Sensor - Instruction Manual

Instruction Manual
optek-sensors AF56
Version 02.2008_1.1US
PN: 1004-2005-02
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen
Germany
Phone: +49-201-63409-0
Fax: +49-201-63409-999
E-Mail: info@optek.de
Internet: www.optek.com
Preface
Preface
This instruction manual is written to assist the user in proper procedures for
trouble-free operation.
It is explicitly pointed out that optek-Danulat GmbH assumes no responsibility for

loss or damage caused due to improper use of this instruction manual or
products described herein.
This manual is protected by copyright. However, the user may produce copies
and translations if required for correct operation of the products.
On request, this manual is available in other languages as well as in digital

format (Acrobat® Reader 5.0 required).
Our products are being continuously improved. Technical data is subject to

change without notice.
Essen, August 2007
optek-sensors AF56, Version 02.2008_1.1US, 06.02.2008

www.optek.com
Preface
For further inquiry, feel free to contact us or our distributing partners at

any time:
Germany
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen / Germany
Phone: +49-201-63409-0
Fax: +49-201-63409-999
E-Mail: info@optek.de
Netherlands
optek-Danulat bv
Grote Brugse Grintweg 12a
4005 AH Tiel / Netherlands
Phone: +31 -344 -683800
Fax: +31 -344 -653950
E-Mail: info@optek.nl
USA
optek-Danulat Inc.
N118 W18748 Bunsen Drive
Germantown WI 53022 / USA
Phone: +1 262 437 3600
Toll free call: +1 800 371 4288
Fax: +1 262 437 3699
E-Mail: info@optek.com
Singapore
optek-Danulat Pte. Ltd.
25 Int’l Business Park
#05-109-f German Centre
Singapore 609916
Phone: +65 6562 8292
Fax: +65 6562 8293
E-Mail: info@optek.com.sg
Internet: http://www.optek.com

www.optek.com
Table of contents
Table of contents
Preface
1 System overview ................................................................................. 1
2 Using the instruction manual ............................................................. 2

2.1 Validity of the instruction manual ....................................................... 2
2.2 Pictograms and signal words ............................................................. 3
2.3 Note regarding return of the sensor ................................................... 4
3 Intended use ........................................................................................ 5
4 Description of AF56-F / AF56-N sensors ........................................... 6
5 Technical data and exploded views ................................................... 8

5.1 Exploded view of AF56-F / AF56-N sensor ...................................... 13
6 Installation .......................................................................................... 14
6.1 Standard sensor bodies - installation instructions ............................ 14
6.2 Installation of the sensor.................................................................. 16
6.3 Air purge.......................................................................................... 17
7 Connection to converter 156 ............................................................ 18
8 Faults .................................................................................................. 22
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Table of contents
9 Maintenance ....................................................................................... 24
9.1 Preventive maintenance .................................................................. 24
9.2 Exchange of lamp module ............................................................... 25
9.3 Exchange of detector module .......................................................... 26
9.4 Return to operation after the exchange of lamp module
and detector module ........................................................................ 27
9.5 Spare parts and accessories ........................................................... 28
9.5.1 Lamp modules / wavelength modules /
detector assembly ................................................................ 28
9.5.2 Standard window (see corresponding
sensor body manual) ............................................................ 29
9.5.3 Gaskets (not wetted) ............................................................ 29
9.5.4 Screw sets ............................................................................ 30
9.5.5 Small part sets ...................................................................... 30
9.5.6 Installation material .............................................................. 30
9.5.7 Accessories cable sets ......................................................... 31
10 Disposal .............................................................................................. 32
11 Appendix ............................................................................................ 33
11.1 Declaration of conformity ................................................................. 34
11.2 TÜV NORD CERT GmbH "GS-mark"............................................... 35
11.3 QM system certificate ...................................................................... 36
11.4 Decontamination declaration ........................................................... 37
11.5 Response via fax ............................................................................. 39
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System overview
1 System overview
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Using the instruction manual
2 Using the instruction manual
2.1 Validity of the instruction manual
This instruction manual is valid for AF56-F, AF56-N sensors and their variants.
There are the following variants:
• PV
• SF
Abbreviations mean the following sensor options:

• F color (NIR) sensor with application specific wavelength
measurement
• N near infrared sensor with wavelength range 730 - 970 nm
• SF silicone-free version with restricted temperature ratings
• PV purge varivent (air purge connections at sensor)
Follow the instruction manual for every operation. If the sensor is not used as
described in this instruction manual, your safety and the sensor function could
be affected.
To keep up reliability of the product, enhance its life cycle and avoid down times,
you have to follow the instructions given in this manual.
Furthermore, please follow the existing accident prevention and environmental

protection instructions, as well as recognized technical instructions for safe and
professional working.
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2.2 Pictograms and signal words
Especially important information in this instruction manual is marked with the

following pictograms:
Danger!
This pictogram indicates immediate danger to life and health of persons.
The text next to the symbol gives information on how to avoid bodily injuries.
If the possible cause of risk can be specified, the corresponding pictogram

preceeds instructions:
Danger!
Electrical voltage.
This pictogram indicates danger due to electrical voltage.
Caution!
This pictogram indicates information on how to avoid material damage.
Note!
This pictogram indicates instructional or general advice.
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2.3 Note regarding return of the sensor
In the appendix of this instruction manual you find a declaration regarding the
decontamination of the sensor. Please fill out that declaration and add it to
sensor packaging when you return the sensor.
Note!
optek can only accept the returned sensor with the filled out and signed
decontamination declaration enclosed in the package.
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Intended use
3 Intended use
The optek-sensors AF56 and their variants are to be applied only as absorption
sensors for liquids and gases in inline applications according to the technical
data.
The use of the sensors in hazardous locations is prohibited.

You can purchase flameproof sensors for hazardous locations from optek. For
these sensors, special instruction manuals are delivered with the sensor.
Unauthorized constructional changes, additional fittings or rebuildings regarding

the sensor are prohibited. The only exception are rebuildings into one of the
variants listed in the chapter "Validity of the instruction manual". Changes to and
interference with the converter program are prohibited as well.
To lay sensor cables underground without protection is prohibited.
The manufacturer is not liable for damage resulting from use contrary to
intended use.
Following this instruction manual is part of the intended use.
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Description of AF56-F / AF56-N sensors
4 Description of AF56-F / AF56-N sensors
This sensor is a high precision absorption sensor. It measures attenuation of

light passing through the process medium. The sensor was designed for direct
installation into pipelines.
Fig. 1 AF56-F / AF56-N
The following are the main sensor components:
6 5 2 1 2 3 4
Fig. 2 Schematic AF56-F / AF56-N
1. Sensor body
2. Windows
3. Filter (VIS or NIR)
4. Detector
5. Optics module
6. Lamp module
Its modular construction offers maximum flexibility in adapting to the process,

without affecting the property of measurement. A precisely defined, constant
light beam penetrates the process medium. A hermetically sealed silicon
photodiode measures intensity of incoming and optically filtered light and
supplies the converter with it in form of photocurrent.
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Description of AF56-F / AF56-N sensors
Attenuation of light intensity, as a result of absorption and / or scattering of

substances in the process medium, is described by the Lambert-Beer Law. It
states, the logarithm of the transmission loss is proportional to concentration of
the substance. This is true for dissolved substances and undissolved material.
Depending on the particular material properties, concentrations can be detected
in ppm as well as in %.
According to this law, the extinction coefficient, defined through ingredient and
wavelength, affects the logarithm of the transmission loss, too. Therefore, the
choice of wavelength or wavelength range is of decisive importance for the
measurement and is defined for each measurement type with the help of optical
filters.
The third factor of influence in the Lambert-Beer Law is the path length of light
passing through the process medium. Equally proportional, the path length, too,
is an important aspect with regard to specification of a photometer. The distance
to be covered by light is defined through the optical path length (OPL), that is the
distance between the windows of a sensor body. In the technical data, OPL is
always given corresponding to window combination A-A.
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Technical data and exploded views
5 Technical data and exploded views
Tab. 1 Technical data AF56-F / AF56-N
AF56-F AF56-N
Material sensor body made of stainless steel 1.4571; SS 316 Ti (standard)

1.4435 (SS 316 L), 1.4539, 1.4462, TFM 4215, Hastelloy® C4, Hastelloy® C22, Titanium, Tantalum,
Special materials
Monel® 400, Inconel® 625, PP, others on request
Line size 1/4" to 8", (DN 6 to DN 200)
ASME-Flange, DIN-Flange, Varivent, JIS-Flange, Tri-Clamp, BBS-Clamp,
Process connections Female Thread NPT, Female Thread DIN ISO 228/1 G,
Sanitary Thread (DIN 11851), others on request
Gaskets Viton®, EPDM (FDA), EPDM (USP Cl. VI), Kalrez®, Chemraz®, Fluoraz®,
Buna (NBR), Silicone, Viton® / FEP (FDA), others on request
Windows Pyrex®, Sapphire
Optical path length 1 mm - 200 mm
10 mbar to 325 bar (0.15 psi to 4713 psi),
Process pressure
depending on process connection, material and design
Data is only valid for appropriate choice of material of sensor body and gaskets! No ice formation on
sensor!
Process temperature permanent:

0 °C to +100 °C (+32 °F to +212 °F)
peak (15 min/day):

0 °C to +120 °C (+32 °F to +248 °F)
operation:
0 °C to +40 °C (+32 °F to +104 °F)
(elevated or reduced ambient temperatures may require restrictions to
Ambient temperature the admissible process temperature!)
transport:
-20 °C to +70 °C (-4 °F to +158 °F)
Air purge connectors available as standard
Light source incandescent tungsten lamp: 5.0 V DC, 775 mA, typical lamp life 3 to 5 years
Wavelengths specific to application from 400 nm - 480 nm 730 nm - 970 nm
Detector silicon photodiode, hermetically sealed
Calibration basic calibration in CU (concentration units)
Measuring range sensor specific 0 to 3 CU 0 - 0.5 to 4 CU
Resolution < ± 0.5 % of respective measuring range
Repeatability < ± 1.0 % of respective measuring range
Linearity specific to application, < ± 2 % of respective measuring range
all optical parts protected according to IP65 if sensor is constructed as intended, valid for
Protection
installation of plug or protection cap
Cable lengths standard: 5, 10, 20, 35, 50 m (16, 33, 66, 115, 164 ft.); maximum: 250 m (820 ft.)
non-metallic sheathed cable with finely stranded copper conductor according to IEC 228 CL.5,
Cable material
insulation PVC (-40 °C … + 70 °C, -40 °F ... +158 °F)
SS-plug-protection special high shielded cable sets, optional rigid stainless steel plug
Certificates ISO 9001:2000, PED, CE, HP0
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Tab. 2 Technical data AF56-SF-F / AF56-SF-N
AF56-SF-F AF56-SF-N
Material sensor body made of stainless steel 1.4571; SS 316 Ti (standard)

1.4435 (SS 316 L), 1.4539, 1.4462, TFM 4215, Hastelloy® C4, Hastelloy® C22, Titanium, Tantalum,
Special materials
Monel® 400, Inconel® 625, PP, others on request
Line size 1/4" to 8", (DN 6 to DN 200)
ASME-Flange, DIN-Flange, Varivent, JIS-Flange, Tri-Clamp, BBS-Clamp,
Process connections Female Thread NPT, Female Thread DIN ISO 228/1 G,
Sanitary Thread (DIN 11851), others on request
Gaskets Viton®, EPDM (FDA), EPDM (USP Cl. VI), Kalrez®, Chemraz®, Fluoraz®,
Buna (NBR), Silicone, Viton® / FEP (FDA), others on request
Windows Pyrex®, Sapphire
Optical path length 1 mm - 200 mm
10 mbar to 325 bar (0.15 psi to 4713 psi),
Process pressure
depending on process connection, material and design
silicone-free version with restricted temperature ratings
permanent:
Process temperature 0 °C to +60 °C (+32 °F to +140 °F)
peak (15 min/day):

0 °C to +80 °C (32 °F to +176 °F)
operation:
0 °C to +40 °C (+32 °F to +104 °F)
(elevated or reduced ambient temperatures may require restrictions to
Ambient temperature the admissible process temperature!)
transport:
-20 °C to +70 °C (-4 °F to +158 °F)
Air purge connectors available as standard
Light source incandescent tungsten lamp: 5.0 V DC, 775 mA, typical lamp life 3 to 5 years
Wavelengths specific to application from 400 nm - 480 nm 730 nm - 970 nm
Detector silicon photodiode, hermetically sealed
Calibration basic calibration in CU (concentration units)
Measuring range sensor specific 0 to 3 CU 0 - 0.5 to 4 CU
Resolution < ± 0.5 % of respective measuring range
Repeatability < ± 1.0 % of respective measuring range
Linearity specific to application, < ± 2 % of respective measuring range
all optical parts protected according to IP65 if sensor is constructed as intended, valid for
Protection
installation of plug or protection cap
Cable lengths standard: 5, 10, 20, 35, 50 m (16, 33, 66, 115, 164 ft.); maximum: 250 m (820 ft.)
non-metallic sheathed cable with finely stranded copper conductor according to IEC 228 CL.5,
Cable material
insulation PVC (-40 °C … + 70 °C, -40 °F ... +158 °F)
SS-plug-protection special high shielded cable sets, optional rigid stainless steel plug
Certificates ISO 9001:2000, PED, CE, HP0
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Fig. 3 Schema for determining dimensions
• A = installation height (in mm)

• B = installation length detector side (in mm)
• C = installation length lamp side (in mm)
Table 3 indicates a part of our extensive range of sensor bodies. Other sensor
bodies with diverse process connections and made of many other materials are
available (see table 1 on page 8). Detailed technical information is given in the
instruction manual "Sensor bodies according to Pressure Equipment Directive,
Module E1" of the corresponding sensor body.
Moreover, Varivent adapters are available in different line sizes to allow quick
and easy adaptation to pipelines.
Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

OPL A-A*) A B C
Process connection Part.-No. Material Design Line size
[mm] [mm] [mm] [mm]
NPT Female thread
0120-1945-03 1.4571 / SS 316 Ti 1/2" 20 96 140 185
(ASME B1.20.1)
NPT Female thread
0120-0104-03 1.4571 / SS 316 Ti 1" 20 96 140 185
(ASME B1.20.1)
NPT Female thread
0120-1104-03 1.4571 / SS 316 Ti 1" 40 96 150 195
(ASME B1.20.1)
Female thread
0120-0103-03 1.4571 / SS 316 Ti 1" 20 96 140 185
(DIN ISO 228/1-G)
Female thread
0120-1103-03 1.4571 / SS 316 Ti 1" 40 96 150 195
(DIN ISO 228/1-G)
Clamp
0120-0102-28 SS 316 L 1" 20 96 140 185
(ISO 2852-1993)
Clamp
0120-1102-28 SS 316 L 1" 40 96 150 195
(ISO 2852-1993)
Clamp
0120-0302-28 SS 316 L 1.5" 30 106 145 190
(ISO 2852-1993)
Clamp
0120-1302-28 SS 316 L 1.5" 40 106 150 195
(ISO 2852-1993)
Clamp
0120-0402-28 SS 316 L 2" 40 112 150 195
(ISO 2852-1993)
Sanitary thread SC
0120-0101-03 1.4571 / SS 316 Ti welded DN 25 20 125 140 185
(DIN 11851)
Sanitary thread SC
0120-1101-03 1.4571 / SS 316 Ti welded DN 25 40 125 150 195
(DIN 11851)
Sanitary thread SC
0120-0301-03 1.4571 / SS 316 Ti welded DN 40 30 125 145 190
(DIN 11851)
Sanitary thread SC
0120-1301-03 1.4571 / SS 316 Ti welded DN 40 40 125 150 195
(DIN 11851)
Sanitary thread SC
0120-0401-03 1.4571 / SS 316 Ti welded DN 50 40 125 150 195
(DIN 11851)
Sanitary thread SC
0120-0501-03 1.4571 / SS 316 Ti welded DN 65 50 140 155 200
(DIN 11851)
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Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

OPL A-A*) A B C
Process connection Part.-No. Material Design Line size
[mm] [mm] [mm] [mm]
Sanitary thread SC
0120-0601-03 1.4571 / SS 316 Ti welded DN 80 50 180 155 200
(DIN 11851)
Sanitary thread SC
0120-0701-03 1.4571 / SS 316 Ti welded DN 100 60 200 160 205
(DIN 11851)
Flange
0120-0106-03 1.4571 / SS 316 Ti welded 1" 20 150 140 185
(ASME B16.5 RF, 150 lbs)
Flange
0120-1106-03 1.4571 / SS 316 Ti welded 1" 40 150 150 195
Flange
0120-0306-03 1.4571 / SS 316 Ti welded 1.5" 30 150 145 190
Flange
0120-1306-03 1.4571 / SS 316 Ti welded 1.5" 40 150 150 195
Flange
0120-0406-03 1.4571 / SS 316 Ti welded 2" 40 150 150 195
Flange
0120-0606-03 1.4571 / SS 316 Ti welded 3" 50 225 155 200
Flange
0120-0706-03 1.4571 / SS 316 Ti welded 4" 60 230 160 205
Flange
0120-0115-03 1.4571 / SS 316 Ti welded DN 25 20 150 140 185
(DIN 2633, E)
Flange
0120-1115-03 1.4571 / SS 316 Ti welded DN 25 40 150 150 195
(DIN 2633, E)
Flange
0120-0315-03 1.4571 / SS 316 Ti welded DN 40 30 150 145 190
(DIN 2633, E)
Flange
0120-1315-03 1.4571 / SS 316 Ti welded DN 40 40 150 150 195
(DIN 2633, E)
Flange
0120-0415-03 1.4571 / SS 316 Ti welded DN 50 40 150 150 195
(DIN 2633, E)
Flange
0120-0515-03 1.4571 / SS 316 Ti welded DN 65 50 150 155 200
(DIN 2633, E)
Flange
0120-0615-03 1.4571 / SS 316 Ti welded DN 80 50 215 155 200
(DIN 2633, E)
Flange
0120-0715-03 1.4571 / SS 316 Ti welded DN 100 60 220 160 205
(DIN 2633, E)
Clamp
0120-1999-08 1.4435 / SS 316 L Biotech 1/4" 1 96 130 175
(TC L14 AM7)
Clamp
0120-1998-08 1.4435 / SS 316 L Biotech 1/4" 5 96 132 177
(TC L14 AM7)
Clamp
0120-2915-08 1.4435 / SS 316 L Biotech 1/2" 1 96 130 175
(TC L14 AM7)
Clamp
0120-1989-08 1.4435 / SS 316 L Biotech 1/2" 10 96 135 180
(TC L14 AM7)
Clamp
0120-1997-08 1.4435 / SS 316 L Biotech 3/4" 11 96 135 180
(TC L14 AM7)
Clamp
0120-1995-08 1.4435 / SS 316 L Biotech 3/4" 15 96 137 182
(TC L14 AM7)
Clamp
0120-2911-08 1.4435 / SS 316 L Biotech 1" 20 96 140 185
(TC L14 AM7)
Clamp
0120-2912-08 1.4435 / SS 316 L Biotech 1" 21 96 140 185
(TC L14 AM7)
Clamp
0120-2918-08 1.4435 / SS 316 L Biotech 1" 40 96 150 195
(TC L14 AM7)
Clamp
0120-2917-08 1.4435 / SS 316 L Biotech 1.5" 20 106 140 185
(TC L14 AM7)
Clamp
0120-1902-08 1.4435 / SS 316 L Biotech 1.5" 21 106 140 185
(TC L14 AM7)
Clamp
0120-1946-08 1.4435 / SS 316 L Biotech 1.5" 40 106 150 195
(TC L14 AM7)
Clamp
0120-2916-08 1.4435 / SS 316 L Biotech 2" 20 112 140 185
(TC L14 AM7)
Clamp
0120-1948-08 1.4435 / SS 316 L Biotech 2" 21 112 140 185
(TC L14 AM7)
Clamp
0120-2914-08 1.4435 / SS 316 L Biotech 2" 40 112 150 195
(TC L14 AM7)
*) Optical path length (OPL) using standard windows model A is given in column
OPL A-A. By using windows of different length, this OPL can be reduced.
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Tab. 4 Window combinations and optical path lengths
OPL Example
Window combination
(A-A) = X OPL (A-A) = 20 mm
A-Z X + 5.0 mm 25.0 mm
AM - AM * X + 5.0 mm 25.0 mm
A - AM X + 2.5 mm 22.5 mm
A-A X 20.0 mm
A - BM X - 2.5 mm 17.5 mm
A-B X - 5.0 mm 15.0 mm
BM - BM * X - 5.0 mm 15.0 mm
A - CM X - 7.5 mm 12.5 mm
B - BM * X - 7.5 mm 12.5 mm
A-C X - 10.0 mm 10.0 mm
B-B* X - 10.0 mm 10.0 mm
B - CM X - 12.5 mm 7.5 mm
CM - CM * X - 15.0 mm 5.0 mm
B-C X - 15.0 mm 5.0 mm
C - CM X - 17.5 mm 2.5 mm
C-C X - 20.0 mm not possible
* preferred combination due to symmetry
You may obtain other window types and combinations on request.
Tab. 5 Cable weights
Cable Weight
Lamp cable (1.5 mm2) 0.9 kg / 10 m

Detector cable (AF56) 0.6 kg / 10 m
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5.1 Exploded view of AF56-F / AF56-N sensor
9 8 8 11
17 15 15 17
16 15 15 16
7 6 5 4 3 2 1 2 3 4 5 10 7
13 12 5 5 14 13
Fig. 4 Photo and exploded view AF56-F / AF56-N
Tab. 6 Exploded view explanations
No. Explanation No. Explanation

1 Sensor body 10 Detector module AF56-F or AF56-N
2 Window ring M24 x 1.5, incl. 8 screws M5 11 Detector cable AF56
3 O-Ring 25.12 x 1.78, Viton® 12 Lamp cable with SS-plug-protection
4 screws M3 x 12 (DIN 7985), 1.4571 (316Ti), incl.
4 Optical housing OH03, M24-AMP11 Purge 13
washer
5 O-Ring 21.95 x 1.78, Viton® 14 Detector cable with SS-plug-protection
6 lamp module AF56 15 O-Ring 4.00 x 1.00, Viton®
7 O-Ring 10.10 x 1.6, Viton® 16 Screw M5 x 06 DIN84, 1.4571 (316Ti)
8 Screws M3 x 6 (DIN 7985), 14571 (316Ti) 17 Purge connection M5, Ms/Ni
9 Lamp cable AF56
Note!
AF56-F / AF56-N sensors are also available als silicone-free version (SF). This
applies to positions 6 and 10 in fig. 4.
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Installation
6 Installation
6.1 Standard sensor bodies - installation instructions
Before installing the sensor, the sensor body has to be installed into the pipeline.
Observe the following conditions:
• As a basic principle, install the sensor body into the pipeline with optical
arms of the sensor in horizontal position (see fig. 5 and fig. 6).
Fig. 5 Vertical alignment of standard sensor body
Fig. 6 Horizontal alignment of standard sensor body
• Avoid installation in vertical position (see fig. 7). Deposits that affect
accurate measurements might form on lower window. Furthermore,
thermical problems, depending on process and ambiance conditions,
cannot be ruled out. If such problems are not expected because of the
process, vertical installation is admissible.
Fig. 7 No vertical alignment of the optical arms
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Installation
• Do not install the sensor body directly behind valves or other flow
obstacles.
• Make sure that no extraneous light sources are located near the sensor
in order not to distort measuring results.
• Already during installation, ensure that at all times during operation the
sensor body is filled completely with process medium. This way,
misinterpretation of measuring results can be avoided.
• Dimensioning details are given in the technical data.
• Windows and window rings have to be installed to the sensor body
correctly (also see instruction manual of the corresponding sensor body).
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Installation
6.2 Installation of the sensor
Tool • not needed
Install sensor as described below:
Note!
O-Rings are delivered separately and are not installed at delivery.
1. Check that there are O-Rings for the sensor assemblies.

2. Place one O-Ring each into the groove of the window rings (see fig. 8).
Fig. 8 O-Ring at window ring
Danger!
Isopropanol is irritating!
Observe the safety regulations when handling Isopropanol!
3. Make sure that the windows of the sensor body are clean. If not, clean them
with Isopropanol.
4. Check the window ring threads for damage and soiling and clean them if
necessary.
5. Screw on sensor assemblies for detector and lamp sides to the sensor body
hand-tight (right-hand thread, fig. 9). It is recommended to use the supplied
installation paste.
Fig. 9 Installed sensor, example AF16-N / AF16-F sensor
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Installation
6.3 Air purge
Should the temperature of the process medium be too low, the temperature of
the air inside the optical housing might fall below dew point. This leads to
condensation deposits on the window surfaces. For this event, there are either
air purge connections on the window rings of the sensor body or on the optical
housings of the sensor.
Note!
If the product is more than 10 °C (18 °F) cooler than the ambient air of the
sensor, always connect air purge.
Tool • Screw driver

• wrench 7 mm
At delivery, the drill holes of the air purge connections are sealed with O-Ring
and sealing screws M5 x 6 (DIN 84).
1. Remove the sealing screws and O-Rings.
2. Check if there are O-Rings on air purge connections.
3. Install air purge connections (24, fig. 10) screwing.
4. Place the air purge hoses on the air purge connections (24).
4 24 24 12 24 4 12 24
Fig. 10 Window ring air purge connections (left) and optical housing air purge connections (right)
After connecting the sensor to the power supply and putting it into operation,
rinse it as described below:
1. Loosen the two adapters (4, 12) turning each 2-3 turns anticlockwise.
2. Rinse the optical housing by aerating it with dry, oil and dust free air for
approx. 10 minutes at a maximum of 0.5 bar (7.25 psi) gauge pressure.
In case you do not have air purge supply of appropriate quality, you can use
the optek Air Drying System ADS.
3. Reduce air pressure to approx. 0.1 bar (1.45 psi).
4. Retighten the adapter. Keep up the gauge pressure. Air consumption in this
operational state is minimal.
5. Make sure the O-Rings are fitted correctly.
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Connection to converter 156
7 Connection to converter 156
For connecting the sensor cables, observe the following basic conditions:
• Bring the sensor cable to the cable entry from underneath.
• Form a loop with the sensor cable close to the cable entry.
• Do not lay sensor cables in ducts of current-carrying lines.
• Observe cable specifications (see technical data).
• To lay sensor cables underground without protection is prohibited.
For the connection of the sensor to the converter, there are sensor cables with
plug-protection on the sensor side (15, 17; fig. 11) or without plug-
protection (11, 14).
Connection to the On the sensor side, mixing up sensor cables is not possible, as plugs are
sensor
distinctive:
• 9-pin plug on the detector side (11, 17),
• 4-pin plug on the lamp side (14, 15)
11 17 15 14
Fig. 11 Plug with and without plug-protection
Tool • not needed
Connection of the sensor cable without plug-protection on the detector and lamp
side:
1. Loosen the connection cover of the sensor.
2. Plug in the sensor cable.
3. Screw-tighten the protection cover.
Fig. 12 Connection of the sensor cable without plug-protection
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Connection of the sensor cable with plug-protection on the detector and lamp
side:
1. Loosen the connection cover of the sensor.
2. Ensure there is an O-Ring (7, fig. 13) for plug-protection.
3. Plug in the sensor cable.
4. Fasten each of the four screws of the plug-protection (17) with washer.
7 17
Fig. 13 Connection of the sensor cable with plug-protection
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Note!
Detailed information on the connection of the sensor to the converter 156 is
given in the instruction manual of the converter. There you can as well find the
corresponding wiring plans.
Connection to the The following connections are on the back of the converter:
converter
LAMP -
5 VOLTAGE
G
DETECTORINPUTS
1 6
LAMP
2 7
3 8 H
mA
4 9
5 115/230V 10
ALARM II ALARM I
5 50/60Hz, 30VA 11
115VAC, T0,630A
12
230VAC, T0,315A
13
14
15
16
LAMP AL
L
19
17
N 230V
20
18
PE
21
OPTEK-DANULAT
MADE IN GERMANY
Fig. 14 Detector inputs and lamp outputs of the converter 156
Letters stand for

• G Detector inputs (5, 1, 2)
• H Lamp outputs (6, 7)
The connections depend on the equipment of your converter and on how many
sensor you would like to connect.
Note!
Stick to the detector inputs and lamp outputs specified in table 7. Thus, danger
of mixing inputs and outputs up is minimized. The detector input (5, 4, 3) is
inactive.
Tab. 7 Connections
Connection to the
Number of sensors
detector input of the Lamp output Cable length max.
Sensor type
converter
1 sensor
Detector input (5, 1, 2) Lamp output (6, 7) 250 m / 820 ft.
AF56
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To be able to allocate the end splices unequivocally to the clamps of the

converter, each end splice is marked with the number of the correct clamp:
Detector cable to sensor

1 = white (A1) 2 = brown (A2) 5 = black (A5)
Lamp cable to sensor

6 = white or blue (6) 7 = brown (7)
Caution!
Lamp voltage must be adjusted to the cable length in order to compensate
voltage loss in the cable. Too low lamp voltage can lead to wrong measuring
results. Too high lamp voltage reduces the life of the lamp module considerably.
Follow the instructions in the instruction manual of the converter. During
operation, voltage at the lamp is 4.8 V DC.
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Faults
8 Faults
Among other possibilities, you can detect faults whenever an error message on
the converter appears. Try to clear the fault using the following table and the
instructions given in the chapter "Software" in the instruction manual of the
converter. Should you have any difficulty clearing the fault, feel free to contact
our customer service. To solve the problem efficiently, we ask you to have the
sheet with system data of your sensor or system at hand.
See preliminary note for our contact data.
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Faults
Tab. 8 Possible faults and remedies
Possible fault Possible remarks Cause Remedy

• Continuity test of lamp cable
• "Lamp failure" LED of Lamp cable between sensor
Failure of • Exchange lamp cable for new
converter flashes. and converter defective
lamp module one.
• Signal loss
Lamp module defective • Exchange lamp module.
• Continuity test of detector
Detector cable between sensor cable
Detector failure - and converter defective • Exchange detector cable for
new one.
Detector defective • Exchange detector.
Humidity gets into optical
housing and forms • Use air purge
condensation deposits on
Unrealistic, random measuring windows.
Condensate formation
results • Disassemble sensor
assemblies and check
O-Ring missing or defective
O-Rings, exchange if
necessary.
• Sensor body windows are
dirty.
• Clean sensor body window.
• Sensor body windows are
• Results are fluctuating. • Exchange sensor body
Wrong results corroded.
• Zero point is drifting. window for sapphire window.
• Lamp module near failure,
• Exchange lamp module.
lamp module near the end of
its life.
• Continuity test of detector
Detector cable between sensor cable
• No function and converter defective • Exchange detector cable for
Connection error • No "Lamp failure" LED
new one.
message
Sensor cable incorrectly • Check and revise
connected to converter connections.
• Amplify measuring range.
• If the measuring range cannot
Process conditions
be amplified, reduce optical
Measuring range Converter indicates flashing path length.
exceeded Wavelength-dependent
• Reduce optical path length
detector module reduces the
and / or change measuring
dynamic measuring range,
wavelength.
optical filters reduce wanted
• Exchange lamp modul.
signal.
The mA-output provides
correct current values when
• Check resistance of wiring.
measuring results are low and Connected load > 600 ohms
• Use appropriate mA-input.
too low current values when
mA-signal (output)
measuring results are high.
• Compensation by adjusting
Poor calibration of the receiving
Small deviations given in % calibration of the sending mA-
mA-input
output.
• Send system (converter and
sensor) to optek for checking
purposes. If necessary, the
None of the above mentioned
Converter defective - sensor body can remain in
errors can be detected.
the pipeline so that only the
optical arms and the
converter have to be sent.
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Maintenance
9 Maintenance
9.1 Preventive maintenance
Tab. 9 Preventive maintenance
Component Maintenance activity Maintenance interval Information

Possible damaged sealing faces
as part of standard
inspection with regard of the sensor body can lead to
Wetted parts installation
to leakages leakages (see instruction manual
maintenance
of the sensor body).
Operation of the lamp below its
nominal voltage (4.8 V DC
instead of 5.0 V DC) enhances
lamp life. Strong vibrations, high
Lamp
exchange 1 - 2 years temperatures or frequent on and
module
off switching of the system can
have negative effects on the
service life. Statistical service life
amounts to 3 years.
Note!
The used detector is not subjected to measurable aging when used properly.
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Maintenance
9.2 Exchange of lamp module
1. Switch the converter voltage-free.

2. Loosen the sensor cable from the lamp module.
3. Loosen the four screws connecting the lamp module to the stainless steel
housing.
4. Pull out the lamp module (8, fig. 15).
5. Check if there is an O-Ring (7) for the lamp module.
6. Insert the new lamp module into the sensor.
7. Fasten the four screws.
8. Re-connect the sensor cable.
9. Switch on the converter.
10. Follow the instructions given in chapter 9.4, page 27.
8 7
Fig. 15 Exchange of the lamp module
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Maintenance
9.3 Exchange of detector module
1. Switch the converter voltage-free.

2. Loosen the sensor cable from the detector module.
3. Loosen the four screws connecting the detector module to the stainless steel
housing.
4. Pull out the detector module (13, fig. 16).
5. Check if there is an O-Ring (7, fig. 16) for the detector module.
6. Insert the new detector module into the sensor.
7. Fasten the four screws.
8. Re-connect the sensor cable.
10. Follow the instructions given in chapter 9.4, page 27.
7 13
Fig. 16 Exchange of the detector module
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Maintenance
9.4 Return to operation after the exchange of lamp module

and detector module
Before return to operation of the entire measuring system, undertake the

following activities:
2. Wait for approx. 15 minutes, until the converter has reached the working
temperature.
3. Check the system's zero-point (see instruction manual of the converter).
4. Document your settings using the form (see instruction manual of the
converter).
5. Check measuring results with regard to plausibility.
6. If settings and measuring results are correct, enable measuring.
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Maintenance
9.5 Spare parts and accessories
9.5.1 Lamp modules / wavelength modules / detector assembly
Tab. 10 Spare parts - lamp modules*
Name sensor type Old part number New part number

lamp module AF56 2100-0205-01 1426-3143-1101-01
lamp module AF56-SF 2100-0205-01 1426-3143-1101-02
* Recommended spare part for 2-3 years of operation
Tab. 11 Spare parts - detector module AF56-N (NIR)
Detector module AF56-N (NIR)

(Choose corresponding wavelength Old part number New part number
module from table 13!)
detector module AF56-N 2500-0307-00 1414-3143-8001-00
detector module AF56-SF-N 2500-0307-00 1414-3143-8002-00
Tab. 12 Spare parts - detector module AF56-F**
Detector module AF56-F*

(Choose corresponding wavelength Old part number New part number
module from table 13!)
detector module AF56-F 2500-0308-00 1414-3145-8001-00
detector module AF56-SF-F 2500-0308-00 1414-3145-8002-00
** other wavelength modules on request
Tab. 13 Spare parts - wavelength modules
Name sensor type New part number

wavelength module AF56-N 1430-3143-7300-00
wavelength module AF56-F0430-10 1430-3145-0430-00
wavelength module AF56-F0450-80 1430-3145-0450-00
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Maintenance
9.5.2 Standard window (see corresponding sensor body manual)
Tab. 14 Spare parts - standard window
Sensor type / name Name / type Old part number New part number
® 0410-0050-01
Pyrex type A
type B 0410-0051-01
type C 0410-0052-01
Sapphire type A 0410-0050-03

standard window* type B 0410-0051-03
(see corresponding sensor
body manual) type C 0410-0052-03
type K 0410-0053-03
type AM 0410-0056-03
type BM 0410-0057-03
type CM 0410-0058-03
*others on request
9.5.3 Gaskets (not wetted)
Tab. 15 Spare parts - gaskets
(4 pieces each) Viton® old part number Viton® new part number
10.10 x 1.60 0208-4004-02 1203-0004-0008-02
21.95 x 1.78 0208-4001-02 1203-0004-0015-02
25.12 x 1.78 0208-4002-02 1203-0004-0016-02
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Maintenance
9.5.4 Screw sets
Tab. 16 Spare parts - screw sets
(10 pieces each) Old part number New part number

M 3 x 6 (DIN 7985) 1206-0010-0023-03
M 3 x 12 (DIN 7985)
1206-0010-0077-01
incl. washer M3 (DIN 7980)
9.5.5 Small part sets
Tab. 17 Spare parts - small part sets
Small part sets New part number

set purge connection M5 1201-3131-0001-00
9.5.6 Installation material
Tab. 18 Spare parts - installation material
Installation material New part number

set Klüberpaste UH1
1201-3131-0002-00
96-402 4 x 12 g
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Maintenance
9.5.7 Accessories cable sets
Tab. 19 Accessories - cable sets standard
Accessories - cable sets standard New part number

5m 2311-0115-0005-00
10 m 2311-0115-0010-00
20 m 2311-0115-0020-00
30 m 2311-0115-0030-00
40 m 2311-0115-0040-00
50 m 2311-0115-0050-00
Other cable lengths on request
Tab. 20 Accessories - cable sets with SS-plug-protection
Accessories - cable sets with SS-plug-

New part number
protection
5m 2311-0315-0005-00
10 m 2311-0315-0010-00
20 m 2311-0315-0020-00
30 m 2311-0315-0030-00
40 m 2311-0315-0040-00
50 m 2311-0315-0050-00
Other cable lengths on request.
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Disposal
10 Disposal
Special legal regulations apply to the return and disposal of industrial waste
equipment. However, manufacturer and user can contractually agree on which
party is to fulfill these legal obligations.
Observe current national disposal regulations!
For disposing of packaging material, please separate materials:

• Paper / paperboard
• Plastic
For disposal, disassemble the system units and separate them according to the
described material groups.
Dispose of materials according to national legislation!
If no agreement has been made regarding the return, you can send optek
electric appliances back to us.
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Appendix
11 Appendix
- 33 -
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Appendix
11.1 Declaration of conformity
Declaration of conformity
in accordance with the EC directives
Electromagnetic compatibility 98/336/EWG, 92/31/EWG 93/68/EWG
Low Voltage Directive 73/23/EEC, 93/68/EEC
We,
the
optek-Danulat GmbH,
Emscherbruchallee 2,
45356 Essen,
declare in sole responsibility, that the measuring systems
each comprising one converter of the series

X56 with X=1 or 5
and one sensor of the

AF56, AS56, TF56 series
have been developed, constructed and manufactured in conformity with the

mentioned EC directives.
Conformity is proven
by application of the norm EN 61326:1997 + EN 61326/A1:1998

+ EN 61326/A2:2001 + EN 61326/A3:2003
by application of IEC 61000-4-2

IEC 61000-4-3
IEC 61000-4-4
IEC 61000-4-5
IEC 61000-4-6
IEC 61000-4-11
as well as by application of the norm EN 61610-1:2001.
Essen, 22.05.07
Jürgen Danulat
General Manager
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Appendix
11.2 TÜV NORD CERT GmbH "GS-mark"
Fig. 17 GS-mark
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Appendix
11.3 QM system certificate
Fig. 18 QM system
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Appendix
11.4 Decontamination declaration
If you send the sensor and/or sensor body back to us, we need the
contamination declaration to comply with legal regulations and to be able to
protect our staff against possible dangers.
• Clean the component before packaging.
• If possible, use original packaging for returning the component.
• Place the filled out and signed decontamination declaration on top of the
packaging content and add a copy to the transportation documents.
• Send component to:
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen
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Appendix
Decontamination declaration
Sensor type /
Sensor body Ser. No.
type
Temperature [°C] [°F] Pressure [bar] [psi]

Process data
Conductivity [µS/cm] Viscosity [mm2/s] [cp]
Possible risks
(Please tick corresponding symbol
and add the safety data sheet, if necessary)
biological risk
flammable
corrosive
harmful /
irritating
harmless
other
toxic
risk
Concentration Identification
of medium CAS No.
Process medium
Cleaning
medium
for process
cleaning
Cleaning
medium of
sensor
Description of
fault
of component
Company
Contact person Phone
Sender
Fax
Address
The signatory hereby certifies that this decontamination declaration is filled out truthfully and completely to the best of his knowledge.
He further certifies that the returned components have been cleaned carefully and that, to the best of his knowledge, they are free of
any residues in dangerous quantities.
________________________ _____________________ ________________________ _______________________

Place Date Name of the signatory Signature
in block letters
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Appendix
11.5 Response via fax
to: optek-Danulat GmbH

Emscherbruchallee 2 Phone: +49-201-63409-0
45356 Essen Fax: +49-201-63409-999
from Company:
Name:
Department:
Street:
ZIP code / city:
Phone:
Fax:
Dear Sir or Madam,
please forward the following information to the office in charge.
O I am interested in inline photometry - please keep me informed on a regular basis.
O Inline photometry is of interest to our employee:
Name: ____________________________________________________
Department:
________________________________________________________________
Phone: ____________________________________________________
O I am interested in the following application: ______________________________
O We are already using your measuring systems. Model: _____________________
O We are currently using the following make: ______________________________
O Please call me.
The instruction manual for the ________________________________ model
is: good O O O O O not good
I have the following improvement suggestions:

________________________________________________________________
________________________________________________________________
________________________________________________________________
Yours faithfully,
Date / signature
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Sensor - Instruction Manual

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Instruction Manual

It is explicitly pointed out that optek-Danulat GmbH assumes no responsibility for

On request, this manual is available in other languages as well as in digital

Our products are being continuously improved. Technical data is subject to

Essen, August 2007

optek-sensors AF56, Version 02.2008_1.1US, 06.02.2008

For further inquiry, feel free to contact us or our distributing partners at

optek-sensors AF56, Version 02.2008_1.1US, 06.02.2008

1 System overview ................................................................................. 1

2 Using the instruction manual ............................................................. 2

3 Intended use ........................................................................................ 5

4 Description of AF56-F / AF56-N sensors ........................................... 6

5 Technical data and exploded views ................................................... 8

7 Connection to converter 156 ............................................................ 18

2 Using the instruction manual

2.1 Validity of the instruction manual

Abbreviations mean the following sensor options:

Furthermore, please follow the existing accident prevention and environmental

2.2 Pictograms and signal words

Especially important information in this instruction manual is marked with the

If the possible cause of risk can be specified, the corresponding pictogram

2.3 Note regarding return of the sensor

The use of the sensors in hazardous locations is prohibited.

Unauthorized constructional changes, additional fittings or rebuildings regarding

To lay sensor cables underground without protection is prohibited.

Following this instruction manual is part of the intended use.

4 Description of AF56-F / AF56-N sensors

This sensor is a high precision absorption sensor. It measures attenuation of

Fig. 1 AF56-F / AF56-N

The following are the main sensor components:

Its modular construction offers maximum flexibility in adapting to the process,

Attenuation of light intensity, as a result of absorption and / or scattering of

5 Technical data and exploded views

Tab. 1 Technical data AF56-F / AF56-N

Material sensor body made of stainless steel 1.4571; SS 316 Ti (standard)

Process temperature permanent:

peak (15 min/day):

Tab. 2 Technical data AF56-SF-F / AF56-SF-N

Material sensor body made of stainless steel 1.4571; SS 316 Ti (standard)

peak (15 min/day):

Fig. 3 Schema for determining dimensions

• A = installation height (in mm)

Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

Tab. 3 Sensor dimensions in dependence of specifications of standard sensor body

Tab. 4 Window combinations and optical path lengths

* preferred combination due to symmetry

You may obtain other window types and combinations on request.

Tab. 5 Cable weights

Lamp cable (2.5 mm2) 1.2 kg / 10 m

5.1 Exploded view of AF56-F / AF56-N sensor

Fig. 4 Photo and exploded view AF56-F / AF56-N

Tab. 6 Exploded view explanations

No. Explanation No. Explanation

6.1 Standard sensor bodies - installation instructions

Fig. 5 Vertical alignment of standard sensor body

Fig. 6 Horizontal alignment of standard sensor body

Fig. 7 No vertical alignment of the optical arms

6.2 Installation of the sensor

Tool • not needed

Install sensor as described below:

1. Check that there are O-Rings for the sensor assemblies.

Fig. 8 O-Ring at window ring

Fig. 9 Installed sensor, example AF16-N / AF16-F sensor

6.3 Air purge