Mettler Toledo InTrac 787 Instruction Manual
In Trac 787-01-CH
52 402 481
InTrac®787
Instruction manual
Betriebsanleitung
Instructions d’utilisation
English Page 3
Deutsch Seite 19
Français Page 35
InTrac®787 3
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
InTrac®787
Instruction manual
4 InTrac®787
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
Contents
1 Introduction..........................................................................5
2 Important remarks ................................................................6
2.1 Checking the shipment ...........................................................6
2.2 Notes on operating instructions ...............................................6
2.3 Normal use...........................................................................7
2.4 Safety instructions..................................................................7
3 Description of function..........................................................9
4 Installation/Startup and shutdown........................................10
4.1 Preparation of the equipment.................................................11
4.2 Fitting and installation works.................................................11
4.2.1 Attaching the flushing lines ...................................................11
4.2.2 Fitting the electrode/sensor....................................................12
4.4 Startup procedure.................................................................12
4.5 Shutdown procedure ...........................................................12
5 Maintenance ......................................................................13
5.1 Important information on maintenance ...................................13
5.2 Replacing seals in contact with the process medium................13
6 Trouble-shooting.................................................................14
7 Product specifications.........................................................15
7.1 Standard equipment.............................................................15
7.2 Technical data.....................................................................15
7.3 Spare parts list ....................................................................16
InTrac®787 5
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
1 Introduction
This operating instructions contains all the information needed
for safe and proper use of the retractable housings InTrac
®
787.
The operating instructions are intended for personnel entrusted
with the operation and maintenance of the retractable housings.
It is assumed that these persons are familiar with the equipment
in which the retractable housing is installed.
Construction of the retractable housings employs leading-edge
technology and complies with safety regulations currently
in force (Mettler-Toledo GmbH as the manufacturer has been
awarded ISO 9001/ EN29001 certification). Notwithstanding
this, improper use could lead to hazards for the user or a thirdparty, and/or adverse effects on the plant or other equipment.
Therefore, the operating instructions must be read and under-
stood by the persons involved before work is started with the
retractable housing.
In addition to these operating instructions, you should also be
familiar with the following:
– all local safety regulations.
– all information and warnings in the documentation dealing
with the products used together with the retractable housing
(electrodes/sensors, control system, etc.).
– all safety regulations governing the equipment in which the
retractable housing is installed.
– all information and warnings affixed to the retractable hous-
ing.
6 InTrac®787
2 Important remarks
Please read through this section carefully. It contains several
important points which will help you use the retractable housing in a safe and proper manner.
2.1 Checking the shipment
On receipt of the shipment, check immediately:
• the retractable housing and accessories for transport damage. Report any damage immediately to the carrier and your
supplier.
• the type designation on the housing body.
• the shipment for completeness. Please notify your supplier
immediately if the shipment is incomplete (see Section 7.1
“Standard equipment”) or does not concur with the order and
delivery documents.
2.2 Notes on operating instructions
Restriction
The information contained in this operating instruction applies
only to the InTrac
®
787. Detailed information on the electrodes
and their installation is not given in these instructions. Such information can be found in the separate documentation accompanying these products. Where necessary, appropriate cross-references to such publications are given in these operating
instructions.
Conventions
This pictogram represents safety and hazard warnings which,
if ignored, could result in injuries to personnel and/or material
damage.
Storage
Please keep these operating instructions in a safe place where
they are always accessible. If these instructions are lost, please
contact your supplier for a replacement.
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
2.3 Normal use
The InTrac®787 is intended solely for measurement with the
specified METTLER TOLEDO 12 mm pH and redox screwcap
electrodes as well dissolved oxygen sensors.
Use the retractable housings solely for this purpose. Usage which
differs from or exceeds this normal usage will be regarded as
usage not for the intended purpose.
The manufacturer/supplier accepts no responsibility for any
damage resulting from such improper usage. The risk is borne
entirely by the user.
Normal use also includes:
– Compliance with the instructions, regulations and informa-
tion in this operating instruction for the InTrac®787 retractable housings.
– Adherence to the stipulated inspection and maintenance
intervals.
– Correct maintenance of the retractable housing.
– Operation with due observance of the stipulated environmen-
tal and operating and the admissible mounting positions.
2.4 Safety instructions
The retractable housings InTrac®787 should be installed, operated, maintained and, if need be, repaired only by personnel
familiar with the housing and who are qualified for such work.
The customer is responsible for ensuring that:
– only trained and authorized personnel work with the
retractable housings.
– the operating instructions should be supplemented by in-
house instructions regarding supervisory duties and obliga-
tion to report, work organization, personnel qualification, etc.
– the chain has to be always adjusted to the shortest possible
length.
Ensure that the material specification of your retractable housing and of the seals satisfies the requirements of the process and
is compatible with the (vessel) cleaning solutions used.
Before every startup, the retractable housing must be checked
for:
– damage to the connections, fastening, etc.
– leaks
A defective retractable housing must neither be installed nor
put into service. If it is suspected that hazard-free operation is
no longer possible (e.g. housing damaged, connections leaking), the retractable housing and the equipment in which the
retractable housing is installed must be shut down and secured
against inadvertent operation.
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© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
8 InTrac®787
Before dismounting the entire retractable housing or commencing any maintenance work on it, ensure that the equipment in
which the housing is installed is in a safe condition (depressurize, empty, rinse, purge, vent, etc.).
In the measuring position no maintenance work must be
done.
Only the maintenance and repair work described in these operating instructions may be performed on the retractable housings.
When changing faulty components, use only original spare
parts obtainable from your supplier.
No attachments or modifications to the retractable housings
and the accessories are allowed. The manufacturer/supplier
accepts no responsibility for damage caused by unauthorized
attachments and modifications or the incorporation of non-original spare parts. The risk is borne entirely by the user.
The rinse connections of the InTrac®787 have a direct connection to the process when the ball valve is open. This means that
you will have the effective process pressure on the rinsing tubes
as well. Never do any manipulation on this connections while
the ball valve is open.
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
3 Description of function
With the InTrac®787 retractable housings, electrodes can be
cleaned or replaced without interrupting the ongoing process.
The process can be closed safely with the integrated ball valve.
The integrated flushing port allow a rinsing of the electrode in
the housing.
The immersion tube is moved into the desired end position
(“Measuring” or “Maintenance”) by hand.
– In the “Measuring” position, the immersion tube is fully in-
serted in the process.
– In the “Maintenance” position, the electrode can be cleaned
or removed/exchanged. The ball valve seals the housing
against ingress of process medium.
InTrac®787 9
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
10 InTrac®787
4 Installation/Startup and shutdown
4.1 Preparation of the equipment
The housings are mounted and fixed on the vessel (reactor, tank,
pipe, etc.) a flange connection or a 1” MNPT external (male)
thread.
– The retractable housing should be mounted in a position
which allows sufficient clearance for its correct functioning
(correct measuring position in the medium) and maintenance (checks, installation and removal of the electrodes/
sensors).
– Avoid mounting the retractable housing at exposed posi-
tions. If this is not possible, appropriate measures must be
taken to protect against damage.
4.2 Fitting and installation works
Warning! For all installation work described below, ensure that
the equipement in which the housing is installed is in a nonhazardous condition (depressurized, empty, rinsed, purged,
etc.).
4.2.1 Attaching the flushing lines
Important information
– When the electrode/sensor is withdrawn, small amounts of
the process medium adhere to the electrode/sensor tip and
can enter the outflow line during the rinsing process. If the
process medium is an environmentally harmful substance
(toxic, corrosive, etc.), it is essential to comply with the local
regulations governing the installation of wastewater services.
– Use only corrosion-resistant and chemically resistant mate-
rials for the rinsing water installation.
Recommendation for proper operation and safe use
Flushing lines must be equipped with valves which may only be
opened when the retractable part of the housing is in the maintenance position. After the flushing and maintenance of the sensors, the flushing valves must be closed.
Basic installation
The basic installation is intended for cleaning/flushing of the
electrodes/sensors when the housing is in the “Maintenance”
position. In the optional accessories you will find Serto or
Swagelok fitting to connect your flushing lines. The position of
the Inlet and Outlet has nor influence to the performance.
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
4.2.2 Fitting the electrode/sensor
InTrac®787 11
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
1. Pull out the immersion tube.
2. Close the ball valve.
3. Disconnect the immersion tube right at the ball valve.
4. Disconnect the electrode holder by turning it counterclockwise.
5. Disconnect the electrode cable.
6. Remove the electrode.
7. Check washers and O-rings on electrodes for damage
and replace if necessary.
8. Remove watering cap from electrode tip and rinse electrode/
sensor with water.
9. Carefully insert the electrode into the electrode holder and
screw in by hand as far as it will go. Important: use no tools!
10. Re-Install the complete housing.
1
2
3
4
5
6
7
12 InTrac®787
4.3 Startup procedure
Before startup, all fitting and installation work must have been
completed and the immersion tube must be secured to the ball
valve with the safety chain!
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
4
2
1
3
1
5
1
4
3
2
1. Warning! Close the valves on both con-
nections of the flushing chamber. Otherwise process media can escape while the
ball valve is opened!
2. Open the ball valve.
3. Carefully push the immersion tube by
hand into the process.
4. Secure immersion tube in this position by
tightening the locking nut.
5. Shorten the safety chain to the shortest
possible length.
4.4 Shutdown procedure
1. Loosen the locking nut.
2. Hold immersion tube, then disconnect
the safety chain.
3. Move immersion tube by hand to “Maintenance” position.
4. Close the ball valve.
5. Caution! Make sure that the process ves-
sel or line is in a non-hazardous condition (depressurized, empty, rinsed,
purged, etc.) when the housing has to be
removed.
5 Maintenance
5.1 Important information on maintenance
Attention! Maintenance and service work on the housings may
only be carried out by trained personnel.
Warning! It is possible that the process medium could harm the
environment and your health (toxic, corrosive, etc.). Hence,
ensure that the equipment is in a non-hazardous condition
before you start with maintenance work.
– The electrode and housing must kept clean.
– Replace any damages seals or components of the housing
– Details in the maintenance of the electrode are contained in
the electrode operation instructions.
5.2 Replacing seals in contact with the
process medium
All seals which come into contact with the process medium
should always be replaced at least once a year for reasons
of safety.
With corrosive media, the seals may need to be changed at correspondingly shorter intervals.
Warning!
– Retractable housings may only be stripped down after hav-
ing been completely dismounted.
– Check the quality of the seals and examine for possible dam-
age. Ensure correct positioning.
InTrac®787 13
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
14 InTrac®787
6 Trouble-shooting
In this section you will find an overview of possible malfunctions
which can occur during operation of the retractable housing, as
well as information on how to rectify them.
Malfunction Cause Remedial action
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
Immersion tube con
not be inserted.
Ball valve is not completely opened.
Check the ball valve
position.
Immersion tube can
not be pulled out.
Retention nut is not
open.
Loosen the retention nut.
Immersion tube can
not be pulled out
completely.
Ball valve is not completely opened.
Ceck the ball valve
position.
Process liquid is flowing out of the rinsing
chamber.
Rinsing chamber is not
closed.
Close the outlet of the
rinsing chamber with
covers or with valves.
Process fluid is entering into the immersion
tube.
O-ring defective. Replace the O-ring in
the electrode holder
(order O-ring set)
7 Product specifications
7.1 Standard equipment
InTrac®787 is supplied with:
– Immersion tube (100mm or 300mm)
– Electrode holder
– Ball valve
– Safety chain
– Electrode holder
– Threat connector 1
1
/2”
– Nut to secure immersion tube
7.2 Technical data
Dimensions see dimensional drawing
Maximum Pressure* 9 bar (130 psi)
Maximum Temperature* 140°C ( 266°F)
Insertion Length variable 0 to 100 (300) mm /
0” to 4(12)”
Wetted Parts Housing: 316L Stainless Steel (3.1B)
O-Rings: Viton
®
Ball valve: Ball 316 (1.4401)
Housing CF-8M (1.4408)
Sealing PTFE
Ball Valve DN40, 1.5” NPT full port
* See electrode specification
InTrac®787 15
© 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee InTrac 787-01-CH
Printed in Switzerland 52 402 481
16 InTrac®787
InTrac 787-01-CH © 02/02 Mettler-Toledo GmbH, CH-8606 Greifensee
52 402 481 Printed in Switzerland
7.3 Spare parts list
Order No. Description
52402422 Ball Valve DN40-1 1/2” NPT 3.1B
52402421 Double nipple 1 1/2” NPT / 787
52402403 O-Ring-Set InTrac®787 Vi(5)cpl.
52402463 O-Ring Set Electr.-hold 787 Vi
52402464 Flushing chamber 787
52402469 Electrode holder 787cpl. 120mm
52402470 Chain 787 cpl.
52402471 Cable fitting 787 cpl.
52402465 Fitting set 787 6 mm SERTO
52402467 Fitting set 787 6 mm SWAGELOCK
52402466 Fitting set 787 6.35 mm SERTO
52402468 Fitting set 787 6.35 mm SWAGEL.
52402402 InTrac®787/300
52402401 InTrac®787/100
52402389 Imm. tube 787 cpl. 100 mm 3.1B
52402390 Imm. tube 787 cpl. 300 mm 3.1B
52402362 Basket guard 787 120 mm 3.1B
52402404 Flange C40 DIN 2566 1 1/2” NPT
52402423 Spanning nut 787
52402391 Spanner ring 787
52402481 Instruction manual InTrac®787 (g,e,f)
52402504 Flyer InTrac®787 (d)
52402505 Flyer InTrac®787 (e)
52402506 Flyer InTrac®787 (f)
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