Hach GA2400-S00 Basic User Manual

DOC024.98.93153

ORBISPHERE Model

GA2X00 O

2

EC Sensor

11/2019, Edition 2

Basic User Manual

Allgemeines Benutzerhandbuch

Manuale di base per l'utente

Manuel d'utilisation de base

Manual básico del usuario

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Grundlæggende brugervejledning

Podstawowa instrukcja obsługi

Allmän användarhandbok

Peruskäyttöohje

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Table of Contents

English..............................................................................................................................3

Deutsch.......................................................................................................................... 22

Italiano............................................................................................................................ 42

Français......................................................................................................................... 62

Español.......................................................................................................................... 83

Nederlands................................................................................................................. 103

Dansk............................................................................................................................123

Polski............................................................................................................................ 142

Svenska....................................................................................................................... 162

Suomi............................................................................................................................181

Magyar......................................................................................................................... 200

2

Table of Contents

1 Table of contents on page 3

2 Specifications on page 3

3 Expanded manual version on page 6

4 General information on page 6

5 Installation on page 8

6 Maintenance on page 13

7 Troubleshooting on page 20

Section 1 Table of contents

Specifications on page 3 Maintenance on page 13

General information on page 6 Troubleshooting on page 20

Installation on page 8

Section 2 Specifications

Specifications are subject to change without notice.

2.1 Sensor specifications

Table 1 ORBISPHERE family of GA2X00 oxygen sensors

Specification Details—Non-ATEX sensors Details—ATEX sensors

Type Electrochemical oxygen sensor

Dimensions (Ø × L) 32 × 86.3 mm (1.26 × 3.40 in.)

Weight 300 g

Pressure resistence 40 bar maximum with default PPS collar (100 bar with stainless steel collar)

Materials Stainless steel Stainless steel or hastelloy

Sensor head: Kalrez

®

O-rings

Sensor bottom: Viton

®

O-rings

1

EPDM and Kalrez

®

O-rings

Sensor head: Kalrez

®

O-rings

Sensor bottom: Viton

®

O-rings or Kalrez

®

O-rings

Other Smart capability Intrinsically safe

Certification CE CE, Ex II 1 G, Ex ia IIC T6

Note: Unlike the GA2400 non-ATEX sensors, the intrinsically safe GA2800 ATEX sensors have no smart capability

to store calibration data. However, all GA2800 ATEX sensors have the ATEX conformity information engraved on

the sensor itself.

2.2 Sensor configurations

Table 2 Beverage

Application Sensor Membrane Cartridge Protection Cap

Beer with ORBISPHERE

3650 Portable

GA2400-S00 2958A-A (optimized response

time)

2952A-A (optimized

maintenance interval)

33051-SP

Beer in-line GA2400-S00 2952A-A 33051-SG

Wort in-line GA2400-S00 29552A-A 33051-S0

1

Viton and Kalrez are trademarks of DuPont Corporation.

English 3

Table 2 Beverage (continued)

Application Sensor Membrane Cartridge Protection Cap

Wort with ORBISPHERE

3650 Portable and special flow

cell 32007W.xxx

GA2400-S00 29552A-A 33051-S0

ORBISPHERE 6110 Total

package analyzer (TPA)

GA2400-S00T 2956A-A 33051-ST

De-aerated water GA2400-S00 2956A-A or 2952A-A 33051-S0

33051-SG (if exposed to

CIP)

Table 3 Pure water applications (Power - Electronics)

Application Sensor Membrane Cartridge Protection Cap

On-line dissolved oxygen traces in pure water GA2400-S00 2956A-A 33051-S0

Dissolved oxygen traces with 3655 Portable GA2400-S00 2956A-A 33051-S0

Table 4 ATEX

Sensor Membrane Cartridge Protection Cap

GA2800-SVS 2956A-A or 29552A-A 33051-SG

GA2800--SKS 2956A-A or 29552A-A 33051-SG

GA2800--HVS 2956A-A or 29552A-A 33051-H0

GA2800--HKS 2956A-A or 29552A-A 33051-H0

2.3 Sensor membrane specifications

2.3.1 Oxygen sensors (Table 1)

Table 5 Membrane specifications - Oxygen sensors (1)

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

Recommended applications Corrosion control,

De-aerated water

Beverage,

Lab. applications

In line wort,

Air/O

2

injection,

Sewage treatment

Corrosion control,

In line beverage,

De-aerated water

Material PFA Tefzel

®

2

PTFE Tefzel

®

Thickness [μm] 25 12.5 50 25

Calibration gas Air Air Air Air / Pure O

2

Dissolved measurement range 0 ppb to 20 ppm 0 ppb to 40 ppm 0 ppb to 80 ppm 0 ppb to 80 ppm

Gaseous measurement range 0 Pa to 50 kPa 0 Pa to 100 kPa 0 Pa to 200 kPa 0 Pa to 200 kPa

Accuracy The greater of

±1% of reading

or ± 0.1 ppb

3

,

or ± 1 ppb

4

,

or ± 0.25 Pa

The greater of

±1% of reading

or ± 1 ppb,

or ± 2 Pa

The greater of

±1% of reading

or ± 2 ppb,

or ± 5 Pa

The greater of

±1% of reading

or ± 2 ppb,

or ± 5 Pa

2

Tefzel is a trademark of DuPont Corporation.

3

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

4

Accuracy is ± 1 ppb for 366x and 3650 instruments

4 English

Table 5 Membrane specifications - Oxygen sensors (1) (continued)

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

Integrated radiation dose limit

[rads]

2 x 10

4

10

8

N/A 10

8

Expected current in air @ 1 bar

25 °C [μA]

26.4 9.4 6.3 5.4

Expected current in pure O

2

[μA] 132 47 31.4 27

O

2

consumption in O

2

saturated

water at 25 °C [μg/hour]

40 14 9.4 8

Temp. compensation range – 5 to 60 °C

Temp. measuring range – 5 to 100 °C

Response time

5

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

Recommended min. liquid flow

rate

6

[mL/min]

180 120 50 50

Recommended min. linear flow

rate

6

[cm/sec]

200 100 30 30

Recommended gaseous flow rate

[L/min]

0.1 to 3

2.3.2 Oxygen sensors (Table 2)

Table 6 Membrane specifications - Oxygen sensors (2)

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

Recommended applications Saturated to super

saturated levels

Saturated to super

saturated levels

In line hot wort

(up to 70 °C)

Material Halar

®

7

Tefzel

®

Tefzel

®

Thickness [μm] 25 125 12.5

Calibration gas Air / Pure O

2

Air / Pure O

2

Pure O

2

Dissolved measurement range 0 ppb to 400 ppm 0 ppb to 400 ppm 0 ppb to 2000 ppm

Gaseous measurement range 0 Pa to 1000 kPa 0 Pa to 1000 kPa 0 Pa to 5000 kPa

Accuracy The greater of

±1% of reading

or ± 10 ppb,

or ± 20 Pa

The greater of

±1% of reading

or ± 10 ppb,

or ± 20 Pa

The greater of

±1% of reading

or ± 50 ppb,

or ± 100 Pa

Integrated radiation dose limit [rads] N/A 10

8

10

8

Expected current in air @ 1 bar

25 °C [μA]

0.9 0.7 0.2

Expected current in pure O

2

[μA] 4.7 3.8 0.9

O

2

consumption in O

2

saturated

water at 25 °C [μg/hour]

1.4 1.3 0.3

Temp. compensation range – 5 to 60 °C

5

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

6

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

7

Halar is a trademark of Solvay Corporation.

English 5

Table 6 Membrane specifications - Oxygen sensors (2) (continued)

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

Temp. measuring range – 5 to 100 °C

Response time

8

2.5 min. 18 min. 80 sec.

Recommended min. liquid flow rate

9

[mL/min]

25 25 5

Recommended min. linear flow rate

9

[cm/sec]

20 60 5

Recommended gaseous flow rate

[L/min]

0.1 to 3

Section 3 Expanded manual version

For additional information, refer to the expanded version of this manual, which is available on the

manufacturer's website.

Section 4 General information

In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential

damages resulting from any defect or omission in this manual. The manufacturer reserves the right to

make changes in this manual and the products it describes at any time, without notice or obligation.

Revised editions are found on the manufacturer’s website.

4.1 Safety information

N O T I C E

The manufacturer is not responsible for any damages due to misapplication or misuse of this product including,

without limitation, direct, incidental and consequential damages, and disclaims such damages to the full extent

permitted under applicable law. The user is solely responsible to identify critical application risks and install

appropriate mechanisms to protect processes during a possible equipment malfunction.

Please read this entire manual before unpacking, setting up or operating this equipment. Pay

attention to all danger and caution statements. Failure to do so could result in serious injury to the

operator or damage to the equipment.

Make sure that the protection provided by this equipment is not impaired. Do not use or install this

equipment in any manner other than that specified in this manual.

4.1.1 Use of hazard information

D A N G E R

Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious

injury.

C A U T I O N

Indicates a potentially hazardous situation that may result in minor or moderate injury.

N O T I C E

Indicates a situation which, if not avoided, may cause damage to the instrument. Information that requires special

emphasis.

8

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

9

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

6 English

4.1.2 Precautionary labels

Read all labels and tags attached to the instrument. Personal injury or damage to the instrument

could occur if not observed. A symbol on the instrument is referenced in the manual with a

precautionary statement.

This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential

injury. If on the instrument, refer to the instruction manual for operation or safety information.

This symbol indicates the need for protective eye wear.

This symbol indicates the need for protective hand wear.

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.

Electrical equipment marked with this symbol may not be disposed of in European domestic or

public disposal systems. Return old or end-of-life equipment to the manufacturer for disposal at no

charge to the user.

4.2 Product components

Make sure that all components have been received. Refer to Figure 1. If any items are missing or

damaged, contact the manufacturer or a sales representative immediately.

Figure 1 Product components

1 Sensor 3 Sensor recharge kit

2 Protection caps

4.2.1 Electrochemical sensor

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

individual order.

The sensor 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.

English

7

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.

4.2.2 Protection caps

Non-ATEX sensors (GA2400)

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.

A fourth protection cap (part number 33051-ST) is delivered for the 6110 TPA application.

ATEX sensors (GA2800)

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

4.2.3 Sensor recharge kit

A recharge kit should have been ordered with the sensor as this will be required to initially make the

sensor operational. It is also required for sensor cleaning and membrane replacement procedures.

Note: There are two different versions of the recharge kit. One version for GA2X00/A110X sensors and one version

for C1100 sensors. Refer to the documentation supplied with the kit for instructions on how to use the version of the

recharge kit with the applicable sensor.

The kit contains:

• four recharge cartridges with pre-mounted membrane and electrolyte. The type of membrane

mounted in the cartridge will be specific to the kit ordered

• two anode cleaning tools

• two sets of five cotton washers and five silicone discs (only for 2956A-XXX)

Note: The box for GA2X00 sensors has a blue label and the box for A110X sensors has a black label.

• one set of replacement O-rings and Dacron

®

mesh patches, applicable for GA2X00 and A110X

sensors

The blue anode cleaning tool is used to clean the anode of any deposits or residue that may have

formed. It is doubled-ended so it can be used for two membrane replacement processes, each end

being used once. Refer to the documentattion supplied with the recharge kit for instructions on how

to use the anode cleaning tool for a GA2X00 sensor or for a A110X sensor.

The cotton washers provide additional protection against the formation of deposits and residue on

the center electrode and anode, which prolongs the time period required between sensor

maintenance.

The silicone discs are required for measurements in ultra-pure water or water containing ammonia.

The Dacron

®

mesh patches provide protection to the membrane when using a protection cap with a

grille.

Section 5 Installation

C A U T I O N

Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the

document.

5.1 Sensor preparation

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal

protective equipment appropriate to the chemicals that are handled. Refer to the current safety data

sheets (MSDS/SDS) for safety protocols.

8 English

Your sensor has been thoroughly cleaned and tested at the factory before shipment. It has been

shipped with a cartridge containing a membrane and electrolyte pre-installed to protect the sensor

head. This cartridge must be removed and replaced with a new one prior to first use to make it fully

operational. The new cartridge is included in the sensor recharge kit.

• Non-ATEX sensors (GA2400). The sensor has been delivered with two protection caps, one with

a grille and one without. Ensure you use the correct protection cap for your application. Refer to

Sensor configurations on page 3 for additional information.

• ATEX sensors (GA2800). The sensor has been delivered with a single protection cap.

The following instructions detail the steps required to make the sensor operational.

Note: It is advisable to perform this procedure with the plastic sensor base installed so as to avoid any damage to

the connection socket and also to provide a suitable stand for the sensor when required.

English 9

1. Hold the main body of the sensor and unscrew the protection cap locking washer by turning

counter-clockwise. Remove it from the sensor and put to one side.

2. Pull/twist off the protection cap and put to one side.

3. Hold the sensor with the membrane facing down to avoid spilling any electrolyte, then carefully

unscrew the shipment cartridge. Drain the old electrolyte into a sink and flush away. Discard the

shipment cartridge and membrane. Remove the cotton washer and silicone disc from the top of

the anode and discard.

4. Rinse the sensor head under a tap for 15 seconds, aiming the jet of water directly onto the sensor

head. Do not dry the center electrode area, as the gap between cathode and guard should be left

filled with water.

5. Take a silicone disc from the recharge kit, hold it between thumb and forefinger and position it on

top of the anode. Take a new cotton washer from the recharge kit. Hold it between thumb and

forefinger and position it on top of the silicone disc.

Note: During this step, it is very important to ensure your finger does not come into contact with the cathode

(golden surface) as it could leave greasy deposits on the surface.

6. Place the recharge cartridge container on a flat work surface and, keeping the container upright

to avoid spilling any of the electrolyte inside, carefully unscrew the top. Remove the packing

component from the center of the cartridge, making sure that the O-ring on top of the cartridge

remains in place. If it comes away then replace it before continuing. If there are any visible

bubbles in the electrolyte, remove them using a stirring motion with the packing component.

Note: The recharge cartridge container will be colored black for all applications except for the 6110 TPA where

it will be colored white.

10

English

7. Hold the container steady between thumb and forefinger of one hand. Lower the sensor into the

container until the top of the anode is covered with electrolyte. Leave for a few seconds to ensure

the cotton washer has fully absorbed some of the electrolyte and that it is no longer dry.

8. Gently screw the sensor clockwise into the replacement cartridge, applying minimum pressure to

avoid any damage to the screw threads.

9. Continue turning until the cartridge is attached to the sensor, and the sensor is automatically

released from the container. The empty container, the screw top and packing component can be

discarded.

Note: It is normal that some of the electrolyte will overflow from the replacement cartridge and into the plastic

container.

English

11

10. Rinse the sensor under a tap for about 5 seconds to remove any excess electrolyte, then gently

wipe with a soft tissue to ensure all parts are completely dry. Drain the overflow electrolyte from

the container into a sink and flush away. Discard the used container.

11. If not using a protection cap with grille proceed to step 12. Otherwise take a new Dacron

®

mesh

patch from the box of O-rings in the recharge kit. Place the mesh in the center of the protection

cap. It is very important that the mesh is in the center of the protection cap and covering the

entire grille. Lower the sensor onto the protection cap making sure not to disturb the mesh.

12. Push the protection cap firmly into place, making sure one of the four slots in the protection cap

fits over the small locking pin (highlighted right). If it is necessary to turn the protection cap to fit

over the locking pin, ensure you only turn it clockwise to avoid unscrewing the cartridge.

13. Finally, screw the protection cap locking washer back into place in a clockwise motion, and

tighten finger tight.

5.2 Sensor installation

5.2.1 Sensor positioning information

Unless the sensor is part of the ORBISPHERE equipment that includes it, the sensor must be

installed in an ORBISPHERE socket or flow chamber, that allows contact with the sample fluid to be

analyzed.

The sensor and measuring instrument are connected by a cable and two 10-pin connectors. The

standard sensor cable length is 3 meters though extension cables of up to 1000 meters are available.

However, smart sensor technology is only available with distances of up to a maximum of

750 meters.

Note: If the model 28117 pressure sensor is used, the maximum cable length is 50 meters.

Ensure that the sensor will be mounted:

• perpendicular to the pipe

• horizontal

• on a horizontal pipe section (or on flow-ascending vertical pipe)

• minimum of 15 meters away from the pump's discharge side

• in a place where the sample flow is stable and rapid, and as far as possible from:

12

English

• valves

• pipe bends

• the suction side of any pumps

• a CO

2

injection system or similar

Note: There may be situations where not all the above conditions can be met. If this is the case, or you have any

concerns, please consult your Hach representative to appraise the situation and define the best applicable solution.

5.2.2 Sensor insertion

Note: Check that the small O-ring at the bottom of the flow chamber is present during removal and installation of

the sensor, as it may stick to the sensor head and fall.

• Insert the sensor straight into the flow chamber or socket.

• Hand tighten the attaching collar.

• Connect the sensor cable.

• Check for leaks; replace O-rings if product leaks are visible.

Note: Do not twist the sensor when inserting it into a micro volume flow chamber. This rotation may twist the

membrane holding ring, thus changing the membrane position. This can modify the membrane measuring

conditions, and affect measurement precision.

5.2.3 Sensor removal

• Shut off the sample flow and drain the sampling circuit of liquid or gas.

• Remove the sensor cable connected at the sensor end.

• Hold the sensor body in one hand to avoid rotation and unscrew the collar with the other hand.

• Pull the sensor straight out of the socket or flow chamber.

• Check that both O-rings remain in place inside the flow chambers.

• Install the sensor storage cap and sensor base (to protect the connection).

Section 6 Maintenance

W A R N I N G

Multiple hazards. Only qualified personnel must conduct the tasks described in this section of the

document.

6.1 Maintenance schedule

The following table shows the recommended schedule for membrane replacement. The table should

only be used as a guideline, as maintenance intervals will vary depending on a number of different

parameters (e.g. water chemistry, CIP frequency, oxygen levels, sample temperature, etc.).

Application Membrane type Membrane replacement

Water applications (> 10 ppb) 2956A Every 3 to 6 months

Pure water applications (power and electronics < 10 ppb) 2956A Every 3 to 6 months

Beer in-line 2952A Every 3 to 6 months

Portable or lab applications 2952A or 2958A Every 3 to 6 months

Wort in-line 29552A or 2995A Every 1 or 2 months

6.2 Prerequisites for sensor maintenance

The following table lists the prerequisites for a sensor maintenance:

English

13

Part No. Description

2959 Electrolyte for oxygen sensors, 50-mL bottle.

29781 Cathode polishing powder (part no.29331) and cloth (part no. 2934).

32301 Electrochemical cleaning and regeneration center (see below)

40089 Tweezers, for maintenance kits

DG33303 Cleaning tool for sensor polishing for A110X and C1100 sensors only

DG33629 Cleaning tool for sensor polishing for GA2X00 sensors only

DG33619 Regeneration Cell for GA2X00/A1100 or C1100 sensors

DG33620 Orbisphere EC sensor support for cleaning

Note: If the sensor is being used in a high level hydrogen sample, this cleaning and regeneration center is not

required. In all other cases it is a prerequisite.

The ORBISPHERE 32301 is a very efficient cleaning and regeneration tool for electrochemical

sensors. Refer to Figure 2. This tool reverses the electrochemical process that is taking place in the

sensor cell during normal operation. This removes oxidation and at the same time regenerates the

surface of the electrodes. In addition, the regeneration center offers a continuity tester for checking

the sensor electronics.

Figure 2 ORBISPHERE 32301 cleaning and regeneration tool

6.3 Membrane replacement and sensor head cleaning

C A U T I O N

Chemical exposure hazard. Obey laboratory safety procedures and wear all of the personal

protective equipment appropriate to the chemicals that are handled. Refer to the current safety data

sheets (MSDS/SDS) for safety protocols.

A sensor recharge kit is required as it contains all the components necessary for this membrane

replacement and sensor head cleaning process. Refer to Sensor recharge kit on page 8.

Note: It is advisable to perform this procedure with the plastic sensor base installed so as to avoid any damage to

the connection socket and also to provide a suitable stand for the sensor when required.

1. Hold the main body of the sensor and unscrew the protection cap locking washer by turning

counter-clockwise. Remove it from the sensor and put to one side.

2. Pull/twist off the protection cap and put to one side. If you are using a protection cap with a grille,

then remove the Dacron

®

mesh from inside the cap and discard it.

3. Hold the sensor with the membrane facing down to avoid spilling any electrolyte, then carefully

unscrew the old cartridge. Drain the old electrolyte into a sink and flush away. Discard the old

cartridge and membrane. Remove the cotton washer and silicone disc from the top of the anode

and discard.

14

English

4. Rinse the sensor head under a tap for 15 seconds to remove any remaining electrolyte and shake

dry. With a soft tissue gently clean around the guard area (indicated right) and then wipe off any

excess moisture from the sensor to ensure all parts are completely dry. Repeat this rinse and dry

process with the protection cap.

5. Clean the anode using the cleaning tool supplied. Place the tool over the sensor head. Clean by

rotating the cleaning tool over the sensor head for a few seconds, in a clockwise direction only.

6. Remove the tool and tap it face down on a flat work surface to remove any powdery deposit.

Check the sensor to ensure that all deposits have been removed from the anode. If not, repeat

step 5. until the anode regains its bright silver appearance.

7. Rinse the sensor head under a tap for 15 seconds, aiming the jet of water directly onto the sensor

head. Do not dry the center electrode area, as the gap between cathode and guard should be left

filled with water.

English

15

8. On the clean polishing cloth (2934) do the steps that follow:

a. Add a few drops of water.

b. Spread a little of the polishing powder (29331) to form a grey, milky liquid.

9. Screw the polishing tool (DG33629) onto the top of the sensor.

10. Polish the electrodes by moving the sensor face in a circular direction against the liquid in the

polishing cloth for about 30 seconds.

11. Remove the polishing tool from the sensor. Remove any polish deposits by rinsing the sensor

head under a tap for 30 seconds, aiming the jet of water directly onto the sensor head.

Note: If the sensor is used in high level hydrogen sample, do not perform the following steps but continue at

step 19.

12. Remove the plastic base from the bottom of the sensor and connect the sensor to the sensor

cleaning and regeneration center (32301).

16

English

13. Push the cleaning tool over the sensor head. Pour enough electrolyte (2959) into the cleaning

tool until it completely covers all the electrodes.

Note: For DG33619 regeneration cell, screw the regeneration cell on the sensor head.

14. On the sensor cleaning and regeneration center, turn the knob to the Anode position and press

the TIMER switch. A red warning light will come on and remain on for 60 seconds while cleaning

takes place.

15. At the end of the 60 second cleaning process, check for an abundant stream of bubbles that

should rise from the anode. If this does not happen, press TIMER again.

Note: The development of bubbles is a sure sign of a clean electrode.

16. On the sensor cleaning and regeneration center, turn the knob to the Guard position and press

the TIMER switch. Again, watch for the formation of bubbles and repeat the cleaning process if

necessary.

English

17

17. On the sensor cleaning and regeneration center, turn the knob to the Cathode position and press

the TIMER switch. Again, watch for the formation of bubbles and repeat the cleaning process if

necessary.

18. When cleaning is complete, unplug the sensor from the cleaning center and re-install the plastic

sensor base for the rest of the procedure. Remove any remaining electrolyte by rinsing the

sensor head under a tap for 60 seconds, aiming the jet of water directly onto the sensor head.

Note: For DG33619 regeneration cell, unscrew the regeneration cell from the sensor head.

19. With the help of a pair of tweezers, remove the old O-ring from the sensor body. Replace the O-

ring with a new one from the recharge kit.

20. Take a silicone disc from the recharge kit, hold it between thumb and forefinger and position it on

top of the anode. Take a new cotton washer from the recharge kit. Hold it between thumb and

forefinger and position it on top of the silicone disc.

Note: During this step, it is very important to ensure your finger does not come into contact with the cathode

(golden surface) as it could leave greasy deposits on the surface.

21. Place the recharge cartridge container on a flat work surface and, keeping the container upright

to avoid spilling any of the electrolyte inside, carefully unscrew the top. Remove the packing

component from the center of the cartridge, and make sure that the O-ring remains in place on

top of the cartridge. If it comes away then replace it before continuing. If there are any visible

bubbles in the electrolyte, remove them using a stirring motion with the packing component.

Note: The recharge cartridge container will be colored black for all applications except for the 6110 TPA where

it will be colored white.

18

English

22. Hold the container steady between thumb and forefinger of one hand. Lower the sensor into the

container until the top of the anode is covered with electrolyte. Leave for a few seconds to ensure

the cotton washer has fully absorbed some of the electrolyte and that it is no longer dry.

23. Gently screw the sensor clockwise into the replacement cartridge, applying minimum pressure to

avoid any damage to the screw threads.

24. Continue turning until the cartridge is attached to the sensor, and the sensor is automatically

released from the container. The empty container, the screw top and packing component can be

discarded.

Note: It is normal that some of the electrolyte will overflow from the replacement cartridge and into the plastic

container.

English

19

25. Rinse the sensor under a tap for about 5 seconds to remove any excess electrolyte, then gently

wipe with a soft tissue to ensure all parts are completely dry. Drain the overflow electrolyte from

the container into a sink and flush away. Discard the used container.

26. If not using a protection cap with grille proceed to step 27. Otherwise, take a new Dacron

®

mesh

patch from the box of O-rings in the recharge kit. Place the mesh in the center of the protection

cap. It is very important that the mesh is in the center of the protection cap and covering the

entire grille. Lower the sensor onto the protection cap making sure not to disturb the mesh.

27. Push the protection cap firmly into place, making sure one of the four slots in the protection cap

fits over the small locking pin (highlighted right). If it is necessary to turn the protection cap to fit

over the locking pin, ensure you only turn it clockwise to avoid unscrewing the cartridge.

28. Finally, screw the protection cap locking washer back into place in a clockwise motion, and

tighten finger tight.

Section 7 Troubleshooting

7.1 Oxygen sensor

Problem Probable cause Possible solution

Sensor won't calibrate, even after

cleaning and/or membrane

change.

Instrument internal

barometric pressure

sensor needs calibration.

Calibrate using a certified barometer. Do not

correct for sea level !

Wet membrane

interface.

Wipe dry with a tissue and re-calibrate.

"H

2

S insensitivity" option

enabled.

Disable from the menu on the measuring

instrument.

"0000" O

2

levels displayed. Wrong reading scale

"XXXX" selected for

display unit.

Change reading scale by selecting "X.XXX, XX.XX

or XXX.X" on the instrument.

Shorter than expected sensor

operation in relatively high

dissolved O

2

concentration.

High O

2

concentrations

generate deposits more

quickly.

Install a less permeable membrane.

Turn off the analyzer when sensor is not in a low

O

2

concentration.

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