Hach-Lange ORBISPHERE A1100 User Manual

Document Number DGA1100-MAN/E

ORBISPHERE A1100 Family of

Oxygen Electrochemical Sensors

USER MANUAL

May 2011, Revision E

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 weight and dimensions ....................................................................................................9

2.2 ORBISPHERE family of A1100 oxygen sensors .........................................................................9

2.3 Sensor configurations for standard applications ........................................................................ 10

2.4 Sensor membrane specifications...............................................................................................11

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

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

Section 3 Introduction ..................................................................................................................... 13

3.1 What you have received ............................................................................................................ 13

3.1.1 A1100 electrochemical sensor ..........................................................................................13

3.1.2 Protection caps .................................................................................................................13

3.1.3 Sensor recharge kit ...........................................................................................................14

3.2 Sensor components ...................................................................................................................15

3.3 Basic principle of operation........................................................................................................ 16

Section 4 Installation........................................................................................................................17

4.1 Sensor preparation .................................................................................................................... 17

4.2 Sensor installation...................................................................................................................... 22

4.2.1 Sensor positioning information..........................................................................................22

4.2.2 Sensor insertion ................................................................................................................ 23

4.2.3 Sensor removal................................................................................................................. 23

4.3 Mounting accessories ................................................................................................................24

4.3.1 External pressure sensor..................................................................................................24

4.3.2 Weld-on stainless steel socket.......................................................................................... 24

4.3.3 The 32003 insertion/extraction valve ................................................................................25

4.3.4 The 33095 sensor housing................................................................................................26

4.3.5 Tuchenhagen Varivent® in-line access unit...................................................................... 26

4.3.6 ORBISPHERE flow chambers .......................................................................................... 26

4.3.7 Multi-parameter flow chamber........................................................................................... 28

Section 5 Maintenance and Troubleshooting ............................................................................ 29

5.1 Maintenance .............................................................................................................................. 29

5.1.1 Maintenance schedule ...................................................................................................... 29

5.1.2 Prerequisites for sensor maintenance............................................................................... 29

5.1.3 Membrane replacement and sensor head cleaning..........................................................30

5.2 Troubleshooting .........................................................................................................................40

Section 6 Accessories and Spare Parts......................................................................................41

6.1 Accessories................................................................................................................................ 41

6.2 Flow chambers and installation devices ....................................................................................41

6.3 Sensor spare parts.....................................................................................................................42

6.4 Recharge kits for A1100 and A110E sensors ............................................................................ 42

6.5 Other spare parts .......................................................................................................................43

Table of Contents

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.

1.2 Contact information

Manufacturing site:

HACH LANGE Sàrl 6, route de Compois 1222 Vésenaz SWITZERLAND Tel. +41 22 594 6400 Fax +41 22 594 6499

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. +49 211 52 880 Fax +49 211 52 88143

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.

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.

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.

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.

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.

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

Section 2 Technical Specifications

Specifications are subject to change without notice.

2.1 Sensor weight and dimensions

The sensor weight is approximately 300 grams.

Figure 1 Sensor dimensions

2.2 ORBISPHERE family of A1100 oxygen sensors

Model A1100 non-ATEX sensors

• Electrochemical oxygen sensor

• Stainless steel

• Maximum pressure 40 bar with default PPS collar (100 bar with stainless steel collar)

• Smart capability

Model A110E ATEX sensors

• Electrochemical oxygen sensor

• Ex II 1 G, Ex ia IIC T6

• Stainless steel or hastelloy

• Viton or kalrez o-rings

• Intrinsically safe

Note: Unlike the A1100 non-ATEX sensors, the intrinsically safe A110E ATEX sensors have no smart capability to store calibration data. However, all A110E ATEX sensors have the ATEX conformity information engraved on the sensor itself.

Technical Specifications

2.3 Sensor configurations for standard applications

Table 1 Sensor configurations for standard applications

Application Sensor Membrane Cartridge Protection Cap

Beer with 3650 Portable A1100-S00

Beer in-line A1100-S00 2952A-A 33051-SG Wort in-line A1100-S00 29552A-A 33051-S0 Wort with 3650 Portable and

special flow cell 32007W.xxx

Beverage

3624 Probrix A1100-S00 2952A-A 33051-SG 3625 Package analyzer A1100-S00 2956A-A or 2952A-A 33051-SP

De-aerated water A1100-S00 2956A-A or 2952A-A

On-line dissolved oxygen traces in pure water

Dissolved oxygen traces with 3655 Portable

(Power - Electronics)

Pure water applications

ATEX

A1100-S00 29552A-A 33051-S0

A1100-S00 2956A-A 33051-S0

A110E-SVS A110E-SKS 33051-SG A110E-HVS 33051-H0 A110E-HKS 33051-H0

2958A-A (optimized response time) 2952A-A (optimized maintenance interval)

2956A-A or 29552A-A

33051-SP

33051-S0 33051-SG (if exposed to CIP)

33051-SG

Note: Non-ATEX sensors are delivered with two protection caps as standard, one with a grille (33051-SP) and one without (33051-S0). A third protection cap (33051-SG) is available as an option. ATEX Sensors are delivered with one protection cap as standard.

Technical Specifications

2.4 Sensor membrane specifications

2.4.1 Oxygen sensors (Table 1)

Table 2 Membrane specifications - Ox yg e n se n so rs (1 )

2956A-A 2958A-A 29552A-A 2952A-A

In line wort,

Air/O

injection,

Sewage treatment

PTFE Tefzel

Recommended applications

Corrosion control,

De-aerated water

Beverage,

Lab. applications

Material PFA Tefzel

Thickness [µm] 25 12.5 50 25 Calibration gas Air Air Air Air / Pure O

Dissolved measurement range

Gaseous measurement range

0 ppb to

20 ppm

0 Pa to 50 kPa

The greater of

±1% of reading

or ± 0.1 ppb

Accuracy

or ± 1 ppb

or ± 0.25 Pa

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

Accuracy is ± 1 ppb for 366x and 3650 instruments Integrated radiation dose limit [rads] 2 x 10 Expected current in air

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

consumption in O2 saturated

water at 25°C [µg/hour]

[µA] 132 47 31.4 27

26.4 9.4 6.3 5.4

40 14 9.4 8

0 ppb to

40 ppm

0 Pa to

100 kPa

The greater of

±1% of reading

or ± 1 ppb,

or ± 2 Pa

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

Temp. compensation range – 5 to 60° C Temp. measuring range – 5 to 100° C Response time Recommended min. liquid flow rate

[mL/min] Recommended min. linear flow rate

[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

Technical Specifications

2.4.2 Oxygen sensors (Table 2)

Table 3 Membrane specifications - Oxygen sensors (2)

2935A-A 29521A-A 2995A-A

Recommended applications

Saturated to super

saturated levels

Material Halar

Saturated to super

saturated levels

Tefzel

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

Accuracy

±1% of reading

or ± 10 ppb,

or ± 20 Pa Integrated radiation dose limit [rads] N/A 10 Expected current in air

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

consumption in O2 saturated

water at 25°C [µg/hour]

[µA] 4.7 3.8 0.9

0.9 0.7 0.2

1.4 1.3 0.3

Air / Pure O2 Pure O2

0 ppb to

400 ppm

0 Pa to

1000 kPa

The greater of

±1% of reading

or ± 10 ppb,

or ± 20 Pa

0 ppb to

2000 ppm

0 Pa to

5000 kPa

The greater of

±1% of reading

or ± 50 ppb,

or ± 100 Pa

Temp. compensation range – 5 to 60° C Temp. measuring range – 5 to 100° C Response time Recommended min. liquid flow rate

[mL/min] Recommended min. linear flow rate

[cm/sec] Recommended gaseous flow rate

[L/min]

Response time at 25 °C for a 90% signal change

Liquid flow through an ORBISPHERE 32001 flow chamber, with protection cap and no grille

2.5 min. 18 min. 80 sec.

25 25 5

20 60 5

0.1 to 3

Section 3 Introduction

3.1 What you have received

3.1.1 A1100 electrochemical sensor

The sensor may be delivered separately or as part of an ORBISPHERE system, depending on the individual order.

The sensor (as illustrated in Figure 2 above) will be delivered fitted with a plastic screw-on storage cap to protect the sensor head. This is held in place with a plastic collar.

A plastic screw-on base is also provided to protect the connection socket, and which also provides a suitable stand for the sensor during maintenance procedures, and when not in use.

3.1.2 Protection caps

Non-ATEX sensors (A1100)

Two protection caps will be delivered with each sensor, one without a grille (part number 33051-S0) and one with a grille (part number 33051-SP).

A third protection cap (part number 33051-SG) is also available as an option and improves the maintenance interval for beer or soft drinks process applications.

The three protection caps are illustrated below:

Figure 2 A1100 sensor with storage cap and base

Figure 3 Protection caps

ATEX sensors (A110E)

Only one protection cap will be delivered with each sensor (part number 33051-SG or 33051-H0).

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