Turner Designs TD-4100XD E09 Installation and operating instructions

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ADDENDUM: CLEAN-IN-PLACE SYSTEM
This addendum provides the appropriate general arrangement drawings, installation specics, and
operating instructions for an E09 TD-4100XD monitor equipped with an integrated clean-in-place (CIP)
system. The functionality and general operational instructions for your monitor remain as described in
the manual, with the exceptions described in this addendum.
In some cases the arrangement and appearance of your CIP-equipped monitor do not match the
graphic images shown in the manual. If you have questions regarding installation, connections, settings,
procedures, or the general appearance of your monitor, contact a service representative at Turner
Designs Hydrocarbon Instruments:
Tel: + 1 559 253 1414, Fax: + 1 559 253 1090, or
Email: [email protected]
A.1 INSTALLING THE CLEAN-IN-PLACE SYSTEM
The following installation steps include references to Figure A.1.1.
1. Install the valve and pipe combo (1) into
the sample pump discharge port as shown.
Remove the exible hose if required.
2. Install the CIP return port (2) as shown.
Make sure that the union half axis is parallel
to the sample pump discharge port axis.
3. If not yet installed, install the CIP return
port (3) into the 3/4” FNPT tank tting. This
section shall be vertical to the ground. For
best results, install prior to the CIP main
body.

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4. Install the CIP return port (4) by joining the
upper and lower union joints together. Make
sure the joints are properly tightened.
5. Install the #10-32 fasteners, attaching the
ball valve to the electric actuator.
6. Install the 3/4” NPT CPVC ball valve actuator
(6) to the CIP frame as shown. Hand tighten
the 1/4-20 fasteners and then install the #10-
32 fasteners, attaching the ball valve to the
electric actuator.
7. Install the oat valve switch into the 1-1/2”
FNPT tank tting.
a. Remove the tank cover.
b. Reach into the tank and remove the tank
adapter nut by turning clockwise.
c. Remove the tank adapter and bushing
assembly from the outside of the tank.
d. Slide the tank adapter and bushing
assembly over the oat arm and tighten
onto the oat valve body.
e. Gently rotate the oat arm and oat
valve body through the tank opening.
f. Reach into the tank and slide the tank
adapter nut over the oat arm. Tighten
the nut onto the tank adapter threads
with a counter-clockwise motion.
NOTE: When mounting the switch, the arrow on
the side of the switch must point up. The conduit
port must point down.

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Figure A.1.1 Monitor showing CIP installation points

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The nished CIP system showing the parts requiring
assembly.
Piece 3
Piece 4
Piece 5
Piece 2
Piece 1
Piece 6
A.1.1 DESIGN INFORMATION
• Power to the pump and valve actuators is supplied by the input mains at 115 VAC.
• The CIP pump can be set for 115 VAC or 230 VAC but must be set at 115 VAC for use with this
monitor.
• Maximum working pressure of cleaning solution pump: 75 psig [517 kPa(g)].
• Cleaning solution maximum pumping capacity: about 18 U.S. gal/min [68 L/min] .
The automatic cleaning system automates all sample valves associated with the monitor. The valves
are directed to avoid cross contamination of uids during the cleaning process. During power failures,
valves will remain in their last state. During start-up after a power failure, the valves will be directed to
the process. During stabilization periods, the valves are directed to the outlet.
WARNING: Although the CIP system pump is dual voltage, it must be wired for 115 VAC operation
with this monitor.
CAUTION: Repair or replace worn or damaged parts immediately. Do not alter or modify the
cleaning solution pump.
CAUTION: Do not block or restrict the cleaning solution tank vent, which is located in the center of
the tank cover. This vent must remain open to atmosphere.
CAUTION: The cleaning solution must be compatible with the process downstream of the monitor
since a portion of the cleaning solution may be directed into the monitor’s drain line when the
cleaning cycle is nished.

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A.1.2 MAKING PIPING CONNECTIONS
The cleaning solution pump and system is partially plumbed at the factory. Some assembly is required,
as detailed in Section A.1 Installing the Clean-In-Place System. To periodically drain the tank, Turner
Designs Hydrocarbon Instruments recommends installing a T-valve with hose bib at the CIP outlet
shown below and on page 1 of Section A.5 Clean-In-Place General Arrangement Drawings.
Rear view of monitor showing CIP system pump with
front panel removed.
CIP pump outlet. 1/2 in. MNPT. Install optional T-valve
and hose bib here for draining the CIP tank easily.
Right view of monitor showing CIP system outlet and
monitor sample return.
CIP pump outlet
Sample return (to process). 1 in. FPT.

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The CIP inlet valve actuator shown in a remote
installation. The 1/2 in. CPVC ball valve switches inlet
from sample stream to CIP system tank.
Turner Designs Hydrocarbon instruments strongly
recommends installing a vacuum breaker, such as the
Plast-O-Matic VBM050V-CP, near the valve outlet.
A pressure regulator is shipped with the monitor and
should be installed on the sample water inlet pipe,
before the actuator.
Note the 3° slope in the outlet piping to the monitor.
Vacuum breaker
Valve outlet pipe
Sample water inlet pipe
Cleaning solution inlet pipe
The monitor sample supply connection is described in Section 2.3.2.2 Installation – Piping Connection.
The monitor sample return connection is described in Section 2.3.1.2 Installation – Piping Connection.
A.1.3 MAKING ELECTRICAL CONNECTIONS
WARNING: Electrical connections should be made only by trained service personnel or certied
electrician, and should only be completed in accordance with site isolation, safe work practices,
and appropriate electrical codes.
The information in this section replaces the relay assignments described in Section 5.7 Conguring
Alarms and Relays.
The following image shows the monitor terminal blocks, located inside the enclosure door on the access
panel.
Figure A.1.3.1 Monitor access panel and terminal blocks

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Make connections at terminal blocks
as shown. See the key on page 7 of
Section A.6 E09 TD-4100XD General
Arrangement Drawings for relay
assignments and letter and number
designations.
The fuses immediately above the terminal
blocks are 6.3 A fast acting, with the
exception of the power (PWR) and CIP
pump (I), which use 5 A slow blow fuses.
The actuated valves are wired as follows:
1. Black (normally closed)
2. Red (normally open)
3. White (neutral)
4. Green (frame ground)
The main power terminal (PWR) is wired
as follows:
1. Black (hot)
2. White (neutral)
3. Green (ground)
The CIP pump terminal block (I) is wired
as follows:
2. Black (normally open)
3. White (neutral)
4. Green (ground)
Inlet valve actuator shown with cover
removed. Make wiring connections as
shown. Connect to the monitor, using
glands and cabling appropriate for your
hazardous area requirements.
Green (ground)
Red (normally open)
Black (normally closed)
White (neutral)

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Bubble trap valve actuator shown with the
cover removed.
The bubble trap valve and outlet valve
must be wired as shown here. Connect
to the monitor, using glands and cabling
appropriate for your hazardous area
requirements.
Green (ground)
White (neutral)
Black (normally closed)
Red (normally open)
CIP system pump shown in shipping
crate, front panel removed. To make
electrical connections at the CIP pump:
1. Remove the four bolts connecting the
pump to the stainless steel panel.
2. Unfasten the pump from the tank by
loosening the O-ring.
3. Remove the cap at the bottom right
side of the pump to access the wiring.
4. Connect to the monitor, using glands
and cabling appropriate for your
hazardous area requirements.
5. Reverse these steps to return the
pump to its mounted position.
Internal switch housing view
After the CIP tank oat switch is installed,
as described in Step 7 of Section A.1
Installing the Clean-In-Place System,
make electrical connections from the
switch to the pump and to the monitor
terminal blocks (I). Use glands and
cabling appropriate for your hazardous
area requirements.
The black, white, and green wires must
be connected as follows: the green leads
can be connected together with a wire nut;
the white leads can also be connected
together with a wire nut; one black lead
should be connected to the normally open
terminal and the other to the common
terminal.
NOTE: When mounting the switch, the
arrow on the side of the switch must point
up. The conduit port must point down.

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A.2 OPERATING THE CLEAN-IN-PLACE SYSTEM
Prior to operating the clean-in-place system:
1. Remove the cleaning solution tank cover.
2. Fill the tank with cleaning solution to a minimum of 5 U.S. gal [19 L]. The volume of the tank is
10 U.S. gal [38 L]. The cleaning solution will depend upon what is likely to cause the fouling.
Your water treatment chemical supplier should be able to help you with a recommended
cleaning solution based upon your site-specic situation. Make sure the cleaning solution is
compatible with the materials of the CIP system and monitor, including 316 stainless steel and
CPVC.
3. Replace the cleaning solution tank cover.
4. Make sure that power is provided to the monitor.
5. You must congure the cleaning system operation on the E09 monitor, as described in the
following procedure.
The following procedures supplement the one described in Section 9.6.1.1 Online Cleaning, which is
specic to the ow cell rather than the entire sample system.
NOTE: Determining the appropriate durations for your cleaning settings will depend on the location
of the actuated CIP inlet valve. The following recommended settings were determined with a test
conguration that used 50 ft of 1/2 in. piping (25 ft inlet, 25 ft outlet). The piping was installed at a
3° slope. See Section A.5 Clean-In-Place General Arrangement Drawings.
To congure the automatic cleaning cycle
At the Home screen, press “Setup” on the keypad.
Press “3” to access the cleaning system settings.
Enter the user access code (8520) when prompted.
You can choose whether you want the monitor to go
into automatic cleaning on a regular timer. If you select
cleaning on a timer, the cleaning will occur starting on a
specic programmed date and time.
To select cleaning on a timer, press “1” to check the box.
Pressing “1” again will uncheck the box.
You must also program the starting date and time (press
“3”).

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Select “1” to set the starting date (must be a current or
future date).
Select “2” to set the starting time (must be a future time).
You must also set the cleaning frequency. Return to the
Cell Cleaning screen, and press “4.” You must set the
interval of the cleaning as well as the units. Use the “→”
key to change the units.
Finally, you must set the cleaning sequence. This is done
by pressing “5” at the Cell Cleaning screen.
Press “1” to set the duration for keeping the inlet valve
closed. Use the keypad to enter a value in seconds.
All settings for the cleaning cycle are entered in seconds.
Press “2” through “5” to enter duration values for the
corresponding steps in the cleaning cycle.
Always allow more time for draining the system than
cycling the cleaning solution.

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This image shows the recommended duration settings
for steps 1–5 of the cleaning cycle (based on installation
specics stated above).
See the next image for “6” More Options.
This screen (More Options) shows the remainder of the
cleaning cycle steps and their recommended settings.
At Step 5 all valves have returned to normal sample
process.
NOTE: The Clean Pump ON time must be at least 90 seconds to allow the bubble trap to ll and
the pressure sensor to trigger the AVS.
To manually start the automatic cleaning cycle
WARNING: Always secure the cover on the cleaning solution tank before operating the CIP
system.
Press CLEAN on the keypad.
At the Cleaning screen, press “1” to start the cleaning
cycle.
Pressing “2” stops all processes and measurements and
allows manual cleaning; for example, cleaning the ow
cell nozzle with a brush.
The actuated valves are automatically opened and closed
as the cleaning cycle progresses through 10 steps, as
shown in the LCD screens.
First, the inlet valve closes and the bubble trap drains.
The recommended duration setting is 45 seconds.

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When the inlet valve has closed, the inlet tubing drains for
a recommended duration of 60 seconds.
Next the bubble trap valve closes. The recommended
duration for this setting is 20 seconds.
When all uid has drained from the sample system, the
outlet valve closes. The recommended duration for this
setting is 15 seconds.
At this point in the process, all valves are closed and the
cleaning solution can be pumped through the system.
The recommended run time for the pump is 120 seconds.
NOTE: Allow a minimum of 90 seconds for this setting in
order to ll the bubble trap and activate the AVS. Cleaning
solution will not enter the ow cell until the AVS is on.
When cleaning is complete, the CIP system pump shuts
off and the cleaning solution drains from the inlet tubing
back to the tank. The recommended duration for this
setting is 60 seconds.

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The bubble trap valve opens and the bubble trap drains
back to the tank. The recommended duration for this
setting is 45 seconds.
Next the bubble trap valve closes. The recommended
duration for this step is 20 seconds.
The outlet valve returns to process. The recommended
duration for this setting is 20 seconds.
The inlet valve returns to process. The recommended
duration for this setting is 20 seconds.
At the end of the cleaning cycle, cleaning solution has
drained back into the cleaning solution tank, all of the
actuated valves have returned to their default positions,
and monitoring continues as normal.
Any step in the cleaning process can be aborted by
pressing ESC on the keypad. Press ESC repeatedly to
abort the entire process.
NOTE: Whenever operating the CIP system, make sure that the cleaning solution tank is at least
half full (5 U.S. gal) by checking the ll-level markings on the side of the tank.
When the monitor is in the cleaning mode, the following will occur:
• The oil concentration measurements stop.
• The 4-20 mA output will remain proportional to the last measured oil concentration.
• The states of all monitored alarms will remain at the last state set during normal operation.

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A.3 MAINTENANCE
Before each use, check that sufcient cleaning solution is present, at least 5 U.S. gal [19 L].
Periodically drain and replace the cleaning solution. The cleaning solution will depend upon what is
likely to cause the fouling. Your water treatment chemical supplier should be able to help you with a
recommended cleaning solution based upon your site-specic situation. The cleaning solution must be
compatible with the wetted materials of the cleaning system and the monitor. Do not select a cleaning
duration longer than the cleaning interval.
Make sure all threaded and tubing connections are tight and leak-free.
For extended shutdown ush the pump to prevent the uid from drying or freezing in the pump and
damaging the pump. The pump will be damaged by uid below 35 °F [4.4 °C].
The pump will need to be overhauled periodically depending upon amount of use. The overhaul period
cannot be predicted since the use time is not dened.
Before undertaking any maintenance and overhaul of the pump, shut off the sample supply and allow
the pump to operate until empty. Flush if necessary. Turn off power and uncouple power line to pump.
Remove pump from the mounting. Carry out all repair work with extreme cleanliness.
Turner Designs Hydrocarbon Instruments recommends you establish a preventive maintenance
schedule based on the pump’s service history. This is especially important for prevention of spills or
leakage due to pump head failure.
No expected maintenance of the automated valves or actuators is required.
A.4 TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Parts of the sample system,
including the ow cell and lines are
not sufciently cleaned during the
cleaning cycle.
Cleaning cycle duration is too
short.
Increase the duration of the
cleaning cycle. See Section A.2
Operating the Clean-In-Place
System.
Cleaning solution is not effective
upon fouling.
Use a different cleaning solution
appropriate for the mode of
fouling. Consult Turner Designs
Hydrocarbon Instruments for
recommendations.
Automated valves fail to switch
position during sample system
cleaning event.
Incorrect wiring. Check wiring connections at the
terminal blocks. See Section
A.6 E09 TD-4100XD General
Arrangement Drawings.
CLEAN key was not pressed, if
manually initiated.
If manually starting, press the
CLEAN key.
Stages of automatic cleaning cycle
are not timed correctly.
Check the settings information in
Section A.2 Operating the Clean-
In-Place System.

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PROBLEM CAUSE SOLUTION
Pump will not run or runs slowly. Incorrect voltage. Make sure that the dual voltage
pump is wired for 115 VAC.
Blockage within pump. Disassemble pump and check for
objects that would obstruct the
movement of internal parts.
No uid in tank. Check the ll-level on the side of
the cleaning solution tank. Make
sure it is lled to a minimum of 5
U.S. gal [19 L].
Blown fuse. Replace the pump fuse. Use slow
blow 5 A fuse, PN 106214.
Pump runs but little or no liquid
ows.
Loose uid connections. Make sure that all suction
connections are tight.
Pump rattles or excessively
vibrates.
Various issues. Contact Turner Designs
Hydrocarbon Instruments.
NOTE: Check all possible problems and causes before disassembling the pump.

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A.5 CLEAN-IN-PLACE GENERAL ARRANGEMENT DRAWINGS
The CIP general arrangement drawings include multiple system views, monitor installation specics, and a process and instrumentation diagram.

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