ABB AP201 User manual
—
ABB MEASUREMENT & ANALYTICS | USER GUIDE | IM/AP200 REV. S
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid
temperature response for critical processes
Measurement made easy
Introduction
The pH / redox (ORP) sensor AP200 provides high
reliability and withstands the toughest
environments for process monitoring and control.
The rugged assembly is built to bear the rigors of
weather and process. Parts in contact with the
process comprise chemically-resistant PPS Ryton™
and stainless steel, or PPS Ryton™ and Hastelloy C.
Flow-through holders are available in polypropylene,
while the PPS Ryton™ insertion adapter enables
installation in alternative material pipelines.
Insertion and Flow-through systems tolerate
temperatures up to 130 °C (266 °F) and pressures up
to 6 bar (90 psi). The inner electrode connections
are ingress-protected to IP 67 / NEMA 6P (exceeds
NEMA 4X).
For more information
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AP200
Rugged pH/Redox (ORP) sensor systems with
rapid temperature response for critical
processes
Data Sheet
DS/AP200-EN
AAO100
Dosing pump
User Guide
IM/DOSPMP
—
AP200 series
Rugged pH/Redox
(ORP) sensor systems
The Company
We are an established world force in the design and
manufacture of instrumentation for industrial process control,
flow measurement, gas and liquid analysis and environmental
applications.
As a part of ABB, a world leader in process automation
technology, we offer customers application expertise, service
and support worldwide.
We are committed to teamwork, high quality manufacturing,
advanced technology and unrivalled service and support.
The quality, accuracy and performance of the Company’s
products result from over 100 years experience, combined with
a continuous program of innovative design and development to
incorporate the latest technology.
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes Contents
IM/AP200 Rev. S 1
Contents
1 Description ......................................................................2
1.1 Introduction ..............................................................2
1.2 Systems ...................................................................2
1.2.1 Typical Systems ............................................2
1.2.2 AP120 Series Electrodes
Used with Holders ........................................2
2 Mechanical Installation ...................................................3
2.1 Installing the Systems ...............................................3
2.1.1 Model AP201 Insertion System .....................3
2.1.2 Model AP202 Inline System ..........................4
2.1.3 Model AP203 Flanged Dip
(Immersion) System ......................................5
2.2 Removing the Sensor Holder ....................................6
2.2.1 Models AP201 Insertion and
AP202 Inline Systems ...................................6
2.2.2 Model AP203 Flanged DIp
(Immersion) System ......................................7
2.3 System Assembly .....................................................8
2.4 Jetwash System .......................................................9
2.5 Jetwash System Assembly .....................................10
3 Electrical Installation .....................................................11
3.1 Analyzer Connections .............................................11
3.2 Shortening the Connection Cable ...........................11
3.3 Extending the Connection Cable ............................12
3.4 Jetwash System Connections ................................12
4 Calibration ..................................................................... 13
4.1 Method .................................................................. 13
4.2 Buffer Solutions ..................................................... 13
4.3 Redox (ORP Sensor) .............................................. 13
5 Maintenance ................................................................. 14
5.1 General Cleaning ................................................... 14
5.1.1 General Sludge and
Loosely Adhering Matter ............................. 14
5.1.2 Heavy, Non-Greasy Deposits ...................... 14
5.1.3 Greasy or Organic Deposits ........................ 14
5.2 Fault Finding .......................................................... 14
5.3 Storing the Electrode ............................................. 14
6 Specification ................................................................. 15
7 Spares ........................................................................... 16
7.1 Model AP201 Insertion System .............................. 16
7.2 Model AP202 Inline System ................................... 17
7.3 Model AP203 Flanged Dip (Immersion) System ...... 18
Notes ................................................................................ 19
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 1 Description
2 IM/AP200 Rev. S
1 Description
1.1 Introduction
This manual describes the installation and maintenance of the
AP200 Series Process pH and Redox (ORP) Electrode Holder
Systems.
1.2 Systems
1.2.1 Typical Systems
1.2.2 AP120 Series Electrodes Used with Holders
See Section 6, page 15 for full details.
Note. The candidate list according to Article 59 of the Regulation (EC) No 1907/2006 on the Registration, Evaluation,
Authorisation and Restriction of chemicals (REACH) continues to expand. Article 33 places a legal obligation on an article
producer to inform recipients of the information requirements when a candidate list substance is contained within an article at
percentage of greater than 0.1% W/W.
The candidate list substance, acrylamide, a substance of very high concern, (CAS 79-06-1) is totally enclosed within the gel
component of the product and should pose no risk to the user during installation, use and decommissioning providing the probe
is handled in accordance with the instructions defined in the user manual.
AP201 Insertion system
AP202 In-line, flow-through system
AP203 Dip (immersion) system
AP121/11000 General process 0 to 14 pH, 0 to 100°C
AP121/21000 High temperature 0 to 14 pH, 0 to 130°C
AP121/31000 Low temperature 0 to 10 pH, –5 to +50°C
AP121/60000 Redox (ORP) platinum 0 to 100°C
Fig. 1.1 System Schematics
In-line System – AP202
Dip (Immersion) System – AP203
Insertion System – AP201
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
IM/AP200 Rev. S 3
2 Mechanical Installation
2.1 Installing the Systems
2.1.1 Model AP201 Insertion System
This system is designed to mount directly into a pipeline or tank. Mounting adaptors are available:
7690 130 PPS Ryton™ R 11/4in. adaptor 7690 128 R 1in. Stainless Steel adaptor
7690 134 Polypropylene 11/4in. NPT adaptor 7690 132 DN25 Straight-weld socket
7690 129 Polypropylene R 11/4in. adaptor 7690 133 DN25 Angled-weld socket
7690 131 1in. NPT Stainless steel adaptor
Dimensions in mm (in.)
Fig. 2.1 Model AP201 Insertion System
ø50
327
(12.87)
100 (3.94)
15° min.15° min.
90 (3.54)
G 1
1
/4G 1
1
/4G 1
1
/4
R 1
1
/4
or 1
1
/4 NPT
ø25
50
(1.97)
40
(1.58)
ø25
ø36
ø25
ø36
1 in. NPT
or R 1in.
20
(0.78)
18
(0.71)
G 1
1
/4
18
(0.71)
50
(1.97)
50
(1.97)
Pipe-Mount System Tank-Mount System
Mounting Adaptors
7690 130
PPS Ryton R11/4in. Adaptor
+
7690 134
PP 11/4in. NPT Adaptor
+
7690 129
PP R11/4in. Adaptor
7690 131
1in. NPT Stainless Steel
Mounting Adapter
+
7690 128
R1in. Stainless Steel
Adaptor
7690 132
DN25 Straight-Weld Socket
(316 SS)
7690 133
DN25 Angled-Weld Socket
(316 SS)
Angled-Weld Socket
15° min. from horizontal
Allowable Mounting Position Note. When installing the Model AP201 insertion system,
ensure that the electrode is fully immersed in sample under all
operating conditions.
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
4 IM/AP200 Rev. S
2.1.2 Model AP202 Inline System
This system is supplied with an inline tee-piece for mounting the system directly into a pipeline. Allow sufficient height above the
system to enable the sensor to be withdrawn from the tee-piece.
Dimensions in mm (in.)
Fig. 2.2 Model AP202 Inline System
67.5
(2.66)
Minimum
clearance
required
(Stainless Steel
versions only)
(Polypropylene
versions only)
To prevent spillage
when system
is removed
To ensure electrode
is always in sample
Isolating
Valve
Isolating
Valve
Typical Installation
Rp 1 in.
Female Threads
Note. Refer to Section 6, page 15 for
information about the different versions.
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
IM/AP200 Rev. S 5
2.1.3 Model AP203 Flanged Dip (Immersion) System
This system is designed to be installed over an unpressurized tank or channel. A sliding flange is supplied to enable adjustment of the
immersion depth. A suitable mounting bracket or support must be supplied by the user.
Dimensions in mm (in.)
Fig. 2.3 Model AP203 Flanged Dip (Immersion) System
100
(3.94)
90
(3.54)
74
(2.91)
ø50
ø56
Thumb-screws
(see Note below)
Mounting Flange
Dimensions
Mounting bracket
supplied by user
Insert
1,2or3m
(39.37, 78.74, 118.11)
Typical Installation
Note. Ensure the thumb-screws compress the
insert when clamping the flange to the dip tube.
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
6 IM/AP200 Rev. S
2.2 Removing the Sensor Holder
2.2.1 Models AP201 Insertion and AP202 Inline Systems
Fig. 2.4 Models AP201 and AP202 – Removing the Sensor Holder
AP201 AP202
1
3
4
2
Open cover and detach cables and
jetwash tubing (if fitted) from cap
Twist cable shroud
counter-clockwise and
remove
Unscrew sensor holder retaining
nut and remove sensor holder
from in-line adaptor
Check O-ring is in position,
located on underside of
electrode holder
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
IM/AP200 Rev. S 7
2.2.2 Model AP203 Flanged DIp (Immersion) System
Fig. 2.5 Model AP203 – Removing the Sensor Holder
2
1
3
Unscrew sensor guard from
dip tube (see Note below)
Open cover and detach
cables and jetwash tubing
(if fitted) from cap
Remove the sensor holder from the dip tube using the
sensor guard as a tool. Engage the sensor guard lugs in the
sensor holder slots. Twist the sensor holder
counter-clockwise to disengage the bayonet lugs from the
slots in the dip tube and withdraw the sensor holder.
Ensure the O-ring remains clean.
Note.
Before refitting the sensor
guard, clean and regrease
the threads and O-ring.
Do not overtighten the
sensor guard.
AP200 series
Rugged pH/Redox (ORP) sensor systems with rapid temperature response for critical processes 2 Mechanical Installation
8 IM/AP200 Rev. S
2.3 System Assembly
Fig. 2.6 System Assembly
11
9
1
8
2
4
6
3
7
5
10
Close cover
Note. Model AP201 shown. When assembling
Models AP202 and AP203, refit the Tee piece to
the sensor holder (AP202) or the sensor guard to
the dip tube (AP203) – see Figs. 2.4 and 2.5.
Clip cables and jetwash tube
(if required) into slots in
protective cover
Route cables and jetwash tube
(if required) through cable
shroud
Locate cable shroud over
sensor holder and twist
clockwise to engage
bayonet lugs in slots
Tighten to
recommended
torque value of
125cNm
Tighten
Connect jetwash
supply tube
(if required – see
Section 2.5,
page 10) and
tighten to
recommended
torque value of
60cNm
Locate sensor
cable connector
over keyway
Insert sensor in holder
Ensure support washer
and O-ring are fitted to
electrode
Connect earth
(ground)
terminal
to rod
This manual suits for next models
2
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