Optek AS56 Series User manual

Instruction Manual
optek-sensors AS56
Version 04.2010_1.2US
PN: 1004-2011-02 (-52)
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen
Phone: [phone]
Fax: [phone]
E-Mail: inf[email protected]e
Internet: www.optek.com

Preface
optek-sensors AS56, Version 04.2010_1.2US, 15.04.2010
www.optek.com
Preface
This instruction manual is written to assist the user in proper procedures for
trouble-free operation.
Itis explicitlypointed out thatoptek-Danulat GmbH assumes no responsibilityfor
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 in digital
format (Acrobat®Reader 7.0 required).
Our products are being continuously improved. Technical data is subject to
change without notice.
Essen, January 2010

Preface
optek-sensors AS56, Version 04.2010_1.2US, 15.04.2010
www.optek.com
For further inquiry, feel free to contact us or our distributing partners at
any time:
Germany
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen / Germany
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Netherlands
optek-Danulat bv
Grote Brugse Grintweg 12a
4005 AH Tiel / Netherlands
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
USA
optek-Danulat Inc.
N118 W18748 Bunsen Drive
Germantown WI 53022 / USA
Phone: [phone]
Toll free call: [phone]
Fax: [phone]
E-Mail: [e-mail]
Singapore
optek-Danulat Pte. Ltd.
25 Int’l Business Park
#05-109-f German Centre
Singapore 609916
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Russian Federation
optek-Danulat GmbH
Liter A, Room 911, 26-N
Kolomjazhskij Prospekt 33
197341 St. Petersburg
Phone: [phone]
E-Mail: [e-mail]
Internet: http://www.optek.com

Table of contents
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Table of contents
Preface
1Using the instruction manual .................................................................................................1
1.1 Validity of the instruction manual......................................................................................... 1
1.2 Pictograms and signal words............................................................................................... 2
1.3 Note regarding return of the sensor..................................................................................... 3
2Intended use ............................................................................................................................4
3Description of AS56-F / AS56-N sensors ..............................................................................5
4Technical data and exploded views ......................................................................................7
4.1 Dimension AS56-F / AS56-N sensor.................................................................................... 9
4.2 Accessories weld-in port AS25 .......................................................................................... 10
4.3 Accessories Varivent adapter port AS25-G60.................................................................... 12
4.4 Accessories Clamp adapter port AS25-G60 ...................................................................... 13
4.5 Accessories optek T-pieces for pipe DIN 11850................................................................ 14
4.6 Accessories optek T-pieces for pipe OD............................................................................ 15
4.7 Accessories sealing flange AS25....................................................................................... 16
4.8 Exploded view of AS56-F / AS56-N sensor........................................................................ 17
5Installation .............................................................................................................................18
5.1 General installation instructions......................................................................................... 18
5.2 Installation of the sensor.................................................................................................... 20
5.3 Airpurge............................................................................................................................. 22
6Connection to converter C4000 ...........................................................................................23
7Connection to converter 156 ................................................................................................27
8Faults ......................................................................................................................................30

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9Maintenance ...........................................................................................................................32
9.1 Preventive maintenance .................................................................................................... 32
9.2 Exchange of lamp module ................................................................................................. 33
9.3 Return to operation after the exchange of lamp module .................................................... 35
9.4 Spare parts and accessories ............................................................................................. 36
9.4.1 Lamp module ...........................................................................................................36
9.4.2 Installation Kit AS .....................................................................................................36
9.4.3 Gaskets (not wetted) ................................................................................................36
9.4.4 Gaskets (wetted)* ....................................................................................................36
9.4.5 Screw sets ...............................................................................................................37
9.4.6 Small part sets .........................................................................................................37
9.4.7 Installation material ..................................................................................................37
9.4.8 Accessories ..............................................................................................................37
9.4.9 Accessories – cables ...............................................................................................38
10 Disposal .................................................................................................................................39
11 Appendix ................................................................................................................................40
11.1 Declaration of conformity................................................................................................... 41
11.2 TÜV NORD CERT GmbH "GS-mark"................................................................................. 42
11.3 QM system certificate........................................................................................................ 45
11.4 Decontamination declaration ............................................................................................. 46
11.5 Response via fax............................................................................................................... 48

Using the instruction manual
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1 Using the instruction manual
1.1 Validity of the instruction manual
This instruction manual is valid for AS56-F / AS56-N sensors. Abbreviations
mean the following sensor options:
• F color sensor (wavelength application specific)
• N near infrared (wavelength range 730 - 970 nm)
Follow the instruction manual for every operation. If the sensor is not used as
described in this instruction manual, your safety and the sensor function could
be affected.
To keep up reliability of the product, enhance its life cycle and avoid down times,
you have to 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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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
preceeds instructions:
Danger!
Electrical voltage.
This pictogram indicates danger due to electrical voltage.
Caution!
This pictogram indicates information on how to avoid material damage.
Note!
This pictogram indicates instructional or general advice.

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1.3 Note regarding return of the sensor
In the appendix of this instruction manual you find a declaration regarding the
decontamination of the sensor. Please fill out that declaration and add it to
sensor packaging when you return the sensor.
Note!
optek can only accept the returned sensor with the filled out and signed
decontamination declaration enclosed in the package.

Intended use
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2 Intended use
The optek-sensors AS56 and their variants are to be applied only as absorption
sensors for liquids and gases in inline applications according to the technical
data.
The use of the sensors 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.
Unauthorizedconstructionalchanges, additionalfittings orrebuildings 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.
To lay sensor cables underground without protection is prohibited.
The manufacturer is not liable for damage resulting from use contrary to
intended use.
Following this instruction manual is part of the intended use.

Description of AS56-F / AS56-N sensors
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3 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 segmentoptimized withrespectto flow andsterilerequirements.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:
Fig. 2 Schematic AS56
1. Optical path length (OPL)
2. Sapphire window
3. Lamp
4. Optics module with filter
5. Detector
A precisely defined, constant light beam penetrates the process medium. A
hermetically sealed silicon photodiode measures intensity of incoming and
optically filtered light and supplies the converter with it in form of photocurrent.
12
2345

Description of AS56-F / AS56-N sensors
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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, the logarithm of the transmission loss is proportional to concentration of
the substance. This is true for dissolved substances and 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 wavelength range 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.

Technical data and exploded views
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4 Technical data and exploded views
Tab. 1 Technical data AS56-N and AS56-F
AS56-N AS56-F
Materials wetted: stainless steel 1.4435 (SS 316 L)
surface: electro-polished Ra < 0.8 μm
windows: sapphire (seal-less)
housing stainless steel 1.4571 (SS 316 Ti)
Port connection thread G 1-1/4", ISO 228/1
for port AS25 (similar to Ingold port)
diameter: 25 mm (0.98"), (D = 25 H7)
O-Ring groove for 30 mm and for 60 mm (1.18" and 2.36") port length
Port gasket O-Ring 18.64 x 3.53 mm (0.73" x 0.14") EPDM (FDA, USP Class VI)
Maximum insertion depth 35 mm (1.38") + OPL at a port length of 60 mm (2.36")
Optical path length (OPL) 5 or 10 mm
Pressure rating PN10 (test pressure PT 15 bar)
Admissible pressure PS 10 mbar - 10 bar for TS 0 °C / +90 °C (+32 °F / +194 °F)
Admissible pressure at
increased temperature TS [°C] < 90 (194 °F) 100 (212 °F)
PS [bar] 10 8
Admissible process
temperature TS 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)
Airpurge connection M5: standard
Light source incandescent tungsten lamp: 5.0 V DC, 450 mA
Wavelengths 730 to 970 nm 430 nm
Detector silicon photodiode, hermetically sealed
Measuring range C4000:
any range between 0–0.05 to 4.0 CU
156:
0–0.5 to 4.0 CU
C4000:
any range between 0–0.05 to 1.5 CU
156:
0–0.5 to 1.5 CU
Cable connection with stainless steel connector, length:
2, 3, 5, 10, 15, 20, ... 45 or 50 m
(7, 10, 16, 33, 49, 66, ...148 or 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)
Weight probe: approx. 2.0 - 2.5 kg, depending on model
cable set: approx. 1.5 kg/10 m
Protection all optical parts protected according to IP65 if sensor is constructed as intended, valid for
installation of plug or protection cap
Certificates ISO 9001:2000, PED, CE, HP0

Technical data and exploded views
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Options:
• Accessories for installation
• Weld-in port AS25-GS60
• Weld-in port AS25-G60 (0°)
• Weld-in port AS25-S60 (0–15°)
• Varivent 50.00 adapter port AS25-G60
• Clamp 1.5-inch adapter port AS25-G60
• Clamp 2.0-inch adapter port AS25-G60
• optek T-pieces for pipe DIN 11850 with port AS25-G60,
DN 50–DN 100
• optek T-pieces for pipe OD (BS 4825-1) with port AS25-G60, 2.0"–4.0"
• Sealing flange AS25

Technical data and exploded views
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4.1 Dimension AS56-F / AS56-N sensor
Fig. 3 Dimension 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
7
6
5
4
3
2
1
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"]

Technical data and exploded views
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4.2 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 (see chapter 9.4.8, page 37).
Fig. 4 Weld-in port
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"]
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"]
Ø27mm [1.06"]
G1¼"A-ISO 228/1
Ø25mm [0.98"] H7
60mm [2.36"]
50mm [1.97"]
Weld-in port AS25-G60
Weld-in port AS25-S60
Weld-in port AS25-GS60

Technical data and exploded views
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Note!
After welding, distortion has to be corrected at port AS25-GS60!
Modify the interior drill hole of ∅24.7 mm to obtain the nominal diameter ∅25 H7
(∅25.0 - ∅25.032 mm) before installing the probe!

Technical data and exploded views
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4.3 Accessories Varivent adapter port AS25-G60
The adapterallows sensorinstallationwithVariventinlinehousings.Theadapter
may be installed on all housings instead of a closing plate ∅ 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
∅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:
Fig. 5 Varivent adapter port AS25-G60
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"]

Technical data and exploded views
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4.4 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):
Fig. 6 Clamp 2.0'' adapter port AS25-G60
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"]

Technical data and exploded views
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4.5 Accessories optek T-pieces for pipe DIN 11850
T-pieces for pipelines according to DIN 11850 comply with the requirements of
the Pressure Equipment Directive up to category II.
Fig. 7 optek T-pieces for pipe DIN 11850
Tab. 4 optek T-pieces for pipelinesaccording 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

Technical data and exploded views
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4.6 Accessories optek T-pieces for pipe OD
T-pieces for pipelines OD according to British Standard BS 4825 Part 1 comply
with the requirements of the Pressure Equipment Directive up to category II.
Fig. 8 optek T-pieces for pipe OD
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