Mettler Toledo EasyClean400 cleaning and calibration system Operating instructions

Type
Operating instructions
Latest Product Information: www.mt.com/pro
EasyClean 400(X)
Probe Controller
Installation Instructions
Electro-Pneumatic Controller
for Retractable Housings
for Fully Automated pH Measurement,
Cleaning and Calibration
English
Trademarks
The following trademarks are used in this manual without further marking:
InTrac®
is a registered trademark of Mettler-Toledo AG
NOTICE
These installation instructions do NOT describe
how to operate the retractable housing
how to control the programs via the M 700(X) process analysis system.
The user manuals for retractable housings and the M700(X) modular process analysis system
are available for free download at www.mt.com/pro.
1 Basics
© 2020 Subject to change
Return of Products Under Warranty
Please contact our Service Team before returning a defective device. Ship the cleaned device to the address
you have been given. If the device has been in contact with process fluids, it must be decontaminated/dis-
infected before shipment. In that case, please attach a corresponding certificate, for the health and safety
of our service personnel.
Environmental protection
Waste electrical products should not be disposed of with household waste. Please recycle
where facilities exist. Check with your Local Authority or retailer for recycling advice.
3
Table of Contents
1 Basics ........................................................................................................ 2
Return of Products Under Warranty .......................................................................... 2
Environmental protection ............................................................................................. 2
Trademarks ......................................................................................................................... 2
2 Short Description .................................................................................... 5
3 Intended Use ............................................................................................ 8
4 Safety Information ................................................................................ 10
5 Package Contents .................................................................................. 12
6 Order Information ................................................................................. 12
Configurator .....................................................................................................................13
Accessories, Spare Parts ...............................................................................................14
7 Checklist for Installation ....................................................................... 15
8 Assembly ................................................................................................ 16
Wall Mounting .................................................................................................................17
Pipe Mounting .................................................................................................................18
Media Adapter with Metering Pumps ....................................................................20
Attaching the Media Connection to the Media Adapter ...............................21
8.1 Media Adapter and Metering Pumps................................................... 22
Connections .....................................................................................................................22
Function Description of Metering Pump ...............................................................24
Bills of Materials ..............................................................................................................25
8.2 Media Connection ................................................................................. 26
Assembly, Connections ................................................................................................ 26
Bill of Material ..................................................................................................................27
8.3 Media Supply: EasyClean 400(X) .......................................................... 28
Compressed Air, Water, Purge Air, Auxiliary Media ............................................ 28
Arrangement of Functional Elements ....................................................................29
Pilot Valves, Control Valves .........................................................................................30
Pressure Gauges and Valve Block .............................................................................31
Connecting the Media Tubes (Media Connection) ............................................ 32
Connecting the Tubes ..................................................................................................33
4
Table of Contents
8.4 Connecting the Retractable Housing .................................................. 36
9 Electrical Installation............................................................................. 42
Connecting the Cables to the EasyClean 400(X) ................................................42
Terminal Assignments EasyClean 400(X) ............................................................... 45
10 Process Control System ......................................................................... 48
11 Control Programs and Measurement Procedures .............................. 51
12 Service and Maintenance ...................................................................... 52
SERVICE Position .............................................................................................................52
Manual Control via M 700(X) .....................................................................................53
13 Commissioning ...................................................................................... 55
Start-Up on the M 700: Automatic Hardware Recognition ............................56
EasyClean 400(X) Parameter Setting on the M 700(X) .....................................57
Start-Up Program ...........................................................................................................58
14 Specifications ......................................................................................... 59
15 Appendix ................................................................................................ 65
Pneumatic Diagram of EasyClean 400 ....................................................................66
Pneumatic Diagram of Media Connection ...........................................................67
Selected Cleaning Agents for EC 400 and their Applications ........................ 68
16 Index ....................................................................................................... 70
5
2 Short Description
The EasyClean 400(X) is an electro-pneumatic controller for fully automated
pHmeasurement, cleaning, and calibration.
The device is modular and functionally structured. The enclosure contains the
electronic controller, filters, and valves. An external media adapter is provided
for calibration buffers and cleaning solution.
The manufacturer offers the following components which form an optimally
matched, fully automated process analysis system:
M 700(X) Modular process analysis system
EasyClean 400(X) Controller for retractable housings ("probes")
Retractable housings, cable, and pH sensor
Max. 10 m
To retractable housing
(pH/temp) max. 20 m
Compressed air
EasyClean 400(X)
controller for retractable housings
M 700(X)
process analysis system
InTrac housing
Media adapter
with metering
pumps
(calibration buffers,
cleaner)
Media connection
Max. 10 m
(EasyClean - InTrac)
pH sensor
Max. 10 m
Power supply
Rinse water
6
2 Short Description
Metering Pump with Container for Buffer or Cleaning Solution
The maintenance-free pumps are located in the “head” of a 3.5 liter bottle.
The integrated funnel allows easy refilling of buffer or cleaning solution,
without removing the pump.
Media adapter
Container with integrated
metering pump
Media Adapter
The media adapter allows connecting up to 3 metering pumps for calibration
buffers and cleaning agent. The pumps are automatically recognized by the
system.
A cleaner pump can be connected to port III of the media adapter
(eg, for dilute acids, dilute alkalis, or solvents, see table on page 68).
Media Connection
The media connection (corrugated hose) connects probe controller, media
adapter and retractable housing (probe). Each fluid is fed to the retractable
housing through a separate tube of the media connection. A multiplug pro-
vided with check valves is connected at the retractable housing to prevent
contamination or mixing of the different fluids.
7
2 Short Description
Monitoring Functions
Leak detection (alerts you to a water leak in the EasyClean)
Compressed-air monitoring (with pressure switch)
Media monitoring
allows monitoring the process value or temperature of each medium in the
calibration chamber of the retractable housing.
False media or a faulty pumping function are recognized.
A level monitoring system
generates the NAMUR* messages “maintenance request” and “failure”.
A “wear counter” monitors the number of probe movements and generates
a message when a critical value is reached.
Measurement Procedures
Continuous measurement
With continuous measurement the pH sensor is located in the process
medium and is retracted for calibration or cleaning.
Short-time measurement
(interval measurement, sampling, sample mode ...)
The pH sensor is only momentarily moved into the process medium.
This method is applied when measuring aggressive or thermally demand-
ing process media which require short measurement times with long rest
periods.
Connection to Process Control / Process Evaluation
The EasyClean 400(X) probe controller can be connected to a superordinated
control system, such as a PLC or DCS (Digital Control System).
NOTICE
Be sure to take account of the chemical resistance of the process-wetted
materials of the media adapter, media connection and pump.
* international user association of automation technology in process industries
8
3 Intended Use
The EasyClean 400(X) probe controller allows fully automated pH measurement
including rinsing, calibration, and cleaning.
The EasyClean 900X is approved for operation in hazardous locations.
The sturdy enclosure (IP 65) can be wall or pipe mounted.
The version with hygienic, polished stainless steel enclosure allows applica-
tion in the field of biotechnology, food processing, and in the pharmaceutical
industry.
The version with coated steel enclosure – extremely corrosion resistant – has
been developed for application in the chemical industry, environmental engi-
neering, water and wastewater treatment, and for application in power plants.
The EasyClean 400(X) evaluates pneumatic and electric check-back signals
from retractable housings. Inductive limit position switches are not supported.
Separate wear-resistant and maintenance-free metering pumps with a very
long service life are used for calibration buffers and cleaner. Each fluid is fed to
the retractable housing through a separate tube. A multiplug provided with
check valves is connected at the retractable housing to prevent contamination
or mixing of the different fluids.
Buffer consumption is extremely low.
The manufacturer recommends to use the EasyClean400(X) in combina-
tion with the M 700(X) process analysis system and an InTrac77x/InTrac79x
retractable housing. This combination ensures optimal media monitoring (pH
value and temperature) as well as traceability according to FDA 21 CFR Part11
(AuditTrail). The M 700(X) process analysis system allows easy adaptation of the
calibration and cleaning programs to the process.
NOTICE
Frost-Free Operation
EasyClean 400(X) is designed for operation in frost-free environments.
If required, protective cabinets and heatable media connections are available
as accessory.
9
3 Intended Use
NOTICE
Drinking Water Pipes
Observe the general requirements of protection devices to prevent pollution
of potable water (EN 1717) when drawing water from drinking water pipes.
We recommend installing a suitable check valve on the water supply to the
EasyClean to protect the drinking water from pollution.
10
4 Safety Information
Application in Hazardous Locations
The EasyClean 400X probe controller is intended for operation in ambient
conditions and applications as specified in this manual (see Intended Use,
page 8 and “Specifications“, page 59).
The EasyClean 400X may be opened during operation.
NOTICE
These installation instructions do NOT describe
how to operate the retractable housing
how to control the programs via the M 700(X) process analysis system.
The user manuals for retractable housings and the M700(X) modular process
analysis system are available for free download at www.mt.com/pro.
!
CAUTION
Power Supply
The EasyClean 400(X) should preferably be supplied through the M700(X).
Be sure to observe the safety information in the user manual for the M700(X)
basic unit.
11
4 Safety Information
!
WARNING
Application in Hazardous Locations
Observe all applicable local codes and standards for the installation of
electrical equipment in hazardous locations. For orientation, please refer to
IEC 60079-14, EU directives 2014/34/EU and 1999/92/EC (ATEX), NFPA 70
(NEC), ANSI/ISA-RP12.06.01.
Take account of the influences of humidity, ambient temperature, chemi-
cals and corrosion. If the specifications in the manual are not sufficient for
assessing the safety of operation, e.g., because your specific applications
are not described, please contact the manufacturer to make sure that the
application is possible and safe. You must observe the specified ambient
conditions and the ranges for temperature and pressure to ensure safe
operation of the device.
In a dust explosion hazardous area you must install the bottles for buf-
fer solutions and cleaning liquids in a way that there is no explosion risk
due to electrostatic discharge. For example, the bottles must be mounted
within a grounded, electrostatically conductive container / cabinet or be
sheathed with grounded, electrostatically conductive material.
You must install the media connection in an electrostatically protected area
or sheath it with grounded, electrostatically conductive material.
Clean the surfaces of media connection and media adapter including the
bottles for buffer solutions and cleaning liquids only with a damp cloth to
prevent electrostatic charging.
For further information, refer to the CENELEC PD CLC/TR 60079-32-1 guidance
for avoiding ignition hazards due to electrostatic charges and EN60079-14,
Explosive Atmospheres - Part 14: “Electrical installations design, selection and
erection“.
12
EasyClean 400(X) Basic unit incl. wall mounting brackets (mounted)
Media connection (corrugated hose)
incl. slotted securing nut and suitable hook wrench
Media adapter (for metering pumps)
3 metering pumps
1 Standard Media Interface
Cable set, consisting of:
1 connecting cable for basic unit – M 700(X)
1 connecting cable for basic unit – media adapter
(with plug)
1 EasyClean 400(X) installation manual
5 Package Contents
Checking the Package Contents
Use the following table to check the package contents:
(Listed here: maximum configuration)
6 Order Information
EasyClean 400 standard devices Description Order no.
EasyClean 400, coated EC 400 C 52 403 596
EasyClean 400, coated, Ex EC 400 XC 52 403 597
EasyClean 400, stainless steel EC 400 S 52 403 598
EasyClean 400, stainless steel, Ex EC 400 XS 52 403 599
Transmitter M 700 modules Description Order no.
pH and EC 400 module EC700 52 121 259
pH and EC 400 module, Ex EC 700 X 52 121 260
13
EasyClean 400 Configurator
In addition to the standard devices, you can also configure a device with the options listed below.
Basic unit*
Explosion protection
N Without
X With
Housing
C Steel, coated
S Stainless steel, polished
Media connection
3 5 m hose (gasket material: FKM)
4 10 m hose (gasket material: FKM)
6 17 m hose (gasket material: FKM)
C 5 m hose (gasket material: EPDM)
D 10 m hose (gasket material: EPDM)
F 17 m hose (gasket material: EPDM)
Media adapter with port I - III
1 With gasket material: FKM
A With gasket material: EPDM
Equipment for port 3
2 Pump with empty 3.5 L bottle (EPDM)
B Pump with empty 3.5 L bottle (FKM)
0 Without pump
Ext. valve actuation (Aux 2)
E With
N Without
E C 4 0 0 -
1 2 3 4 5 6 7 8 9 10 11 12
Basic unit* consisting of:
Equipment for port 1: Pump and empty 3.5 L bottle
Equipment for port 2: Pump and empty 3.5 L bottle
6 Order Information
Configurator
14
6 Order Information
Accessories, Spare Parts
Accessories for EasyClean 400(X)
Order No.
Additional external valve, Aux 2 52 403 751
Pipe-mount kit EasyClean 400 52 403 747
Pipe mount kit for media adapter EasyClean 400 52 403 750
Spare Parts and Retrot Parts for EasyClean 400(X)
Order No.
Media connection 5 m 52 403 724
Media connection 10 m 52 403 726
Media connection 10 m, Ex 52 403 727
Interface for InTrac 52 403 728
Interface for InTrac, Ex 52 403 729
Pump 52 403 730
Pump, Ex 52 403 731
Media adapter 52 403 732
Media adapter, Ex 52 403 733
15
Spare Parts and Retrot Parts for EasyClean 400(X)
Order No.
Media connection 5 m 52 403 724
Media connection 10 m 52 403 726
Media connection 10 m, Ex 52 403 727
Interface for InTrac 52 403 728
Interface for InTrac, Ex 52 403 729
Pump 52 403 730
Pump, Ex 52 403 731
Media adapter 52 403 732
Media adapter, Ex 52 403 733
7 Checklist for Installation
M 700(X) • EasyClean 400(X) • Retractable Housing
M 700(X)
Correct power supply?
M 700(X) - EasyClean 400(X)
Mounting surface / pipe (incl. drilling plan) for M700(X)
(see M700(X) manual)
Mounting surface (incl. drilling plan) for EasyClean 400(X)
(see page 17 and following)
Mounting surface (incl. drilling plan) for media adapter (see page 20)
Permissible mounting clearances corresponding to specifications
(see page16)
EasyClean 400(X)
Flexible pressure connection, G 1/4” internal
Compressed air 0.4 ... 1.0 MPa, oil- and condensate-free
Flexible rinse water connection G 1/4” internal or 3/4” coupling
Rinse water 0.2 … 0.6 MPa, 5 … 65°C, 100 µm filtered
Retractable Housings
InTrac 7xx
Check if the process adaptation corresponds to your order acknowledge-
ment (compare product coding)
Installation position and clearance above connecting flange
according to documentation for retractable housing
!
CAUTION
Only operate the retractable housing when a sensor is installed!
When the sensor has been removed, it must always be replaced by a dummy!
16
8 Assembly
Arrangement of Components:
Permissible Distances and Lifting Heights
295
200
800700
± 250
± 250
90
Max. 300
(left or right)
EasyClean 400(X)
Media adapter
4x Ø 6.4
2x Ø 8.5
Cable lengths:
EasyClean - M 700(X): 10 m
EasyClean - Retractable housing: 5 m, 10 m
Lifting height of pumps: max. 10 m
!
CAUTION
Mounting Site
The mounting site must have sufficient mechanical strength and be free of vibrations.
Ambient Temperature
Be sure to observe the permissible ambient temperature (see Specifications in the
respective user manual). It should never sink below +5 °C.
Direct Sunlight
Special measures must be taken for outdoor installation:
Direct sunlight can cause an impermissible temperature increase.
Mounting Distances
The cables are pre-assembled and cut to length.
Be sure to observe the appropriate mounting distances.
You can use the media adapter (corrugated hose) to check the mounting distances.
Dimensions in mm
17
8 Assembly
Wall Mounting
Media connection
Connection to retractable housing (e.g. InTrac 7xx)
and to media adapter
295
106
26
6.4
200
Ø 6.5
200
310
310
Cable glands
M20 x 1.5
Equipotential bonding
terminal ("PA")
Media
connection
Air connec
-
tion G 1/4"
Air lter
Water
connection
G 1/4" or
G 3/4"
Water
connection
Air lter
Dimensions in mm
18
8 Assembly
Pipe Mounting
Media connection
Connection to retractable housing (e.g. InTrac 7xx) and to media adapter
200
200
310
310
Cable glands
M20 x 1.5
Equipotential bonding
terminal ("PA")
Media
connection
Air connection
G 1/4"
Air lter
Water
connection
G 1/4" or
G 3/4"
Water
connection
Air lter
200
23
72
92
Ø 30 … 65 mm
transverse or longitudinal pipe
Hex bolts
M6 x 10 (4 x)
Washers M6 (4 x)
Cap nuts M6 (4 x)
Threaded rods
M6 x 110 (4 x)
Washers M6 (4 x)
Hex nuts
M6 x 10 (4 x)
Dimensions in mm
19
8 Assembly
Pipe Mounting
Pipe diameter: 30 … 65 mm
20
8 Assembly
Media Adapter with Metering Pumps
8.5
350
90
15
300
200
400
Ø 16 (screw head)
Dimensions in mm
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Mettler Toledo EasyClean400 cleaning and calibration system Operating instructions

Type
Operating instructions

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