Hach-Lange ORBISPHERE 31xxx User Manual

Document Number DGEC-MAN/E

ORBISPHERE Model 31xxx

Electrochemical Sensors

INSTALLATION and MAINTENANCE MANUAL

June 2010, Revision H

Table of Contents

Section 1 General Information.........................................................................................................3

1.1 Disclaimer ....................................................................................................................................3

1.2 Contact information...................................................................................................................... 3

1.3 Safety information ........................................................................................................................3

1.3.1 Use of hazard information ...................................................................................................3

1.3.2 Service and repairs ............................................................................................................. 3

1.3.3 Precautionary labels............................................................................................................ 4

1.4 Product recycling information....................................................................................................... 5

1.5 Product disposal .......................................................................................................................... 7

1.6 Restriction of hazardous substances (RoHS) .............................................................................. 8

Section 2 Technical Specifications................................................................................................. 9

2.1 Sensor design.............................................................................................................................. 9

2.2 Sensor weight and dimensions ....................................................................................................9

2.3 EC sensors and parts used on ORBISPHERE configured systems .......................................... 10

2.4 Sensor membrane specifications...............................................................................................10

2.4.1 Hydrogen sensors .............................................................................................................10

2.4.2 Oxygen sensors (Table 1)................................................................................................. 11

2.4.3 Oxygen sensors (Table 2)................................................................................................. 12

2.4.4 Ozone sensors .................................................................................................................. 13

Section 3 Introduction .....................................................................................................................15

3.1 What you have received ............................................................................................................ 15

3.1.1 An oxygen, ozone, or hydrogen electrochemical sensor ..................................................15

3.1.2 A sensor maintenance kit..................................................................................................15

3.2 Basic principle of operation........................................................................................................ 15

Section 4 Installation........................................................................................................................19

4.1 Initial sensor cell cleaning .......................................................................................................... 19

4.2 Positioning information............................................................................................................... 19

4.3 Sensor insertion .........................................................................................................................20

4.4 Sensor removal..........................................................................................................................20

4.5 Mounting accessories ................................................................................................................20

4.5.1 External pressure sensor.................................................................................................. 20

4.5.2 Weld-on stainless steel socket.......................................................................................... 21

4.5.3 Insertion/extraction valve .................................................................................................. 22

4.5.4 ORBISPHERE flow chambers ..........................................................................................22

4.5.5 Multi parameter flow chamber........................................................................................... 24

Section 5 Maintenance.....................................................................................................................25

5.1 Disassembly and assembly ....................................................................................................... 25

5.1.1 Taking the sensor apart (membrane removal) .................................................................. 25

5.1.2 Sensor assembly (membrane installation) ........................................................................ 26

5.2 Electrochemical cleaning and regeneration center .................................................................... 29

5.3 Chemical cleaning: oxygen and ozone sensor cell .................................................................... 30

5.3.1 Membrane support cleaning.............................................................................................. 30

5.3.2 Electrodes ammonia cleaning ...........................................................................................30

5.3.3 Anode and cathode nitric acid cleaning ............................................................................31

5.3.4 Sensor face polishing........................................................................................................31

5.3.5 O

5.4 Hydrogen sensor cell cleaning................................................................................................... 33

Sensor only: final center electrode cleaning................................................................ 32

3

Section 6 Troubleshooting.............................................................................................................. 35

6.1 Oxygen sensor...........................................................................................................................35

6.2 Hydrogen sensor........................................................................................................................ 35

6.3 Ozone sensor............................................................................................................................. 36

Section 7 Spare Parts and Accessories ......................................................................................37

7.1 Sensor parts............................................................................................................................... 37

1

Table of Contents

7.2 Accessories................................................................................................................................37

7.3 Flow chambers and installation devices.....................................................................................37

7.4 Protection caps and related part kits ..........................................................................................39

7.5 Maintenance kits for EC sensors................................................................................................40

7.5.1 Kits for O

7.5.2 Kits for O

7.5.3 Kits for H

sensors ............................................................................................................40

2

sensors ............................................................................................................41

3

sensors ............................................................................................................41

2

2

Section 1 General Information

1.1 Disclaimer

The information in this manual has been carefully checked and is believed to be accurate.
However, Hach Lange assumes no responsibility for any inaccuracies that may be contained in
this manual. In no event will Hach Lange be liable for direct, indirect, special, incidental, or
consequential damages resulting from any defect or omission in this manual, even if advised of
the possibility of such damages. In the interest of continued product development, Hach Lange
reserves the right to make improvements in this manual and the products it describes at any
time, without notice or obligation.

Copyright © 2010 by Hach Lange. All rights reserved. No part of the contents of this manual
may be reproduced or transmitted in any form or by any means without the written permission of
Hach Lange.

1.2 Contact information

Manufacturing site:

HACH LANGE Sàrl
6, route de Compois
1222 Vésenaz
SWITZERLAND
Tel. [phone]
Fax [phone]

1.3 Safety information

Please read the entire manual before unpacking, setting up, or operating this sensor.

Pay particular attention to all warning and caution statements. Failure to do so could result in
serious injury to the operator or damage to the equipment.

To the ensure the protection provided by this equipment is not impaired, do not use or install
this equipment in any manner other than that which is specified in this manual.

1.3.1 Use of hazard information

WARNING

A warning is used to indicate a condition which, if not met, could cause serious personal injury
and/or death. Do not move beyond a warning until all conditions have been met.

CAUTION
A caution is used to indicate a condition which, if not met, could cause minor or
moderate personal injury and/or damage to the equipment. Do not move beyond a
caution until all conditions have been met.

European HQ:

HACH LANGE GmbH
Willstätterstraße 11
40549 Düsseldorf
GERMANY
Tel. [phone]
Fax [phone]

Note: A note is used to indicate important information or instructions that should be considered

before operating the equipment.

1.3.2 Service and repairs

None of the sensor’s components can be repaired by the user. Only personnel from Hach
Lange or its approved representative(s) is (are) authorized to attempt repairs to the sensor and
only components formally approved by the manufacturer should be used.

Any attempt at repairing the sensor in contravention of these principles could cause damage to
the sensor and corporal injury to the person carrying out the repair. It renders the warranty null
and void and could compromise the correct working of the sensor and the electrical integrity or
the CE compliance of the sensor.

If you have any problems with installation, or using the sensor please contact the company that
sold it to you. If this is not possible, or if the results of this approach are not satisfactory, please
contact the Customer Service department of Hach Lange.

3

General Information

1.3.3 Precautionary labels

Read all labels and tags attached to the sensor. Personal injury or damage to the sensor could
occur if not observed.

This symbol, if noted on the product, indicates the need for protective eye wear.

This symbol indicates the need for protective hand wear.

Electrical equipment marked with this symbol may not be disposed of in European public
disposal systems. In conformity with European local and national regulations, European
electrical equipment users must now return old or end-of-life equipment to the manufacturer
for disposal at no charge to the user.

Products marked with this symbol indicates that the product contains toxic or hazardous
substances or elements. The number inside the symbol indicates the environmental protection
use period in years.

4

1.4 Product recycling information

ENGLISH

Electrical equipment marked with this symbol may not be disposed of in
European public disposal systems after 12 August 2005. In conformity with
European local and national regulations (EU Directive 2002/96/EC), European
electrical equipment users must now return old or end-of-life equipment to the
manufacturer for disposal at no charge to the user.

Note: For return for recycling, please contact the equipment

manufacturer or supplier for instructions on how to return end-of-life
equipment for proper disposal.

DEUTSCH

Elektrogeräte, die mit diesem Symbol gekennzeichnet sind, dürfen in Europa nach dem 12.
August 2005 nicht mehr über die öffentliche Abfallentsorgung entsorgt werden. In
Übereinstimmung mit lokalen und nationalen europäischen Bestimmungen (EU-Richtlinie
2002/96/EC), müssen Benutzer von Elektrogeräten in Europa ab diesem Zeitpunkt alte bzw. zu
verschrottende Geräte zur Entsorgung kostenfrei an den Hersteller zurückgeben.

Hinweis: Bitte wenden Sie sich an den Hersteller bzw. an den Händler, von dem Sie das Gerät
bezogen haben, um Informationen zur Rückgabe des Altgeräts zur ordnungsgemäßen
Entsorgung zu erhalten.

General Information

FRANCAIS

A partir du 12 août 2005, il est interdit de mettre au rebut le matériel électrique marqué de ce
symbole par les voies habituelles de déchetterie publique. Conformément à la réglementation
européenne (directive UE 2002/96/EC), les utilisateurs de matériel électrique en Europe doivent
désormais retourner le matériel usé ou périmé au fabricant pour élimination, sans frais pour
l'utilisateur.

Remarque: Veuillez vous adresser au fabricant ou au fournisseur du matériel pour les
instructions de retour du matériel usé ou périmé aux fins d'élimination conforme.

ITALIANO

Le apparecchiature elettriche con apposto questo simbolo non possono essere smaltite nelle
discariche pubbliche europee successivamente al 12 agosto 2005. In conformità alle normative
europee locali e nazionali (Direttiva UE 2002/96/EC), gli utilizzatori europei di apparecchiature
elettriche devono restituire al produttore le apparecchiature vecchie o a fine vita per lo
smaltimento senza alcun costo a carico dell’utilizzatore.

Nota: Per conoscere le modalità di restituzione delle apparecchiature a fine vita da riciclare,
contattare il produttore o il fornitore dell’apparecchiatura per un corretto smaltimento.

DANSK

Elektriske apparater, der er mærket med dette symbol, må ikke bortskaffes i europæiske offentlige
affaldssystemer efter den 12. august 2005. I henhold til europæiske lokale og nationale regler
(EU-direktiv 2002/96/EF) skal europæiske brugere af elektriske apparater nu returnere gamle eller
udtjente apparater til producenten med henblik på bortskaffelse uden omkostninger for brugeren.

Bemærk: I forbindelse med returnering til genbrug skal du kontakte producenten eller
leverandøren af apparatet for at få instruktioner om, hvordan udtjente apparater bortskaffes
korrekt.

5

General Information

SVENSKA

Elektronikutrustning som är märkt med denna symbol kanske inte kan lämnas in på europeiska
offentliga sopstationer efter 2005-08-12. Enligt europeiska lokala och nationella föreskrifter
(EU-direktiv 2002/96/EC) måste användare av elektronikutrustning i Europa nu återlämna gammal
eller utrangerad utrustning till tillverkaren för kassering utan kostnad för användaren.

Obs! Om du ska återlämna utrustning för återvinning ska du kontakta tillverkaren av utrustningen
eller återförsäljaren för att få anvisningar om hur du återlämnar kasserad utrustning för att den ska
bortskaffas på rätt sätt.

ESPANOL

A partir del 12 de agosto de 2005, los equipos eléctricos que lleven este símbolo no deberán ser
desechados en los puntos limpios europeos. De conformidad con las normativas europeas
locales y nacionales (Directiva de la UE 2002/96/EC), a partir de esa fecha, los usuarios
europeos de equipos eléctricos deberán devolver los equipos usados u obsoletos al fabricante de
los mismos para su reciclado, sin coste alguno para el usuario.

Nota: Sírvase ponerse en contacto con el fabricante o proveedor de los equipos para solicitar
instrucciones sobre cómo devolver los equipos obsoletos para su correcto reciclado.

NEDERLANDS

Elektrische apparatuur die is voorzien van dit symbool mag na 12 augustus 2005 niet meer
worden afgevoerd naar Europese openbare afvalsystemen. Conform Europese lokale en
nationale wetgegeving (EU-richtlijn 2002/96/EC) dienen gebruikers van elektrische apparaten
voortaan hun oude of afgedankte apparatuur kosteloos voor recycling of vernietiging naar de
producent terug te brengen.

Nota: Als u apparatuur voor recycling terugbrengt, moet u contact opnemen met de producent of
leverancier voor instructies voor het terugbrengen van de afgedankte apparatuur voor een juiste
verwerking.

POLSKI

Sprzęt elektryczny oznaczony takim symbolem nie może być likwidowany w europejskich
systemach utylizacji po dniu 12 sierpnia 2005. Zgodnie z europejskimi, lokalnymi i państwowymi
przepisami prawa (Dyrektywa Unii Europejskiej 2002/96/EC), użytkownicy sprzętu elektrycznego
w Europie muszą obecie przekazywać Producentowi stary sprzęt lub sprzęt po okresie
użytkowania do bezpłatnej utylizacji.

Uwaga: Aby przekazać sprzęt do recyklingu, należy zwrócić się do producenta lub dostawcy
sprzętu w celu uzyskania instrukcji dotyczących procedur przekazywania do utylizacji sprzętu po
okresie użytkownia.

PORTUGUES

Qualquer equipamento eléctrico que ostente este símbolo não poderá ser eliminado através dos
sistemas públicos europeus de tratamento de resíduos sólidos a partir de 12 de Agosto de 2005.
De acordo com as normas locais e europeias (Directiva Europeia 2002/96/EC), os utilizadores
europeus de equipamentos eléctricos deverão agora devolver os seus equipamentos velhos ou
em fim de vida ao produtor para o respectivo tratamento sem quaisquer custos para o utilizador.

Nota: No que toca à devolução para reciclagem, por favor, contacte o produtor ou fornecedor do
equipamento para instruções de devolução de equipamento em fim de vida para a sua correcta
eliminação.

6

1.5 Product disposal

Note: The following only applies to European customers.

Hach Lange is committed to ensuring that the risk of any environmental damage or pollution
caused by any of its products is minimized as far as possible. The European Waste Electrical
and Electronic Equipment (WEEE) Directive (2002/96/EC) that came into force on August 13
2005 aims to reduce the waste arising from electrical and electronic equipment; and improve the
environmental performance of all those involved in the life cycle of electrical and electronic
equipment.

In conformity with European local and national regulations (EU Directive 2002/96/EC stated
above), electrical equipment marked with the above symbol may not be disposed of in
European public disposal systems after 12 August 2005.

General Information

Hach Lange will offer to take back (free of charge to the customer) any old, unserviceable or
redundant analyzers and systems which carry the above symbol, and which were originally
supplied by Hach Lange. Hach Lange will then be responsible for the disposal of this
equipment.

In addition, Hach Lange will offer to take back (at cost to the customer) any old, unserviceable
or redundant analyzers and systems which do not carry the above symbol, but which were
originally supplied by Hach Lange. Hach Lange will then be responsible for the disposal of this
equipment.

Should you wish to arrange for the disposal of any piece of equipment originally supplied by
Hach Lange, please contact your supplier or our After Sales Service department in Geneva for
instructions on how to return this equipment for proper disposal.

7

General Information

1.6 Restriction of hazardous substances (RoHS)

The European Union RoHS Directive and subsequent regulations introduced in member states
and other countries limits the use of six hazardous substances used in the manufacturing of
electrical and electronic equipment.

Currently, monitoring and control instruments do not fall within the scope of the RoHS Directive,
however Hach Lange has taken the decision to adopt the recommendations in the Directive as
the target for all future product design and component purchasing.

This product is compliant with the European Union RoHS Directive.

Note: The following only applies to exports of this product into the People’s Republic of China.

Connector socket X
Central tube X

O:

X:

8

Section 2 Technical Specifications

Specifications are subject to change without notice.

2.1 Sensor design

Table 1 Sensor design

Gas

O

O

H

2

3

2

Max. Press

Rating (bar)

20 31 11x.yz Where :

50 31 12x.yz
100 31 13x.yz
200 31 14x.yz

20 31 31x.yz
100 31 33x.yz

50 31 21x.yz
100 31 23x.yz

200 31 24x.yz

Sensor
Models

• All ORBISPHERE electrochemical sensors’ enclosures are certified IP68 / NEMA4

• PEEK (Polyetheretherketone) is a highly crystalline thermoplastic

2.2 Sensor weight and dimensions

Sensor weight is from 140 to 700 grams, depending on the construction material.

Comments

x = Sensor special characteristics

(0 to 6 ; depending on application)
y = Membrane O-ring material
(0 = EDPM / 1 = Viton / 2 = Kalrez / 4 = Nitril)
z = Head material
(1=Stainless Steel / 2=Peek / 4=Hastelloy / 5=Titanium / 7= Monel)

Suffixes (when used) :

A denotes a sensor with fast response to temp. change
E denotes an EEx certified sensor (Ex-Proof)
s denotes a Smart sensor

Figure 1 Sensor dimensions

9

Technical Specifications

2.3 EC sensors and parts used on ORBISPHERE configured systems

Table 2 ORBISPHERE configured systems

Configured System Sensor Membrane

3625 Package

analyzer

3624 ProBrix 31 110.02 2952A 29104.0 29054 32702

29981 Pharmapack 31 110A.02

31 110.02 2956A

2956A plus one

Goretex

membrane ref.

32918

®

Protection

Cap

29111 (as used
on TC sensors)

None Not applicable

Protection

Cap Kit

28002 Tefzel

washers only

Maintenance

Kit

32703

32703 plus

32918

(10 piece box)

2.4 Sensor membrane specifications

2.4.1 Hydrogen sensors

Table 3 Membrane specifications - Hydrogen sensors

Membrane Model 2956A 2952A 2995A 29015A

Recommended
applications

Material PFA Tefzel
Thickness [µm] 25 25 12.5 23
Calibration gas 1% pure H2 10% pure H2 100% pure H2 100% pure H2
Dissolved measurement

range
Gaseous measurement

range

Accuracy

Integrated radiation dose
limit

Expected current in air @
1 bar 25°C [µA]

Expected current in pure
gas [µA]

Temp. compensation
range

Temp. measuring range –5 to 100° C

2

[mL/min]

2

[cm/sec]

1

Response time
Recommended min. liquid

flow rate
Recommended min. linear

flow rate
Recommended gaseous

flow rate [L/min]

Trace

measurement

0 ppb to

75 ppb
0 Pa to

5 kPa

The greater of ±1%

of reading

or ± 0.03 ppb,

or ± 1 Pa

4

2 x 10

150 50 5 0.5

0 to 50°C 0 to 50°C 10 to 45°C 10 to 45 °C

2 sec. 5 sec. 6 sec. 50 sec.

50 to 220 40 to 200 20 to 70 20 to 40

200 150 50 30

The greater of ±1%

Low

concentration

®

0 ppb to
300 ppb

0 Pa to

20 kPa

of reading

or ± 0.09 ppb,

or ± 6 Pa

8

10

concentration

3200 ppb

The greater of ±1%

of reading

or ± 1 ppb,

or ± 50 Pa

N/A

0.005 to 3

Average

®

Te dl ar

0 ppb to

0 Pa to

200 kPa

8

10

concentration

The greater of ±1%

High

Saran

0 ppb to

32 ppm

0 kPa to

2000 kPa

of reading

or ± 10 ppb,

or ± 1 kPa

N/A

10

Technical Specifications

2.4.2 Oxygen sensors (Table 1)

T able 4 Membrane specifications - Oxygen sensors (1)

Membrane Model 2956A 2958A 29552A 2952A

Recommended
applications

Corrosion control,

De-aerated water

Beverage,

Lab. applications

Material PFA Tefzel

®

In line wort,

injection,

Air/O

2

Sewage treatment

PTFE Tefzel
Thickness [µm] 25 12.5 50 25
Calibration gas Air Air Air Air / Pure O
Dissolved measurement

range
Gaseous measurement

range

Accuracy

Integrated radiation dose
limit [rads]

Expected current in air @
1 bar 25°C [µA]

Expected current in pure

[µA]

O

2

consumption in O2

O

2

saturated water at 25°C

0 ppb to

20 ppm
0 Pa to

50 kPa

The greater of ±1%

of reading

1

or ± 0.1 ppb

or ± 1 ppb

,

2

,

or ± 0.25 Pa

1

Accuracy is ± 0.1 ppb for 410, 510, 362x, 360x and 3655 instruments

2

Accuracy is ± 1 ppb for 366x and 3650 instruments

4

2 x 10

0 ppb to

40 ppm

0 Pa to

100 kPa

The greater of ±1%

of reading

or ± 1 ppb,

or ± 2 Pa

8

10

0 ppb to

80 ppm

0 Pa to

200 kPa

The greater of ±1%

of reading

or ± 2 ppb,

or ± 5 Pa

N/A 10

26.4 9.4 6.3 5.4

132 47 31.4 27

40 14 9.4 8

[µg/hour]
Temp. compensation

range

– 5 to 60° C

Temp. measuring range – 5 to 100° C
Response time

1

Recommended min. liquid

2

flow rate

[mL/min]

Recommended min. linear
flow rate

2

[cm/sec]

Recommended gaseous
flow rate [L/min]

7.2 sec. 9.5 sec. 90 sec. 38 sec.

180 120 50 50

200 100 30 30

0.1 to 3

Corrosion control,

In line beverage,

De-aerated water

0 ppb to

80 ppm

0 Pa to

200 kPa

The greater of ±1%

of reading

or ± 2 ppb,

or ± 5 Pa

8

®

2

11

Technical Specifications

2.4.3 Oxygen sensors (Table 2)

Table 5 Membrane specifications - Oxygen sensors (2)

Membrane Model 2935A 29521A 2995A

Recommended
applications

Material Halar

Saturated to super

saturated levels

®

Saturated to super

saturated levels

®

Te fz e l

In line hot wort

(up to 70°C)

Tedlar
Thickness [µm] 25 125 12.5
Calibration gas Air / Pure O
Dissolved measurement

range
Gaseous measurement

range

0 ppb to

400 ppm

0 Pa to

1000 kPa

The greater of ±1%

Accuracy

of reading

or ± 10 ppb,

or ± 20 Pa

Integrated radiation dose
limit [rads]

Expected current in air @
1 bar 25°C [µA]

Expected current in pure
O

[µA]

2

consumption in O2

O

2

saturated water at 25°C

N/A 10

0.9 0.7 0.2

4.7 3.8 0.9

1.4 1.3 0.3

Air / Pure O2 Pure O2

2

0 ppb to

400 ppm

0 Pa to

1000 kPa

The greater of ±1%

of reading

or ± 10 ppb,

or ± 20 Pa

8

0 ppb to 2000 ppm

0 Pa to 5000 kPa

The greater of ±1%

of reading

or ± 50 ppb,

or ± 100 Pa

10

[µg/hour]
Temp. compensation

range

– 5 to 60° C

Temp. measuring range – 5 to 100° C
Response time

1

Recommended min. liquid

2

flow rate

[mL/min]

Recommended min. linear
flow rate

2

[cm/sec]

Recommended gaseous
flow rate [L/min]

2.5 min. 18 min. 80 sec.

25 25 5

20 60 5

0.1 to 3

®

8

12