ParTech IL55 User manual

INSTRUCTION MANUAL
IL55 and IL55BV2 Sensor
In Line Sludge Density and Turbidity Sensor

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L55 and IL55BV2 Sensor Instruction Manual
Table of Contents
1 Introduction...................................................................................................................................................................4
1.1 IL55/IL55BV2 Sensors.......................................................................................................................................4
1.2 IL55BV2 Sensor.................................................................................................................................................4
1.3 7200 Monitor......................................................................................................................................................4
2 Installation.....................................................................................................................................................................5
2.1 Horizontal Pipelines...........................................................................................................................................5
2.2 Vertical Pipelines...............................................................................................................................................6
2.3 Mounting Boss Installation.................................................................................................................................6
3 Electrical Installation.....................................................................................................................................................7
3.1 Cable Routing....................................................................................................................................................7
4 IL55BV2 Sensor............................................................................................................................................................8
4.1 Installation Procedure........................................................................................................................................9
4.2 Sensor Removal..............................................................................................................................................10
5 IL55 Sensor.................................................................................................................................................................11
5.1 Sensor Removal..............................................................................................................................................12
6 Setup & Calibration.....................................................................................................................................................13
7 Maintenance...............................................................................................................................................................14
7.1 Sensor Cleaning..............................................................................................................................................14
7.2 Inspection.........................................................................................................................................................14
7.3 Fault Finding....................................................................................................................................................14
8 Application Example: Sludge Density Monitor............................................................................................................15
9 Spare Parts.................................................................................................................................................................16
9.1 Sensors............................................................................................................................................................16
9.2 Mounting Accessories......................................................................................................................................16
9.3 Miscellaneous..................................................................................................................................................16
10 Technical Support.....................................................................................................................................................17
10.1 Returning Equipment for Repair.....................................................................................................................17
11 Technical Specification (should be last section)........................................................................................................18
12 Appendix 1: Preparation of Formazin Turbidity Standard..........................................................................................19
12.1 Health & Safety Precautions..........................................................................................................................19
12.2 Method of Preparation...................................................................................................................................19
12.3 Preparation of Dilution’s.................................................................................................................................19
12.4 Calibration......................................................................................................................................................19
12.5 Storage Life....................................................................................................................................................19
13 Appendix 2: Fuller's Earth.........................................................................................................................................20
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IL55 and IL55BV2 Sensor Instruction Manual
1 Introduction
This manual covers the IL55 and IL55BV2 in-line sensors and should be read in conjunction with the manual for the
monitor being used.
Whilst every attempt has been made to ensure that the instructions are correct, common sense and good engineering
practice should always be used to adapt to specific site details. If you are in any doubt please contact Partech or your
local distributor for further information.
1.1 IL55/IL55BV2 Sensors
The IL55 and IL55/BV2 sensors are mounted onto a pipe to measure or detect the suspended solids, turbidity or
sludge density of the liquid flowing. The optical surface will be located such that it is flush with the inside wall of the
pipeline and perpendicular to the flow. The optical surface will be kept clean by the flow of the fluid, however a routine
cleaning regime will be required to ensure long term reliability.
The sensor uses 180° Back Scatter of infrared light to detect the presence of solids in the pipe, the sensor electronics
provides an output signal that is used by either the 8100/8200 or 7200 Monitor to infer the level of Sludge Density,
Suspended Solids or Turbidity.
The stainless steel and glass construction is resistant to corrosion and damage in most applications, if aggressive
chemicals or highly abrasive materials are present consult Partech before installation.
1.2 IL55BV2 Sensor
The IL55/BV2 differs from the IL55 in so much as that it is possible to remove it from the process without the need to
shut down or drain the line. This is due to the addition of a ball-valve mechanism enabling closure of the line and safe
and easy removal of the sensor.
1.3 7200 Monitor
The IL55/ IL55BV2 sensor is supplied with a 7200 Monitor for the measurement of suspended solids, turbidity and
sludge density. Please refer to the 7200 Monitor manual (167300IM) for full details about calibration and setup.
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L55 and IL55BV2 Sensor Instruction Manual
2 Installation
A reliable accurate measurement from any instrument can only be achieved by correct installation of the measuring
device, in the case of turbidity and suspended solids this is particularly important. If you are in any doubt contact your
Partech representative for advice.
Below are some points that should be considered before starting to install the sensor, and again if the results obtained
are not meeting your requirements.
•Avoid areas of extreme flow or turbulence, air bubbles will disturb the readings.
•The pipe, to which the sensor is fitted, is required to be completely flooded at all times.
•There should be no rapid changes in pipe size near to the sensor installation point.
•Do not place the sensor in an area of no flow, as the suspended solids will settle out and not provide a
representative reading.
•Both the IL55 & IL55BV2 are removable from their mountings. It is therefore important to leave sufficient space
around the instrument so as to enable removal.
•The sensor must be monitoring in an area that is representative of the whole process to gain accurate results.
To allow a single technician to calibrate and maintain the system the sensor should be placed within sight of the
controller. Although cable runs of up to 100 metres are possible, operational problems may be encountered.
163790IM-Iss05 Issue Date 11/05/210 Page 5 of 22
MAXIMUM ±45 DEGREES
FROM HORIZONTAL

IL55 and IL55BV2 Sensor Instruction Manual
2.1 orizontal Pipelines
When mounting either an IL55 or IL55BV2 Sensor in to a horizontal pipeline, the sensor should be mounted in the
ideally horizontal or at an angle of up to 45o from the horizontal.
If the sensor is mounted vertically at the top of the pipe then air bubbles can cause unstable readings, if the sensor is
vertical at the bottom of the pipe the sensor could become prone to excessive fouling.
2.2 Vertical Pipelines
When mounting is to a vertical pipe, then the sensor should be mounted perpendicular to the pipe, in the horizontal
plane, as shown below:
2.3 Mounting Boss Installation
The IL55 sensor requires a mounting boss to facilitate its installation on the required pipe section. The boss is
available from Partech in several variations dependent upon customer requirements. The main options are: -
Direct Fitting: This boss has been designed to fit directly to the existing pipe section. Depending upon pipe material,
the boss will be welded (steel), or adhered (plastic) to the parent material. A hole to suit the inside diameter of the
boss will be required through the pipe wall, to allow entry of the sensor. Any welds should be of a minimum 5mm leg,
preferable the same size as the thickness of the pipe wall. All joints should be hydro-statically tested to at least 1.25
working pressure before putting the system back on-line. Competent personnel should only carry out this work. A safe
system of work should be exercised at all times e.g. all lines are drained and locked-off before starting, fire watch for
one-hour after welding.
Quick Fitting: With this option a special pipe section is supplied with the mounting boss attached. The section is
connected into the existing line using standard flange connections. Pipe sections are designed to meet customer
requirements.
With both methods care must be taken to ensure the boss is positioned as previously described in this manual. Failure
to do so will impair the performance and life of the sensor.
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L55 and IL55BV2 Sensor Instruction Manual
3 Electrical Installation
For details of the electrical connections for the IL55 and IL55BV2 Sensors, refer to the 7200 Monitor instruction
manual.
3.1 Cable Routing
Care should be taken to ensure that the cable routing does not cause problems with the sensor measurement. Good
engineering practice should be followed with particular attention being paid to the following points:
•The sensor cable should be kept to the minimum length possible.
•Sufficient spare cable should be provided to allow complete and easy removal of the sensor from the process.
•Any spare cable should be safely stored.
•The sensor cable should be kept separate from the mains carrying cable.
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IL55 and IL55BV2 Sensor Instruction Manual
4 IL55BV2 Sensor
The IL55BV2 sensor is designed to allow the sensor to be withdrawn while the pipeline is in operation. The ball valve
allows the pipeline to be isolated while maintenance or calibration is carried out on the sensor.
WARNING: It must be noted that the IL55BV2 can only be used in applications that have a maximum line p essu e of
2 Ba o less.
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Mounting
Boss Ball Valve
Sensor
shaft
Ball valve
coupling nut
Dowty
Seal
Dowty seal
retaining nut
Sensor shaft
locking nut
collar
Sensor
body
Ball valve
coupling nut
120 mm
1 1/4" BSP internal thread hole in pipe 42 dia mounting boss
450.0 mm approx
sensor shaft in position
'L' dimension from inside of tube
collar setting dimension from end of sensor shaft to collar dimension = = 'L' + 45
connector male 1" BSP hand tighten to lock
collar
Douwty seal

L55 and IL55BV2 Sensor Instruction Manual
4.1 Installation Procedure
Figure 4 below shows all major parts of the IL55/BV2. Installation of the sensor is simplified if the sensor is firstly split
into two parts, the ball valve section and the sensor shaft and body.
1. Once the mounting boss has been positioned and fastened to the pipeline, the ball valve mechanism via coupling
nut can be screwed into the mounting boss.
2. Insert the sensor shaft into the ball valve mechanism by screwing and tightening both coupling nut between ball
valve and sensor and Dowty seal retaining nut
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2, Insert shaft, tighten
ball valve coupling nut
and dowty seal
retaining nut
3, Open ball valve,
slide sensor into
pipe, position collar and
tighten shaft
locking nut

IL55 and IL55BV2 Sensor Instruction Manual
4.2 Sensor Removal
The IL55BV2 can be removed without the need for de-pressurising or draining of the line. This is achieved by the use
of the ball valve mechanism.
The removal of the IL55BV2 sensor is the reverse procedure of the installation process as outlined in the previous
section:
1. Loosen the shaft locking nut.
2. Ensure that there is sufficient free cable to allow sensor removal
3. Withdraw sensor to end stop.
4. Close ball valve.
5. Unscrew Dowty seal retaining nut and remove sensor.
6. Ensure that the optical surface is protected while out of the pipe.
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1,Loosen shaft retaining nut
2, Withdraw sensor
3, Close ball valve
4, Unscrew dowty seal retaining
nut and remove sensor

L55 and IL55BV2 Sensor Instruction Manual
5 IL55 Sensor
The IL55 sensor is designed to be used in applications where the IL55BV2 is ruled out for reasons of line pressure or
space. The pipeline must be isolated and drained before removal of the sensor.
WARNING: It must be noted that the IL55 can only be used in applications that have a maximum line p essu e of 5
Ba o less.
163790IM-Iss05 Issue Date 11/05/210 Page 11 of 22
Mounting Boss Threaded Collar
Fit 'O' Ring into
recess
30 mm dia
Lens Holder
230 MM APPROX
MOUNTING BOSS TO SUIT CUSTOMER REQUIREMENTS HOLE IN PIPE 42 DIAMETER
TYPICAL PIPE SHOWN 90 OUTSIDE DIAMETER 5 WALL THICKNESS
'O' Rings
Stainless steel
Body 62 dia
Black Acetal
Black Acetal
'O' Ring
72 dia

IL55 and IL55BV2 Sensor Instruction Manual
5.1 Sensor Removal
The IL55 can only removed once the pipeline is de-pressurized and drained. Care must be taken to ensure that it is
safe to remove the sensor before carrying out the procedure below:
1. Loosen the knurled ring
2. Ensure that there is sufficient free cable to allow the sensor to be removed
3. Undo the knurled ring, do rotate the sensor whilst doing this as damage could be caused to the internal cables
4. Remove the sensor from the pipeline.
5. Ensure that the optical surface is protected while out of the pipe.
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L55 and IL55BV2 Sensor Instruction Manual
6 Setup & Calibration
The setup and calibration procedure is the same for both the IL55 and IL55BV2 Sensors, the operation of the monitor
is described in the appropriate manual.
In addition to the steps described in the monitor instruction manual the following precautions must be carried out with
the IL55/IL55BV2 sensors to ensure accurate calibration.
The sensor must be held in a dark (light proof) container for zero and calibration. The container must ensure that the
sensor face is at least 65mm from any object. (i.e. the base of the container). The optical face of the sensor should be
below the surface of the liquid.
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IL55 and IL55BV2 Sensor Instruction Manual
7 Maintenance
7.1 Sensor Cleaning
The frequency of cleaning and servicing of the sensor is dependant upon the application in which it is being used, and
the conditions present on site. It is advisable that, if possible, the sensor is regularly observed in the period after
installation. It is from these observations that the cleaning intervals should be determined to suit the level of fouling
experienced in the particular installation.
The sensor is not self-cleaning and the optical surfaces of the sensor will be subject to fouling. It is advisable that this
fouling is not allowed to build up to such an extent that it affects the sensors ability to make the required measurement.
Cleaning should be carried out with a soft non-abrasive cloth. Where fouling is particularly bad or where the fouling
has dried onto the optical surface a detergent or weak acid solution can be used. Care must be taken not to damage
the optical surface.
7.2 Inspection
It is envisaged that an inspection of the sensor will include the following:
•Check security of mountings.
•Check for damage to cable.
•Removal of the sensor from the pipe.
•Cleaning the sensor using a suitable detergent and removal of debris.
•Inspection of the glass lens for staining, scouring, cracks or chips.
•Check for moisture/signs of leakage inside the glass lens.
7.3 Fault Finding
Any faults that occur which are not a result of incorrect system configuration can be due to the following:
•Excessive fouling of the sensor lens - remove sensor, manually clean and re-install.
•Check the lens assembly is not damaged.
•There is a poor connection in the sensor cable - check all connections between sensor and controller.
•A fault has occurred with the measurement system in the sensor.
•Further fault finding information is contained in the monitor instruction manual.
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L55 and IL55BV2 Sensor Instruction Manual
8 Application Example: Sludge Density Monitor
A common application for the IL55/IL55BV2 sensor is the in-line monitoring of Sludge Density in the outlet pipe of
settlement tanks. The sensor in combination with either a 7200 or 8100/8200 monitor will detect the sludge density in
the pipe, providing information that allows the user to control the de-sludging of the tank.
The instrument will warn of a low level of suspended solids being pumped from the tank allowing the user to stop
pumping and allow the sludge density to build up in the tank. This prevents water or thin sludge being passed to the
sludge treatment system.
The system is often used for the de-sludging of settlement tanks as shown below in
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IL55 SENSOR
SETTLEMENT
TANK
SLUDGE
SLUDGE
SUPERNATENT SUPERNATENT
8100
MONITOR

IL55 and IL55BV2 Sensor Instruction Manual
9 Spare Parts
9.1 Sensors
118510......................................IL55 Senso
118520......................................IL55BV2 Senso
9.2 Mounting Accessories
171310......................................IL55 Mounting Boss, Stainless Steel
171300......................................IL55BV2 Mounting Boss, Stainless Steel
For pipe sections, please consult Partech Instruments.
9.3 Miscellaneous
163790......................................IL55 /IL55BV2 Inst uction Manual
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L55 and IL55BV2 Sensor Instruction Manual
10 Technical Support
Technical Support is available by phone, fax, or email, the details of which are shown below.
•Phone: [phone]
•Fax: [phone]
•Email: [e-mail]
•Website: www.partech.co.uk
To enable us to provide quick and accurate technical support please have the following information ready when you
contact us:
•Serial Number or original purchase details
•Sensor Type, and Serial Number
•Application details
•Description of fault
10.1 Returning Equipment for Repair
If equipment needs to be returned to Partech for repair or service the following address should be used:
SERVICE DEPARTMENT
PARTECH (ELECTRONICS) LTD
CHARLESTOWN
ST AUSTELL
CORNWALL
PL25 3NN
UNITED KINGDOM
Please include the following information with the returned equipment. Also ensure that sensors are adequately
protected for transportation (Advice on packing can be provided by our service department).
•Contact name and phone number
•Return address for equipment
•Description of fault or service required
•Any special safety precautions because of nature of application
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IL55 and IL55BV2 Sensor Instruction Manual
11 Technical Specification (should be last section)
Physical Featu es
Maximum Line P essu e............IL55 - 5 Ba
IL55BV2 - 2 Ba
Ope ating Tempe atu e Range..0 to +50 ° C
Sto age Tempe atu e Range.....-20 to +60 ° C
Envi onmental Rating................IP68
Cable Type................................4 Co e, Polyu ethane.
Mate ials....................................Stainless Steel 316, Black Acetyl, PVC, Polyu ethane, Glass
Weight.......................................IL55 - 2.5 Kg,
IL55BV2 - 7.2 Kg
Dimensions...............................IL55 - Length 190mm,
IL55BV2 - Length 392mm (695mm extended)
Standa d Cable Length.............10 met es
Maximum Cable Length............100 met es
EMC Emmision..........................EN 50081-1
EMC Immunity...........................EN 50082-1
Minimum Pipe Size....................65mm Inte nal diamete
Measu ement Featu es
Measu ing P inciple...................Inf a ed Light Backscatte
Light Sou ce..............................Inf a ed LED, 950nm
Measu ing Range......................0-1000 FTU to 0-5% Suspended Solids
Linea ity..................................... ± 2% FSD
Accu acy................................... ± 5% FSD (Actual Sample)
Repeatability............................. ± 1% FSD
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L55 and IL55BV2 Sensor Instruction Manual
12 Appendix 1: Preparation of Formazin Turbidity Standard
12.1 ealth & Safety Precautions
The chemicals used when following this procedure are harmful, therefore the correct safety precautions must be
carried out. During handling, avoid inhalation and contact with the eyes or skin. Wash hands thoroughly after use.
Refer to the data sheets for further details of the chemicals used.
12.2 Method of Preparation
The preparation of a Formazin Turbidity Standard should be carried out with great care. Absolute cleanliness should
be observed at all times to avoid any contamination of the solution.
All water used should be freshly distilled or de-mineralised. During preparation and use, keep the solution covered to
prevent contamination.
1. Dissolve the Hydrazinium Sulphate 10g (32112680) into 1 litre of water. Stir the solution thoroughly.
2. Dissolve the Hexamine 100g (32112630) into 1 litre of water. Stir the solution thoroughly.
3. Pour the above solutions into a 2.5 litre Winchester or similar type amber glass bottle and mix thoroughly. Allow the
mixture to stand undisturbed for 24 hours at 25°C. The resultant solution will have a turbidity of 4000 FTU.
4. Prior to use the standard should be mixed thoroughly, i.e. before pouring out the standard, shake the bottle well.
12.3 Preparation of Dilution’s.
The 4000 FTU standard can be used to prepare solutions of lower values by diluting with water. The formula below
can be used to calculate the ratio of water to 4000 FTU standard to produce a solution of the required value.
W
A
= −
4000
1
W = parts water to 1 part 4000 FTU standard
A = Required FTU value
The Formazin Dilution Chart (table QAP 6.14.4) provides the mixture requirements to make various solutions using the
4000 FTU standard.
12.4 Calibration
When Formazin solutions are used for calibration/testing of sensors, sufficient solution is required such that the sensor
is completely immersed. When using light scatter sensors it is important that the sensor is positioned away from the
sides and bottom of the container to prevent the light being reflected.
12.5 Storage Life
The turbidity standard should be stored in a Winchester bottle and kept in a cool dark place. The bottle should be
labelled to identify its content and also the date of preparation should be recorded. The 4000 FTU standard has a shelf
life of one year after which it should be discarded and a fresh solution should be prepared.
Solutions made by diluting the 4000 FTU standard should also be stored in suitably labelled amber glass bottles and
kept in a cool dark place. Solutions above 400 FTU have a shelf life of one month after which they should be
discarded. Solutions below 400 FTU should be prepared from the 4000 FTU standard daily.
Solutions can be used outside of the storage lives specified above but any results taken must acknowledge this and
be accepted as less accurate. When using solutions, watch for flocculation (the particles in the solution will appear to
link together), if this occurs discard the solution and prepare a fresh standard.
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IL55 and IL55BV2 Sensor Instruction Manual
13 Appendix 2: Fuller's Earth
The Fuller's Earth is supplied in a sealed 20g package, the package contains sufficient to make a 20,000 mg/l (20 g/l)
solution when combined with 1 litre of water. Alternate solutions can be obtained by increasing the amount of water
used as shown in the table below.
Solution Required (g/l) Add pack to water
(litres)
2.5 8.0
5.0 4.0
10.0 2.0
20.0 1.0
40.0 0.5
The following points should be observed when preparing and using Fullers Earth solutions:
•The water used should be freshly distilled or de-mineralised.
•Ensure the container used for the solution is clean.
•During preparation and use, keep the solution covered to prevent contamination.
•When using the solution it must be continually stirred to ensure accurate and consistent measurements and to
prevent settling.
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