40
4.0" 250 101,6 x 2,1 97.4 118.5 167 40
G1¼"A-ISO 228/1
H
Ø25mm [0.98"]
50mm [1.97"]
58.3mm [2.3"]
L
70mm [2.76"]
H1
ØDI
S
Fig.8: optek T-pieces for pipe OD
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Technical data and exploded views
5.7 Accessories sealing flange AS25
The sealing flange is of the same contour as the sensor and may be used to close
the port for maintenance activities.
The sealing flange is designed for the straight AS25-G60 weld-in port and the 15°
AS25-S60 weld-in port and may as well be used for other and shorter weld-in
ports as the second groove for the O-ring is located 30 mm (1.18 '') higher. Both
grooves are designed for O-rings Ø18.64 x 3.53 mm. The swivel nut is designed
for short threads G1-1/4'' ISO 228/1.
58.8mm [2.31"]
28.8mm [1.13"]
64mm [2.52"]
Ø25mm [0.98"]
19mm [0.75"]
57mm [2.24"]
Fig.9: Sealing flange AS25
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