Optek TF56 User manual

Instruction Manual
optek-sensors TF56
Version 02.2008_1.1US
PN: 1004-2007-02
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen
Germany
Phone: [phone]
Fax: [phone]
E-Mail: inf[email protected]e
Internet: www.optek.com

Preface
optek-sensors TF56, Version 02.2008_1.1US, 06.02.2008
www.optek.com
Preface
This instruction manual is written to assist the user in proper procedures for
trouble-free operation.
Itis explicitlypointed out that optek-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 5.0 required).
Our products are being continuously improved. Technical data is subject to
change without notice.
Essen, August 2007

Preface
optek-sensors TF56, Version 02.2008_1.1US, 06.02.2008
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]
Internet: http://www.optek.com

Table of contents
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Table of contents
Preface
1 System overview .................................................................................1
2 Using the instruction manual .............................................................2
2.1 Validity of the instruction manual....................................................... 2
2.2 Pictograms and signal words............................................................. 3
2.3 Note regarding return of the sensor................................................... 4
3 Intended use ........................................................................................5
4 Description of the TF56 sensor ..........................................................6
5 Technical data and exploded views ...................................................8
5.1 Exploded view of TF56 sensor......................................................... 11
5.2 Exploded view of TF56-HT sensor................................................... 12
5.3 Exploded view of TF56-PV sensor................................................... 13
5.4 Exploded view of TF56-HT-PV sensor............................................. 14
6 Installation ..........................................................................................15
6.1 Standard sensor bodies - installation instructions............................ 15
6.2 Installation of the sensor.................................................................. 17
6.3 Air purge.......................................................................................... 18
7 Connection to converter 556 ............................................................19
8 Faults ..................................................................................................23

Table of contents
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9 Maintenance .......................................................................................25
9.1 Preventive maintenance.................................................................. 25
9.2 Exchange of lamp module ............................................................... 26
9.3 Exchange of detector module.......................................................... 27
9.4 Return to operation after the exchange of lamp module
and detector module........................................................................ 28
9.5 Spare parts and accessories ........................................................... 29
9.5.1 Lamp modules / wavelength modules /
detector assembly ................................................................29
9.5.2 Standard window ..................................................................30
9.5.3 Gaskets (not wetted) ............................................................30
9.5.4 Screw sets ............................................................................31
9.5.5 Small part sets ......................................................................31
9.5.6 Installation material ..............................................................31
9.5.7 Accessories cable sets .........................................................32
10 Disposal ..............................................................................................33
11 Appendix ............................................................................................34
11.1 Declaration of conformity................................................................. 35
11.2 TÜV NORD CERT GmbH "GS-mark"............................................... 36
11.3 QM system certificate...................................................................... 37
11.4 Decontamination declaration ........................................................... 38
11.5 Response via fax............................................................................. 40

System overview
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optek-sensors TF56, Version 02.2008_1.1US, 06.02.2008
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1 System overview

Using the instruction manual
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2 Using the instruction manual
2.1 Validity of the instruction manual
This instruction manual is valid for TF56 sensor and its variants. There are the
following variants:
•HT
•PV
•HT-PV
•SF
Abbreviations mean the following sensor options:
• HT high temperature
• PV purge varivent (air purge connections at sensor)
• SF silicone-free version with restricted temperature ratings
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.

Using the instruction manual
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2.2 Pictograms and signal words
Especially 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.

Using the instruction manual
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2.3 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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3 Intended use
The optek-sensors TF56 and their variants are to be applied only as scattered
light turbidimeters 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 orrebuildingsregarding
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 the TF56 sensor
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4 Description of the TF56 sensor
The TF56 model is a high precision dual channel scattered light turbidimeter. It
measures direct light and light scatterd from particles in the process medium at
an angle of 11°. The sensor is made entirely of stainless steel and designed for
direct installation into pipelines.
Fig. 1 TF56
The following are the main sensor components:
Fig. 2 Schematic TF56
1. Sensor body
2. Windows
3. Optics module
4. Detector (direct light)
5. Detector (scattered light)
6. Optics module
7. Lamp
12 276 3
4
5
5

Description of the TF56 sensor
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Its modular construction offers maximum flexibility in adapting to the process,
without affecting the property of measurement. An appropriately defined light
beam penetrates the process medium. The light scattered from particles in the
process medium, e. g. traces of suspended solids, immiscible liquids or gas
bubbles, is detected by four hermetically sealed silicon photodiodes at an angle
of 11°. Simultaneously, the unscattered light is detected as direct light by
another photodiode. The receiver optics design guarantees that extraneous
lights created inside the sensor body are not included in measurements. Due to
the small scattering angle, direct light and scattered light practically travel the
same distance in the process medium. This is whyproduct specific disturbances
such as color or color changes of the carrier medium as well as soilings on
windows may be optimally compensated.

Technical data and exploded views
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5 Technical data and exploded views
Tab. 1 Technical data TF56
TF56 TF56-PV TF56-HT TF56-HT-PV
Material sensor body made of stainless steel 1.4571, SS 316 Ti (standard)
Special materials 1.4435 (SS 316 L), 1.4539, 1.4462, TFM 4215, Hastelloy®C4, Hastelloy®C22, Titanium,
Tantalum, Monel®400, Inconel®625, PP, others on request.
Line size 1/4" to 8", (DN 6 to DN 200)
Process connections ASME-Flange, DIN-Flange, Varivent, JIS-Flange, Tri-Clamp, BBS-Clamp, Female Thread NPT,
Female Thread DIN ISO 228/1 G, Sanitary Thread (DIN 11851), others on request
Gaskets Viton®, EPDM (FDA), EPDM (USP Cl. VI), Kalrez®, Chemraz®, Fluoraz®, Buna (NBR), Silicone,
Viton®/ FEP (FDA), others on request
Windows Pyrex®, Sapphire
Optical path length 40 mm (1.58'') standard, others on request
Process pressure 10 mbar to 325 bar, (0.15 psi to 4713 psi),
depending on process connection, material and design
Process temperature Data is only valid for appropriate choice of
material of sensor body and gaskets! No ice
formation on sensor!
permanent:
0 °C to +100 °C (+32 °F to + 212 °F)
peak (15 min/day):
0 °C to +120 °C (+32 °F to +248 °F)
high temperature version
permanent:
-20 °C to +190 °C (-4 °F to +374 °F)
peak (15 min/day):
-20 °C to +210 °C (-4 °F to +410 °F)
Ambient temperature operation:
0 °C to +40 °C (+32 °F to +104 °F)
(When higher or lower ambient temperatures are given, it may be necessary to impose restrictions
on the admissible process temperature!)
transport:
-20 °C to +70 °C (-4 °F to +158 °F)
Air purge connectors available as standard
Light source incandescent tungsten lamp: 5.0 V DC, 775 mA, typical lamp life 3 to 5 years
Wavelengths 400 nm - 1100 nm
Detector silicon photodiodes, hermetically sealed
Calibration basic calibration in ppm (DE), FTU, EBC
Measuring range any measuring range between
0 - 25 to 500 ppm (DE)
0 - 10 to 200 FTU
0 - 2.5 to 50 EBC
Resolution < ± 0.5 % of respective measuring range
Repeatability < ± 1 % of respective measuring range
Linearity application specific, < ± 2 % standard solution
Protection all optical parts protected according to IP65 if sensor is constructed as intended, valid for
installation of plug or protection cap
Cable lengths standard: 5, 10, 20, 35, 50 m (16, 33, 66, 115, 164 ft.) maximum: 250 m (820 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)
SS-plug-protection special high shielded cable sets, optional rigid stainless steel plug
Certificates ISO 9001:2000, PED, CE, HP0

Technical data and exploded views
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Fig. 3 Schema for determining dimensions
• A = installation height (in mm)
• B = installation length detector side (in mm)
• C = installation length lamp side (in mm)
Table 2 indicates a part of our extensive range of sensor bodies. Other sensor
bodies with diverse process connections and made of many other materials are
available (see table 1 on page 8 and table 2 on page 9).
Detailed technical information is given in the instruction manual "Sensor bodies
according to Pressure Equipment Directive, Module E1" of the corresponding
sensor body.
Moreover, Varivent adapters are available in different line sizes to allow quick
and easy adaptation to pipelines.
Tab. 2 Sensor dimensions in dependence of specifications of standard sensor body
Process connection Part.-No. Material Design Line
size OPL A-A*) [mm] A [mm] B [mm] C [mm]
NPT Female thread
(ASME B1.20.1) 0120-1104-03 1.4571 /
SS 316 Ti 1" 40 96 160 195
Female thread
(DIN ISO 228/1-G) 0120-1103-03 1.4571 /
SS 316 Ti 1" 40 96 160 195
Clamp
(ISO 2852-1993) 0120-1102-28 SS 316 L 1" 40 96 160 195
Clamp
(ISO 2852-1993) 0120-1302-28 SS 316 L 1.5" 40 106 160 195
Clamp
(ISO 2852-1993) 0120-0402-28 SS 316 L 2" 40 112 160 195
Sanitary thread SC
(DIN 11851) 0120-1101-03 1.4571 /
SS 316 Ti welded DN 25 40 125 160 195
Sanitary thread SC
(DIN 11851) 0120-1301-03 1.4571 /
SS 316 Ti welded DN 40 40 125 160 195
Sanitary thread SC
(DIN 11851) 0120-0401-03 1.4571 /
SS 316 Ti welded DN 50 40 125 160 195
Sanitary thread SC
(DIN 11851) 0120-0501-03 1.4571 /
SS 316 Ti welded DN 65 50 140 165 200
Sanitary thread SC
(DIN 11851) 0120-0601-03 1.4571 /
SS 316 Ti welded DN 80 50 180 165 200
Sanitary thread SC
(DIN 11851) 0120-0701-03 1.4571 /
SS 316 Ti welded DN 100 60 200 170 205
Flange
(ASME B16.5 RF, 150 lbs) 0120-1106-03 1.4571 /
SS 316 Ti welded 1" 40 150 160 195
Flange
(ASME B16.5 RF, 150 lbs) 0120-1306-03 1.4571 /
SS 316 Ti welded 1.5" 40 150 160 195
Flange
(ASME B16.5 RF, 150 lbs) 0120-0406-03 1.4571 /
SS 316 Ti welded 2" 40 150 160 195

Technical data and exploded views
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*) Optical path length (OPL) using standard windows model A is given in column
OPL A-A.
For the TF56 sensor, the sensor body and window combination have to be
chosen so that a type A window is installed on the detector side and the optical
path length is 40 mm (1.58''). That means, if a sensor body with 50 mm (1.97'')
OPL A-A is chosen, a type A window has to be installed on the detector side and
a type C window has to be installed on the lamp side.
Flange
(ASME B16.5 RF, 150 lbs) 0120-0606-03 1.4571 /
SS 316 Ti welded 3" 50 225 165 200
Flange
(ASME B16.5 RF, 150 lbs) 0120-0706-03 1.4571 /
SS 316 Ti welded 4" 60 230 170 205
Flange
(DIN 2633, E) 0120-1115-03 1.4571 /
SS 316 Ti welded DN 25 40 150 160 195
Flange
(DIN 2633, E) 0120-1315-03 1.4571 /
SS 316 Ti welded DN 40 40 150 160 195
Flange
(DIN 2633, E) 0120-0415-03 1.4571 /
SS 316 Ti welded DN 50 40 150 160 195
Flange
(DIN 2633, E) 0120-0515-03 1.4571 /
SS 316 Ti welded DN 65 50 150 165 200
Flange
(DIN 2633, E) 0120-0615-03 1.4571 /
SS 316 Ti welded DN 80 50 215 165 200
Flange
(DIN 2633, E) 0120-0715-03 1.4571 /
SS 316 Ti welded DN 100 60 220 170 205
Clamp
(TC L14 AM7) 0120-2918-08 1.4435 /
SS 316 L Biotech 1" 40 96 160 195
Clamp
(TC L14 AM7) 0120-1946-08 1.4435 /
SS 316 L Biotech 1.5" 40 106 160 195
Clamp
(TC L14 AM7) 0120-2914-08 1.4435 /
SS 316 L Biotech 2" 40 112 160 195
Tab. 2 Sensor dimensions in dependence of specifications of standard sensor body
Process connection Part.-No. Material Design Line
size OPL A-A*) [mm] A [mm] B [mm] C [mm]
Tab. 3 Cable weights
Cable Weight
Lamp cable (1.5 mm2)0.9 kg / 10 m
Lamp cable (2.5 mm2)1.2 kg / 10 m
Lamp cable (4.0 mm2)1.5 kg / 10 m
Detector cable (TF56) 1.2 kg / 10 m

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5.1 Exploded view of TF56 sensor
Fig. 4 Photo and exploded view of TF56
Note!
TF56 sensors are also available als SF version. This applies to positions
4, 8, 14 in fig. 4.
5876 4 3211312 14
20 21
20 22
10 16
719 18
7915
11 10
9
18 17 7
Tab. 4 Exploded view explanations
No. Explanation No. Explanation
1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3O-Ring 25.12 x 1.78, Viton®14 Detector assembly TF56, 1.4571 (316 Ti)
4Lamp adapter TF56, 1.4571 (316 Ti), incl.
wavelength module (see table 12 on page 29) 15 Detector socket, 9-pin
5O-Ring 31.47 x 1.78, Viton®16 Detector cable TF56
6 Optical housing OH06, 1.4571 (316Ti) 17 Lamp cable TF56 with SS-plug-protection
7O-Ring 21.95 x 1.78, Viton®18 4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
washer
8 Lamp module TF56 19 Detector cable TF56 with SS-plug-protection
9O-Ring 10.10 x 1.60, Viton®20 O-Ring 4.00 x 1.00 Viton®
10 4 screws M3 x 6 (DIN 7985), 1.4571 (316Ti) 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 Lamp cable TF56 22 Purge connection M5, Ms/Ni

Technical data and exploded views
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5.2 Exploded view of TF56-HT sensor
Fig. 5 Photo and exploded view of TF56-HT
Note!
For TF56-HT, the cable set always has to be equipped with plug-protection.
TF56 sensors are also available als SF version. This applies to positions
4, 8, 14 in fig. 5.
5876 4 3211312 14
20 21
20 22
719 18
79159
18 17 7
Tab. 5 Exploded view explanations
No. Explanation No. Explanation
1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3O-Ring 25.12 x 1.78, Viton®14 Detector assembly TF56-HT, 1.4571 (316 Ti) / PEEK
4Lamp adapter TF56-HT, PEEK, incl. wavelength
module (see table 12 on page 29) 15 Detector socket, 9-pin
5O-Ring 31.47 x 1.78, Viton®16 -
6 Optical housing OH06, 1.4571 (316Ti) 17 Lamp cable TF56 with SS-plug-protection
7O-Ring 21.95 x 1.78, Viton®18 4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti),
incl. washer
8 Lamp module TF56 19 Detector cable TF56 with SS-plug-protection
9O-Ring 10.10 x 1.60, Viton®20 O-Ring 4.00 x 1.00 Viton®
10 - 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 - 22 Purge connection M5, Ms/Ni

Technical data and exploded views
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5.3 Exploded view of TF56-PV sensor
Fig. 6 Photo and exploded view of TF56-PV
Note!
TF56 sensors are also available als SF version. This applies to positions
4, 8, 14 in fig. 6.
18
9
17 7
786453
1011
18719
2 1 12 13 14 157
20 21
9
20 22
10 16
22 20
21 20
Tab. 6 Exploded view explanations
No. Explanation No. Explanation
1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3O-Ring 25.12 x 1.78, Viton®14 Detector assembly TF56, 1.4571 (316 Ti)
4Lamp adapter TF56, 1.4571 (316 Ti), incl.
wavelength module (see table 12 on page 29) 15 Detector socket, 9-pin
5O-Ring 31.47 x 1.78, Viton®16 Detector cable TF56
6 Optical housing OP06 Purge, 1.4571 (316Ti) 17 Lamp cable TF56 with SS-plug-protection
7O-Ring 21.95 x 1.78, Viton®18 4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
washer
8 Lamp module TF56 19 Detector cable TF56 with SS-plug-protection
9O-Ring 10.10 x 1.60, Viton®20 O-Ring 4.00 x 1.00 Viton®
10 4 screws M3 x 6 (DIN 7985), 1.4571 (316Ti) 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 Lamp cable TF56 22 Purge connection M5, Ms/Ni

Technical data and exploded views
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5.4 Exploded view of TF56-HT-PV sensor
Fig. 7 Photo and exploded view of TF56-HT-PV
Note!
For TF56-HT-PV, the cable set always has to be equipped with plug-protection.
TF56 sensors are also available als SF version. This applies to positions
4, 8, 14 in fig. 7.
18
9
17 7
786453
18719
2 1 12 13 14 157
20 21
9
20 22
22 20
21 20
Tab. 7 Exploded view explanations
No. Explanation No. Explanation
1 Sensor body 12 Window ring M58 x 1.5, incl. 8 screws M5
2 Window ring M24 x 1.5, incl. 8 screws M5 13 O-Ring 50.52 x 1.78, Viton®
3O-Ring 25.12 x 1.78, Viton®14 Detector assembly TF56-HT, 1.4571 (316 Ti) / PEEK
4Lamp adapter TF56-HT, PEEK, incl. wavelength
module (see table 12 on page 29) 15 Detector socket, 9-pin
5O-Ring 31.47 x 1.78, Viton®16 -
6 Optical housing OP06 Purge, 1.4571 (316Ti) 17 Lamp cable TF56 with SS-plug-protection
7O-Ring 21.95 x 1.78, Viton®18 4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
washer
8 Lamp module TF56 19 Detector cable TF56 with SS-plug-protection
9O-Ring 10.10 x 1.60, Viton®20 O-Ring 4.00 x 1.00 Viton®
10 - 21 Screw M5 x 6 (DIN 84), 1.4571 (316 Ti)
11 - 22 Purge connection M5, Ms/Ni

Installation
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6Installation
6.1 Standard sensor bodies - installation instructions
Before installing the sensor, the sensorbody has tobe installed into the pipeline.
Observe the following conditions:
• As a basic principle, install the sensor body into the pipeline with optical
arms of the sensor in horizontal position (see fig. 8 and fig. 9).
Fig. 8 Vertical alignment of standard sensor body
Fig. 9 Horizontal alignment of standard sensor body
• Avoid installation in vertical position (see fig. 10). Deposits that affect
accurate measurements might form on lower window. Furthermore,
thermical problems, depending on process and ambiance conditions,
cannot be ruled out. If such problems are not expected because of the
process, vertical installation is admissible.
Fig. 10 No vertical alignment of the optical arms