Hamilton Retractex BC Steel Operating Instructions Manual

Brand: Hamilton

Model: Retractex BC Steel

Type: Operating Instructions Manual

This manual is also suitable for

Retractex

3Retractex Manual

WARRANTY / COPYRIGHT

Hamilton Warranty

Please refer to the General Terms of Sales (GTS).

Important note

The reproduction of any part of this document in any form is forbidden without the

express written agreement of Hamilton Bonaduz AG.

Contents of this manual can be modified without previous announcement. Technical

modifications reserved. Greatest possible care was used on the correctness of the

information in this manual. If errors should be discovered nevertheless, Hamilton

Bonaduz AG is pleased to be informed about it. Regardless of this, Hamilton Bonaduz

AG cannot assume liability for any errors in this manual or for their consequences.

5Retractex Manual

1 Safety and protection measures ........................................ 6

1.1 Introduction ...................................................................................................... 6

1.2 Safety ............................................................................................................... 6

1.3 Proper use ........................................................................................................ 6

1.4 Hazard areas and residual hazards .................................................................. 7

1.5 Equipment ........................................................................................................ 7

1.6 Safety equipment ............................................................................................. 8

1.7 Staff .................................................................................................................. 8

1.8 Disposal ........................................................................................................... 8

1.9 Symbols and pictograms ................................................................................. 8

1.10 Use in potentially explosive atmospheres ......................................................... 9

1.10.1 Coupling situation ................................................................................10

1.10.2 Maximum process temperature permitted ..........................................10

2 Product description ............................................................11

2.1 Retractex automatic retractable housing .........................................................11

2.2 Process integration .........................................................................................13

3 Delivery ...............................................................................15

3.1 Package contents ...........................................................................................15

3.2 Checking the delivery ......................................................................................15

4 Installation ..........................................................................16

4.1 Preparing the system ......................................................................................16

4.2 Prepare the housing ........................................................................................16

4.3 Install the holder ..............................................................................................16

4.4 Adjust the protection cage ..............................................................................17

4.5 Installing the cleaning pipes ............................................................................18

4.6 Installing the pneumatic tubes ......................................................................... 19

4.7 Installing the sensor ........................................................................................ 20

5 Operation ............................................................................22

5.1 Commissioning the housing ........................................................................... 22

5.2 Automatic operation of the housing ............................................................... 22

6 Servicing .............................................................................23

6.1 Servicing instructions ..................................................................................... 23

6.2 Checking wetted seals ................................................................................... 23

6.3 Removing the sensor ......................................................................................24

6.4 Removing the pneumatic tubes ......................................................................24

6.5 Removing the cleaning chamber with process connection ............................25

6.6 Replacing the wetted sealing ......................................................................... 26

6.6.1 Replace O-rings on cleaning cartridge ................................................27

6.6.2 O-ring replacement on Long insertion tube (LT) on

RETRACTEX C Steel LT / C Plastic LT ................................................28

6.6.3 Replacement seals on Retractex BC Steel / Retractex BC Plastic ..... 29

6.6.4 O-ring replacement on Retractex B M ................................................ 29

6.6.5 O-ring replacement on Retractex C M with flange connection ........... 30

6.7 Removing the insertion rod ............................................................................ 30

6.8 Installing the insertion rod ............................................................................... 32

6.9 Assembling the drive unit and cleaning chamber ........................................... 33

6.10 Function and leak tests .................................................................................. 33

6.11 Replacing the drive unit .................................................................................. 34

6.12 Servicing plan ................................................................................................. 35

6.13 Disposal ......................................................................................................... 35

7 Troubleshooting ................................................................. 36

7.1 Housing does not move from «service» position to «measuring» position...... 36

7.2 Housing does not move from «measuring» position to «service» position...... 36

7.3 Incorrect position reply ....................................................................................37

7.4 No position reply .............................................................................................37

7.5 Frequent contamination of sensor ...................................................................37

7.6 Sensor breaks frequently ............................................................................... 38

7.7 Leakage of process liquid at inspection window ............................................ 38

7.8 Compressed air emitted at inspection window .............................................. 38

8 Technical Specifications ................................................... 39

8.1 Standards ....................................................................................................... 39

8.2 Material properties ......................................................................................... 39

8.3 Cleaning ports ................................................................................................ 40

8.4 Sensors .......................................................................................................... 40

8.5 Pneumatic equipment .................................................................................... 40

8.6 Dimensions .....................................................................................................41

8.7 Ambient conditions .........................................................................................47

8.8 Process conditions Retractex C Steel / C Steel LT / B / BC ............................47

8.9 Process conditions Retractex C Plastic/C Plastic LT ...................................... 48

8.10 Ordering structure Retractex C Steel ............................................................. 49

8.11 Ordering structure Retractex C Steel LT ......................................................... 50

8.12 Ordering structure Retractex C Plastic ............................................................51

8.13 Ordering structure Retractex C Plastic LT .......................................................52

8.14 Ordering structure Retractex B Plastic ........................................................... 53

8.15 Ordering structure Retractex BC Steel ........................................................... 54

8.16 Ordering structure Retractex B ...................................................................... 55

9 Parts and accessories ...................................................... 56

TABLE OF CONTENTSTABLE OF CONTENTS

7Retractex Manual

SAFETY AND PROTECTION MEASURES SAFETY AND PROTECTION MEASURES

1 Safety and protection measures

1.1 Introduction

These operating instructions are intended for the Retractex retractable housing for application in

biotechnology and chemical industries.

Hamilton housings are quality products produced in accordance with the latest scientific and

technical knowledge. Follow the instructions given here to ensure maximum safety and durability.

These instructions should be read, understood, and followed by all staff using the device.

Hamilton can assume no responsibility for damage and operational disruptions arising from

failure to observe these instructions.

1.2 Safety

This housing and its parts are built to the current state of technology and are safe to operate.

However, there can be risk to life and limb if they are not operated correctly and appropriately.

The housing is only to be used:

• For the intended purpose

• In optimum safety and running conditions!

Everyone involved in the operation and maintenance of this housing should carefully read and

follow these operating instructions. Your personal safety may be at stake. Special attention is

needed for the O-rings as their lifetime depends on the application conditions.

The O-rings used are wearing parts. They must be replaced according to the service plan. If the

service plan is not followed leakage might occur.

1.3 Proper use

The Retractex retractable housing is intended to be attached to tanks or tubing. A sensor is in-

serted into the process liquid by the drive unit in order to measure chemical or physical charac-

teristics. The insertion procedure is automatically controlled and cannot be operated manually.

The material of housings and equipment should be chosen based on the process. The

retractable housing should be serviced on a regular basis. Establish a service plan adapted to

your process. Only perform the services described in the operation manual. Modifications to

the housing must be agreed with the manufacturer.

ATTENTION! The manufacturer is not liable for any damages resulting from

improper or inappropriate use.

1.4 Hazard areas and residual hazards

Retractable housings are connected to tanks and tubing that may be under pressure. Leaking of

process liquid only occurs in cases of negligence and improper operation. Prior to commission-

ing and after every servicing, ensure that all seals and connections are complete and in working

order. Never remove the lower and top housing cramp screws during operation of the housing.

Take appropriate protective measures before touching the housing as parts of the retractable

housing may take on the process temperature.

1.5 Equipment

Only use certified and approved accessories and equipment.

Seals

Choose materials for seals and O-rings according to process medium and cleaning liquid.

Observe swelling ability and acid and alkaline resistance of seal material.

Sensor

Choose a suitable sensor and review information in chapter 8 «Technical Specifications».

Pressure air

Filter (40 mm), clean and deoil compressed air. Ensure that the pressure is between 4 and 6 bar.

Cleaning liquid/detergent

Choose cleaning liquid and detergent according to process, housing, and seal material and

dispose in an appropriate way.

9Retractex Manual

SAFETY AND PROTECTION MEASURES SAFETY AND PROTECTION MEASURES

1.6 Safety equipment

Position «service»

The retract protection prevents the insertion rod from insertion without sensor into the process

as this would cause a leakage of process liquid. The sensor can only be installed/removed when

the housing is in the «service» position. Driving the housing into measuring position withouth

having a sensor installed is considered as negligence.

Position «measuring»

In the «measuring» position the sensor is immersed in the drive unit. You cannot remove the

sensor. Trying to remove the sensor in the «measuring» position is considered as negligence.

Protection cage

You may adjust the protection cage at the end of the insertion rod in order to protect the sensor

from mechanical impacts.

1.7 Staff

Qualifications

Leave installation and servicing of retractable housing to trained staff.

Protective clothing

The operation staff must wear goggles and suitable protective clothing during commissioning

and servicing works.

Accident prevention regulations

Observe work safety laws and regulations applicable in the operator’s country and at the site of use.

1.8 Disposal

Observe regulations and rules for waste disposal applicable in the operator’s country

and at the site of use.

1.9 Symbols and pictograms

Pictograms and symbols are used in the operation manual to provide better orientation.

ATTENTION! The safety note with the ATTENTION! signal indicates the risk of

personal danger and high material damage in case of failure to observe the

instructions.

NOTE: The safety note with the NOTE signal indicates the risk of material damage in

case of failure to observe the instructions.

1.10 Use in potentially explosive atmospheres

The Retractex housing is approved for use in potentially explosive atmospheres of category

1 to 3 (Zone 0 to 2) under the terms of the ATEX directive 2014/34/EU and IECEx scheme.

ATEX approval is attested by the EU type examination certificate TÜV 03 ATEX 7005 X. IECEx

approval is documented in IECEx Certificate of Coformity IECEx TUR 14.0001 X. The conditions

specified in the certificate must be respected (download www.hamiltoncompany.com).

ATEX / IECEx marking

Gas: CE 0035

ll 1/2 G Ex ia llC T4/T5/T6 Ga/Gb

Dust:

ll 1/2 D Ex ia lllC T x °C Da/Db

Manufacturer: Hamilton Bonaduz AG, CH-7402 Bonaduz

EC type examination report: TÜV 03 ATEX 7005 X

IECEx certificate of conformity: IECEx TUR 14.0001 X

Other relevant regulations are to be complied with. These include particularly:

• Machine directive 2006/42/EC

• Other national regulations

In issue 10 of TÜV 03 ATEX 7005 X and in Issue 2 of IECEx TUR 14.0001 X repectively, restrictions

for the use of different versions of RETRACTEX are stated. The materials used for the wetted

part of RETRACTEX, and the geometry of the process connections do limit the use in explosive

atmospheres. These restrictions need to be observed. In case of doubt, contact Hamilton.

The operator of equipment in potentially explosive atmospheres is responsible for ensuring

that all components of the system are certified for that area classification and are compatible

with each other. Thus the sensor which is fitted to the housing must also be approved for the

area in questions.

11Retractex Manual

SAFETY AND PROTECTION MEASURES PRODUCT DESCRIPTION

The Retractex housing may be used with sensors of different types which have a-length of

225 mm and 325 mm and whose ATEX / IECEx approval are certified. Please consider the table

of assignment in the EU type examination certificate resp. IECEx Certificate of Conformity.

ATTENTION! When using sensors from third party manufacturers, the Ex

protection level must be individually determined in each case. Improper use of

sensors or dismantling of the armature or of the sensors may lead to unintended

release of a potentially explosive atmosphere.

1.10.1 Coupling situation

The housing forms an interface between Ex Zone 0 and 1. It is important to realize that only

the immersed part of the housing is certified for Ex Zone 0. The entire remainder of the housing

is in Zone 1.

1.10.2 Maximum process temperature permitted

The maximum process temperature permitted is not limited by the housing itself, but by the sen-

sor that is fitted into the housing. Therefore, referring to the EC type examination certificate of

the sensor, you should check how the maximum allowable process temperature of the relevant

Ex Zone is defined.

ATTENTION! Avoid electrostatic charge. Therefore wipe only with a damp

cloth, especially the drive unit.

ATTENTION! During the movement of the drive unit from the measurement

position to the cleaning position, the cleaning chamber is briefly connected to

the process. Therefore, the cleaning ports must be closed to prevent an explo-

sive mixture emerging from the process.

ATTENTION! An explosive mixture may leak from the inspection window if the

O-rings are not tight. Explanation see chapter 6.2.

2 Product description

2.1 Retractex automatic retractable housing

Components

PNEUMATIC CONNECTIONS 1-4

DRIVE UNIT

LOWER HOUSING CRAMP

PROCESS CONNECTION

SENSOR

INSERTION ROD WITH

PROTECTION CAGE

SENSOR

CLEANING PORT «IN»

CLEANING PORT «OUT»

CLEANING CHAMBER

TOP HOUSING CRAMP

SPARE SCREWS

Fig. 1: Retractable housing

13Retractex Manual

PRODUCT DESCRIPTION PRODUCT DESCRIPTION

Variations

Retractable housings are attached to tanks or tubing by process connection. For compat-

ibility with various processes, the Retractex housing can be fabricated from stainless steel

or plastic. You can further choose between different process and cleaning ports and sealing

materials.

Retractex C Steel /C Plastic

Retractex C Steel / C Plastic is a retractable housing made of stainless steel (C Steel) or plastic

(C Plastic) for installation of Ø 12 mm sensors on tanks or pipelines.

• For all kinds of Ø 12/225 mm sensors with thread PG13,5 (glass pH, conductivity,

temperature, and other optical sensors)

• Chemicals

• Water treatment

• Rough processes

• Requirement of automated sensor cleaning

Retractex C Steel LT /C Plastic LT

Retractex C Steel LT / C Plastic LT is a retractable housing made of stainless steel (C Steel LT)

or plastic (C Plastic LT) for installation of Ø 12/325 mm sensors on tanks or pipelines, with an

extended immersion length up to 207 mm.

Retractex BC Steel / BC Plastic

Retractex BC Steel / BC Plastic is a retractable housing made of stainless steel (BC Steel) or

plastic (BC Plastic) for installation of Ø 12 mm sensors on tanks or pipelines with a G 1¼"

connection.

• For all kinds of Ø 12/225 mm sensors with thread PG13,5 (glass pH, conductivity,

temperature, and other optical sensors)

• Chemicals

• Water treatment

• Rough processes

Retractex B

Retractex B is a retractable housing made of stainless steel for hygienic installation of Ø 12 mm

sensors on tanks or with a G 1¼" connection.

• For all kind of Ø 12/225 mm sensors with thread PG13,5 (glass pH, conductivity,

temperature, and other optical sensors)

• Food

• Pharmaceuticals

• Requirement of automated sensor cleaning

Drive

Compressed air is supplied via the pneumatic connections onto the drive unit. The drive unit

inserts the insertion rod into the process medium up to the maximal insertion depth. For safety

reasons this is only possible with a sensor installed.

Measuring

When completely in the final position of the «measuring» position, the control receives a pneu-

matic position signal. In this position the sensor head is immersed in the drive unit and cannot

be removed. The sensor measures the chemical or physical properties of the process liquid.

Service

Cleaning, rinsing and calibration of the sensor is possible while the process is running.

For this purpose the housing must be moved to the «service» position. Another pneumatic

position signal is caused when the final position is reached. In the «service» position the

insertion rod seals the cleaning chamber against the process to prevent leakage of process

liquid. The cleaning liquid is introduced into the cleaning chamber via the cleaning port «IN»

and subsequently drained via the cleaning port «OUT».

2.2 Process integration

Control

The Retractex retractable housing can be operated by the automatic control RetractoControl

Plus. It optimally matches the functions of the holder.

Transmitter

The sensor can be connected to the transmitter while in the retractable housing.

Process control

The external control and the transmitter can be connected to a process control system. The

measuring and cleaning intervals are then controlled automatically according to the measuring

results.

15Retractex Manual

PRODUCT DESCRIPTION DELIVERY

TRANSMITTER

PROCESS CONTROL

SYSTEM

CONTROL

DRAIN

FEED

Fig. 2: Process flow

Pressure / Temperature

The choice of the applicable housing is subject to the pressure and temperature conditions of

the process. The retractable housing of stainless steel can be used for a pressure of up to 16

bar and the plastic model up to 10 bar according to the temperature. The process temperature

should be between -10° and 140°C.

ATTENTION! Observe pressure and temperature charts in chapter 8!

Installation position

The operation of the housing is generally possible in any position. The reliability of the measuring

results depends on the properties of the selected sensor.

NOTE: Note, that the passive emptying of the cleaning chamber is not guaranteed in

every installation position.

3 Delivery

3.1 Package contents

The retractable housing is inspected at the factory and delivered ready for installation in a pack-

aging providing optimal protection for the housing.

Package contents:

• Retractex housing

• Hexagon key (2.5 mm)

• 4 spare screws M 4 x 8 (DIN 912)

• 2 spacers for sensors

• Operation manual

ATTENTION! Store the housing in the packaging. This ensures optimal

protection until the installation.

3.2 Checking the delivery

Before approving the retractable housing for installation the following should be ensured:

• Packaging and device are in apparent good order

• The data plate of the retractable housing corresponds to the specifications on the order

NOTE: In case of further inquiries please contact your partner directly.

17Retractex Manual

INSTALLATION INSTALLATION

4 Installation

4.1 Preparing the system

Ensure that:

• Sufficient working space for operation of the retractable housing is available

• The process is shut off

• Tank and tubing are pressure-free, empty and clean

• Connection flange and process connection of the retractable housing fit together

• The process seal is positioned on the connection flange

• There is no potentially explosive atmosphere

4.2 Prepare the housing

The housing must be in the «service» position.

The insertion rod should be completely inserted in the

cleaning chamber.

4.3 Install the holder

Prior to installation, ensure the following:

Fig. 3: «Service» position

• The system is prepared (chapter 4.1)

• The housing is prepared (chapter 4.2)

How to install the housing:

• Position retractable housing on process seal

• Tighten process connection

4.4 Adjust the protection cage

A protection cage is fitted to the lower end of the insertion rod and can be adjusted with the flow

direction. The symbol on the drive unit cylinder indicates the position of the opening in the inser-

tion rod. If the symbol is parallel to the flow direction the insertion rod is fully flown through. If the

symbols are perpendicular to the flow the sensor is fully protected from direct flow. The insertion

rod can be adjusted in any intermediate position.

DIRECTION

OF FLOW

A B

Fig. 4: Protection cage, A = Sensor maximally streamed / B = Sensor minimally streamed

Ensure that:

• The process is shut off

• Tank and tubing are pressure-free, empty and clean

• There is no potentially explosive atmosphere

ATTENTION! Leakage of process liquid occurs when housing cramp is opened

during running process. Burns and cauterization may occur depending on prop-

erties of process liquid. If leakage occurs stop process! Tanks and tubing must

be pressure-free.

How to adjust the protection cage:

• Loosen screws of lower housing cramp

• Rotate drive unit and adjust symbol in flow direction

• Tighten screws of lower housing cramp

19Retractex Manual

INSTALLATION INSTALLATION

4.5 Installing the cleaning pipes

Cleaning of the sensor is possible while the process is running. This requires supply and drain-

ing of cleaning liquid to the cleaning chamber. If cleaning of the sensor is not desired the clean-

ing ports must be sealed by pegs.

CLEANING PORT «IN»

CLEANING PORT «OUT»

Fig. 5: Cleaning ports

ATTENTION! Cleaning pipes must be installed or cleaning ports «IN» and

«OUT» must be selad by pegs. If the cleaning ports are open, process liquid may

leak out. Depending on the characterization of the process liquid this may cause

burns or cauterization.

ATTENTION! If the process pressure is higher than the cleaning pressure pro-

cess liquid enters the cleaning pipes while the housing is moving to the service

position. A cleaning pipe with valve must be installed at the cleaning ports «IN»

and «OUT».

ATTENTION! If the cleaning liquid pressure exceeds 6 bar housing and sensor

may be damaged. Install a pressure reducer, if necessary.

ATTENTION! Contaminated cleaning liquid can cause damage to the housing.

Install a cleaning pipe with dirt trap at the cleaning port «IN».

How to install the cleaning pipes:

• Install valve and dirt trap in the cleaning pipe for the cleaning liquid supply

• Attach supply cleaning pipe to the cleaning port «IN»

• Install valve in cleaning pipe for drainage of the cleaning liquid

• Attach cleaning pipe to the cleaning port «OUT»

• Check all connections for tightness

NOTE: To avoid premature contamination of the sensor the pressure of the cleaning

liquid should be at least 1 bar.

4.6 Installing the pneumatic tubes

The Retractex retractable housing is operated with compressed air. The extension of the cylin-

der of the drive unit is fitted with four compressed air connections.

Fig. 6: Pneumatic connections 1 - 4

21Retractex Manual

INSTALLATION INSTALLATION

ATTENTION! Emitted compressed air can cause material or personal damage.

Ensure tightness of pneumatic tubes before supplying compressed air.

ATTENTION! Contaminated compressed air causes damages to the drive unit.

Use filtered (40 nm), water-free and deoiled compressed air.

You will need:

• 2 pneumatic tubes Ø= 4 mm

• 2 pneumatic tubes Ø= 6 mm

How to install the pneumatic tubes:

• Connection 1: Air supply «measuring» position (black, 6 mm)

• Connection 2: Air supply «measuring» position (blue, 6 mm)

• Connection 3: Reply «service» position (black, 4 mm)

• Connection 4: Reply «service» position (blue, 4 mm)

Use the external control to move the Retractex from the «service» position into the «measuring»

position and vice versa.

4.7 Installing the sensor

Sensors used with Retractex retractable housing must have a 12 mm diameter and a con-

nection thread of PG13,5.

The length of the sensor depends on the sensor type and the selected housing.

NOTE: Observe information in chapter 8.4 «Sensors».

Fig. 7: Sensor filled with gel

ATTENTION! Sensors that are too long could be damaged during installation.

Check the sensor length and use delivered spacer if necessary.

Ensure that

• The housing is in the «service» position

• All seals connected to the sensor are available

• The sensor is not longer than the specified length

How to install the sensor:

• Insert sensor and tighten

• Attach sensor cable

The retractable unit is now ready for operation.

23Retractex Manual

OPERATION SERVICING

5 Operation

5.1 Commissioning the housing

ATTENTION! Check all seals and connections of the housing before start-

ing the process. Otherwise, there is a risk of injury by leaking process liquid.

Depending on the characterization of the process liquid this may cause burns

or cauterization. Wear goggles and protective clothing.

Prior to the commissioning ensure the following:

• Seals are complete and in good working condition

• Sensor is installed and tightened

• Cleaning ports are sealed with pegs

or:

• Cleaning pipes are installed and tight

• Pneumatic tubes are installed and tight

• Protection cage is adjusted correctly

5.2 Automatic operation of the housing

An external control is required for automatic operation of the retractable housing.

Note the functions of the pneumatic connections.

• Connection 1: Air supply «measuring» position, black 6 mm

• Connection 2: Air supply «measuring» position, blue 6 mm

• Connection 3: Reply «service» position, black 4 mm

• Connection 4: Reply «service» position, blue 4 mm

Use the external control to move the retractable holder from the «service» position into the

«measuring» position and vice versa.

6 Servicing

6.1 Servicing instructions

Establish a service plan adapted to your process.

Leave servicing works to qualified staff.

Always wear applicable protective clothes when performing servicing works.

Only perform the service works described in the operation manual.

Constructional modifications must be agreed upon with the manufacturer.

Tubing and tanks must be pressure-free, empty and clean before disconnecting the housing

from the process.

Ensure that there is no potentially explosive atmosphere.

6.2 Checking wetted seals

The retractable housing is fitted with an inspection window situated between the lower hous-

ing cramps. This inpection window has the purpose to dedect leakage as early as possible.

Therefore check regulary the window for leakage. If process media is leaking out of the window,

replace the O-rings in contact with the media immediately. See instructions in chapter 6.6 how

to replace the O-rings.

Fig. 8: Inspection window on lower housing cramp

25Retractex Manual

SERVICING SERVICING

ATTENTION! Process liquid is leaking out ot the inspection window! Risk de-

pending on process liquid property! Replace wetted seals. Observe instructions

in chapter 6.6.

6.3 Removing the sensor

How to remove the sensor:

• Move holder to «service» position

• Remove sensor cable

• Remove PG connector cable gland

• Remove sensor

NOTE: If the sensor is broken the O-rings in contact with the media may be dam-

aged. In this case always replace the O-rings. See instructions in chapter 6.6 for O-ring

replacement.

6.4 Removing the pneumatic tubes

How to remove all four pneumatic tubes:

• Move the housing to «service» position

• Stop compressed air supply

• Push down plastic ring «A» on pneumatic connection

• At the same time pull pipe «B» (Fig. 9)

Fig. 9: Removing the pneumatic tubes

6.5 Removing the cleaning chamber with process connection

ATTENTION! System is under pressure. Process liquid will leak when housing

is improperly disconnected from the process. Tubing or tanks must be pressure-

free, empty, clean and without potentially explosive atmosphere.

How to remove the cleaning chamber:

• Move holder to «service» position

• Switch off compressed air supply

• Remove pneumatic tubes (chapter 6.4)

• Remove sensor (chapter 6.3)

• Loosen process connection

• Remove process seals and housing

• Remove lower housing cramps (Fig. 1)

• Disconnect cleaning chamber with process connection «A» from drive unit «D»

• Remove cleaning cartridge «B» from insertion rod «C»

27Retractex Manual

SERVICING SERVICING

B C D

Fig. 10: Removing the cleaning chamber and process connection

A = Cleaning chamber with process connection, B = Cleaning cartridge, C = Insertion rod, D = Drive unit

6.6 Replacing the wetted sealing

ATTENTION! System is under pressure. Process liquid will leak when hous-

ing is disconnected from process in an inappropriate way. Ensure that system

is pressure-free before replacing the sealing. Drain and clean tubing or tanks.

Ensure that there is no potentially explosive atmosphere.

ATTENTION! Emitted compressed air can cause material damage or personal

injury. Switch off compressed air supply before removing the pneumatic tubes.

Install the seals chosen appropriately for the housing and the process.

Only use original parts.

How to replace the seals:

• Remove cleaning chamber with process connection (chapter 6.5)

• Remove and replace outer O-ring «A», and inner O-ring «B» on insertion rod

O-rings

Ø in [mm]

A: 18.72 x 2.62

B: 10.77 x 2.62

Fig. 11: O-rings on insertion rod, B is left out

6.6.1 Replace O-rings on cleaning cartridge

(only applicable for Retractex C Steel and Retractex C Plastic)

Remove and replace O-rings «D» on cleaning cartridge.

O-ring

Ø in [mm]

D: 21.95 x 1.78

Fig. 12: O-ring on cleaning cartridge

• Remove PTFE scraper «E» on cleaning chamber

• Remove and replace O-ring «F»

29Retractex Manual

SERVICING SERVICING

• Position PTFE scraper «E» on O-ring «F»

E/F

Scraper

Ø in [mm]

E: 19 x 6 x 1

O-ring

Ø in [mm]

F: 21.89 x 2.62

Fig. 13: O-rings/scraper on cleaning chamber

Replace the PTFE scraper as follows:

6.6.2 O-ring replacement on Long insertion tube (LT) on

RETRACTEX C Steel LT / C Plastic LT

Separated cleaning chamber: Remove and replace O-ring «G».

O-ring

Ø in [mm]

G: 30 x 1.5

Fig. 14: Cleaning chamber C Steel LT / C Plastic LT

6.6.3 Replacement seals on Retractex BC Steel /

Retractex BC Plastic

Clean the chamber of the Retractex BC M, exchange O-ring «H» and «I». Then change the

scraper ring «J».

Scraper

Ø in [mm]

J: 18 x 6 x 1

O-rings

Ø in [mm]

H: 21.95 x 1.78

I: 18.77 x 1.78

Fig. 15: Cleaning chamber BC Steel / BC Plastic

6.6.4 O-ring replacement on Retractex B M

Cleaning chamber Retractex B without PTFE scraper, exchange O-ring «H» and «I».

O-rings

Ø in [mm]

H: 21.95 x 1.78

I: 18.77 x 1.78

Fig. 16: Cleaning chamber B

31Retractex Manual

SERVICING SERVICING

6.6.5 O-ring replacement on Retractex C M with flange

connection

• Loosen flange screws (a)

• Release flange from rinsing chamber and echange O-ring K

• Remount flange to rinsing chamber

O-ring

Ø in [mm]

K: 29,82 x 2,62

Fig. 17: Cleaning chamber C Steel / C Plastic

6.7 Removing the insertion rod

ATTENTION! System is under pressure. Process liquid will leak when housing is

disconnected from process. Ensure that system is pressure-free before removing

the insertion rod. Drain and clean tubing or tanks.

ATTENTION! Emitted compressed air can cause material damage or personal

injury. Switch off compressed air supply before removing the pneumatic tubes.

How to remove the insertion rod from the drive unit:

• Remove cleaning chamber and process connection (chapter 6.5)

• Remove outer O-ring on insertion rod (Fig. 12 «A»)

• Remove top housing cramps

• Completely pull off cylinder «D» from cylinder extension «A» (Fig. 18)

Fig. 18: Removing the cylinder

A = Cylinder extension, B = Piston, C = Insertion rod, D = Cylinder

Loosen screws «E» and remove pins «F» (Fig. 19).

Fig. 19: Removing the fixing elements

E = 2 x M4 x 8, F = 2 x pins

Remove insertion rod «C» from piston «B».

33Retractex Manual

SERVICING SERVICING

If the golden pins (G) fall out of the Drive Unit, insert them back into the dedicated holes. The

pins can be inserted in either direction. We recommend to put them in with the o-ring to the

outside (see picture).

Fig. 20: Drive Unit

6.8 Installing the insertion rod

The descriptions refer to Fig. 18 and Fig. 19 in chapter 6.7 «Removing the insertion rod».

How to assemble the insertion rod and the drive unit:

• Adjust grooves in insertion rod «C» to piston «B» and put together

• Insert pins «F»

• Tighten screws «E»

• Grease inside wall of cylinder «D»

• Slide cylinder «D» over insertion rod «C»

• Adjust cylinder «D’s» pin to cylinder extension «A’s» hole

• Squeeze until cylinder snaps into place, releasing the air pressure

• Bring top housing cramp in position and tighten screws

• Insert O-rings at insertion rod (Fig. 11 «A» and «B»)

6.9 Assembling the drive unit and cleaning chamber

Ensure that all seals are installed and in good working condition. Insertion rod and drive unit are

assembled (chapter 6.8).

How to install the cleaning chamber:

• Insert cleaning cartridge in cleaning chamber until it snaps into place.

• Insert drive unit with insertion rod.

• Press both components tightly together.

• Adjust drive unit until it snaps into place in the cleaning chamber.

• Adjust protection cage (chapter 4.4).

• Bring lower housing cramp in position and tighten.

The housing can now be reinstalled in the process.

Also observe the following instructions in chapter 4:

• chapter 4.3 «Installing the housing»

• chapter 4.4 «Adjusting the protection cage»

• chapter 4.5 «Cleaning pipes»

• chapter 4.6 «Installing the pneumatic tubes»

• chapter 4.7 «Installing the sensor»

6.10 Function and leak tests

A function and leak test must be carried out after each disassembly of the insertion tube and

the rinsing chamber and after changing O-rings. This is done as follows:

Function test

To do a simple function test insert the assembly tool into the sensor thread and push the inser-

tion tube into the «measuring» position and pull it back out again. Repeat this several times and

watch out for unusual resistance or sounds.

Leak Test

A simple leak test can be carried out by introducing a sensor into the housing. Close the outlet

35Retractex Manual

SERVICING SERVICING

of the rinsing chamber tightly and apply an air pressure of maximum 4 bar to the rinsing cham-

ber inlet. Insert the housing vertically to about 2 cm above the rinsing chamber in clear water

and check that there are no air bubbles released.

ATTENTION! Ingress of moisture into cylinder can cause material damage. Do

not insert the whole housing into the water as water can get into the pneumatic

connections and lead to irreparable damage.

Carry out the leak test in the rinsing position as well as in the measuring position. Make sure

that the rinsing chamber is pressure-free when manually moving between the rinsing and

measuring positions.

6.11 Replacing the drive unit

ATTENTION! System is under pressure. Process liquid will leak when the

housing is disconnected from process in an inappropriate way. Ensure that

system is pressure-free before replacing the drive unit. Drain and clean tubing

or tanks. Ensure that there is no potentially explosive atmosphere.

ATTENTION! Emitted compressed air can cause material damage or personal

injury. Switch off compressed air supply before removing the pneumatic tubes.

The new drive unit can now be installed:

• Prior to installation, remove cleaning chamber with process connection (chapter 6.5)

• Remove insertion rod (chapter 6.8)

• Clean and dispose of cylinder, cylinder extension, pivot, housing cramps, if required

How to install the new drive unit:

• Put the drive unit with insertion rod into the cleaning chamber

• Assemble the drive unit and cleaning chamber

• Bring lower housing cramp in position and tighten

6.12 Servicing plan

Carry out the servicing works in the recommended intervals.

Weekly

• Checking wetted seals (chapter 6.2)

• Checking process connection

• Checking cleaning pipes

• Checking pneumatic connections

Quarterly

• Checking and tighten screws of top and lower housing cramps

Once a year

• Replacing wetted seals (chapter 6.6)

• Removing and inspect insertion rod (chapter 6.7)

Every 3 years

• Replacing drive unit (chapter 6.11)

6.13 Disposal

Housing

Ensure that the housing is free from hazardous and toxic substances. Depending on your

material the individual components must be disposed separately. Observe regulations and rules

for waste disposal applicable in the operator’s country and at the site of use.

Packaging

The packaging is made of cardboard and can be disposed with the waste paper.

37Retractex Manual

TROUBLESHOOTING TROUBLESHOOTING

7 Troubleshooting

Refer to the instructions and warnings in the specified chapters.

7.1 Housing does not move from «service» position to

«measuring» position

Possible reason Action

No compressed air Check pneumatic tubes (chapter 6.4, chapter 4.6)

Pressure too low Pressure must be between 4 and 6bar (chapter 8.5)

No sensor Installing the sensor (chapter 4.7)

Loose sensor Tighten sensor (chapter 4.7)

7.2 Housing does not move from «measuring» position to

«service» position

Possible reason Measure

No compressed air Checking pneumatic tubes (chapter 6.4, chapter 4.6)

Pressure too low Pressure must be between 4 and 6 bar (chapter 8.5)

Insertion rod or protection cage • Preparing the system (chapter 4.1)

blocked Housing remains in «measuring» position

• Removing the cleaning chamber with

process connection (chapter 6.5)

• Removing insertion rod (chapter 6.7)

7.3 Incorrect position reply

Possible reason Action

Pneumatic tubes are connected

incorrectly Check pneumatic tubes (chapter 6.4, chapter 4.6)

7.4 No position reply

Possible reason Measure

No compressed air Checking pneumatic tubes (chapter 6.4, chapter 4.6)

Pressure too low Pressure must be between 4 and 6bar (chapter 8.5)

Drive unit defect Replacing the drive unit (chapter 6.11)

7.5 Frequent contamination of sensor

Possible reason Measure

Cleaning pipes incorrectly connected Check cleaning pipes (chapter 4.5)

Cleaning liquid pressure too low • Raise cleaning pressure.

Cleaning chamber is blocked • Pressure must be between 1 and 4bar (chapter 8.3)

Cleaning liquid not adequate Choose adequate cleaning liquid

Cleaning period too short Extend cleaning period

Cleaning interval too long Reduce cleaning interval

39Retractex Manual

TROUBLESHOOTING TECHNICAL SPECIFICATIONS

7.6 Sensor breaks frequently

Possible reason Measure

Sensor too long Choose adequate sensor (chapter 4.7)

Seals on sensor are missing Inserting seals on sensor (chapter 4.7)

Process liquid contains solids Adjusting the protection cage (chapter 4.4)

7.7 Leakage of process liquid at inspection window

Possible reason Measure

Wetted seals are defect Replacing the wetted sealing (chapter 6.6)

7.8 Compressed air emitted at inspection window

Possible reason Measure

Drive unit defect Replacing the drive unitit (chapter 6.11)

8 Technical Specifications

8.1 Standards

These housings are built in respect to pressure equipment directive.

8.2 Material properties

Wetted components

Housing

Retractex stainless steel plastic seals

C Steel 1.4404, 2.4602 EPDM / FPM / FFKM

C Steel LT 1.4404, 2.4602 EPDM / FPM / FFKM

C Plastic PVDF / PEEK / PP EPDM / FPM / FFKM

C Plastic LT PVDF / PEEK EPDM / FPM / FFKM

B 1.4404 EPDM / FDA / FPM

BC Steel 1.4404, 2.4602 EPDM / FKM / FFKM

BC Plastic PVDF / PEEK / PP EPDM / FKM / FFKM

Drive unit

Retractex cylinder cylinder extension seals

All types 1.4404 PA66 GF30 EPDM

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Hamilton Retractex BC Steel Operating Instructions Manual

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Model: Retractex BC Steel

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