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ABB TB404, Operating Instruction, Page: 1 / 40

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A B B ME A SUR EMENT & A N A LY TIC S | OPER ATING INSTRUC TION | OI/ TB 4 0 4 - EN R E V. B

TB404

Toroidal conductivity sensors

TB404 – perfect for use in standard 
to highly corrosive solutions

Measurement made easy

Introduction

TB404 toroidal conductivity sensors expand the 
advancements in process conductivity 
measurement initiated by ABB with 4-electrode 
conductivity measurement. Unlike 4-electrode 
sensors, toroidal sensors have no electrodes.

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TB404 conductivity 
sensors

Summary of Contents for TB404

Page 1: ...use in standard to highly corrosive solutions Measurement made easy Introduction TB404 toroidal conductivity sensors expand the advancements in process conductivity measurement initiated by ABB with 4 electrode conductivity measurement Unlike 4 electrode sensors toroidal sensors have no electrodes TB404 conductivity sensors ...

Page 2: ...he Data Sheet for the TB404 toroidal conductivity sensors is available for free download from www abb com analytical or by scanning this code Search for or click on Data sheet TB404 toroidal conductivity sensors DS TB404 EN ...

Page 3: ...ed in this document include Mylar Viton Tri Clamp PEEK Registered trademark of E I DuPont de Nemours Company Incorporated Registered trademark of E I DuPont de Nemours Company Incorporated Registered trademark of Alfa Laval Incorporated Trademark of Victrex plc ...

Page 4: ...on have been prepared in procedure format By treating each task as a separate entity the procedures provide an easy method for finding the information needed to perform each task The proce dures can be removed and placed in separate folders or notebooks or carried to the job site The procedures have check boxes in the margin by each step When per forming a procedure check each box as each step is ...

Page 5: ... 1 1 through 1 6 August 23 2006 2 1 through 2 3 Original 3 1 Original 4 1 August 23 2006 PR1 1 through PR1 2 August 23 2006 PR2 1 through PR2 3 August 23 2006 PR3 1 through PR3 5 August 23 2006 PR4 1 through PR4 2 August 23 2006 PR5 1 through PR5 3 August 23 2006 PR6 1 through PR6 2 August 23 2006 Index 1 Original When an update is received insert the latest changed pages and dispose of the supers...

Page 6: ...DUCTION 4 1 REPLACEMENT PARTS 4 1 PROCEDURES PR1 SUBMERSIBLE ASSEMBLY PR2 IN LINE FLOW ASSEMBLY PR3 HOT TAP ASSEMBLIES PR4 TWO INCH SANITARY TRI CLAMP ASSEMBLY PR5 REMOVING SENSOR FROM HOT TAP ASSEMBLIES PR6 SENSOR CLEANING List of Figures No Title Page 2 1 Type TB4042 Sensor 2 2 2 2 Sensor Orientation Requirements 2 3 PR1 1 Submersible Assembly PR1 2 PR2 1 In Line Assembly Exploded View PR2 2 PR2...

Page 7: ...tinued No Title Page ii PR5 2 High Pressure Hot Tap Assembly PR5 3 List of Tables No Title Page 1 1 Reference Documents 1 2 1 2 Nomenclature 1 3 1 3 Specifications 1 4 1 4 Accessories1 1 6 2 1 Installation Procedures 2 3 ...

Page 8: ...cause the insertion rod to retract from the ball valve assembly with great velocity This could injure personnel standing in the path of the retracting insertion rod Allow only properly trained personnel to handle these types of sensor assemblies p PR5 1 Open one of the flushing ports after the sensor is retracted and the ball valve is closed If a continuous stream of liquid exists damage to the ba...

Page 9: ...iv Safety Summary continued THIS PAGE INTENTIONALL LEFT BLANK ...

Page 10: ...such as tanks and open vessels or waterways The in line flow assembly provides installation capability for pipelines and tanks There are also two types of hot tap assemblies available Low pressure units with either hand or wrench tight compression fittings and high pressure units The high pressure units can be ordered with ball valves Ball valves for low pressure units must be ordered separately F...

Page 11: ...W TO USE THIS INSTRUCTION Read this entire instruction in sequence before attempting to install maintain or repair the sensor After gaining a complete understanding of this instruc tion and the sensor it can be used as a reference The installation section of this instruction has been prepared in procedure format Table 2 1 directs installation personnel to the appropriate procedure By treating each...

Page 12: ...TB4043 3 7 S 1 Submersible adapter in NPT CPVC S 2 Submersible adapter in NPT 316 stainless steel S 3 Submersible adapter in NPT Kynar F 1 In line flow 1 in NPT CPVC F 2 In line flow 1 in NPT 316 stainless steel F 3 In line flow 1 in NPT Titanium L 1 Low pressure hot top without ball valve wrench tight com pression fitting 316 stainless steel2 L 2 Low pressure hot top without ball valve hand tight...

Page 13: ...hen using the sensor with ABB instrumentation 2 If hot tap hardware and compression fittings are ordered and Kalrez O rings are desired position 8 must be a 4 3 Positions 9 and 10 require 00 when ordering replacement sensors or Type TB4043 sanitary sensors 4 An insertion length must be specified in position 11 for all sensors having L1 L2 L3 or L4 in positions 9 and 10 The type of material selecte...

Page 14: ...rials Process connection Minimum 0 to 400 μS maximum 0 to 2 000 mS 689 kPa 100 psig 150 C 302 F Teflon ferrule in compression fitting O rings per sensor nomenclature 316 stainless steel and Titanium Minimum 1 in NPT depending on type of ball valve chosen TB4042 S Range1 Minimum 0 to 400 μS maximum 0 to 2 000 mS Pressure2 689 kPa 100 psig with 316 stainless steel adapter 689 kPa 100 psig with CPVC ...

Page 15: ...are kit for high pressure hot tap assembly with 316 stainless steel hardware and EPDM hardware O rings Nos 014 and 132 4TB9515 0070 Hardware kit for high pressure hot tap assembly with 316 stainless steel hardware EPDM hardware O rings Nos 014 and 132 and ball valve 4TB9515 0071 Hardware kit for high pressure hot tap assembly with 316 stainless steel hardware and Viton hardware O rings Nos 014 and...

Page 16: ...perfor mance of the sensor Use the original packing material and container for storage The storage environment should be protected and free from extremes in temperature and humidity and fall within the environmental specifications listed in Table 1 3 LOCATION CONSIDERATIONS The Type TB404 sensor employs an encapsulated design that makes it ideal for aggressive and harsh process streams Sensor vari...

Page 17: ...lexible piping or conduit The sensor position must not allow accumulation of excess sediment or other foreign material around the sensing area The sensor position must insure that the internal temperature sensor is facing into the fluid flow path NOTE The temperature sensor is located at the sensing area on the same side as the embossed PEEK insignia Fig 2 1 Lubricate all O rings with a silicone g...

Page 18: ...sor Orientation Requirements SENSING AREA P ARALLELTO FLOW FLUID LEVEL BELOW SENSINGAREA PERPENDICULARTO FLOW FLOW FLUID LEVEL FLUIDLEVEL ABOVE FLUID LEVEL PEEK PEEK PEEK FLOW SENSING AREA Table 2 1 Installation Procedures Description Procedure Submersible assembly PR1 In line flow assembly PR2 Hot top assemblies PR3 Two inch sanitary in line flow assembly PR4 ...

Page 19: ...ture of its design complete sensor replacement is required when it has been damaged or does not properly func tion Contact ABB for replacement toroidal conductivity sensors If using a high or low pressure hot tap assembly the sensor must be removed from the hot tap hardware for replacement or service Refer to PR5 for the procedure PR6 contains the sensor cleaning procedures ...

Page 20: ...0 Fax 1 775 850 4808 www abb com instrumentation REPLACEMENT PARTS When making repairs at your facility order spare parts from a ABB sales office Provide this information 1 Spare part description part number and quantity 2 Model and serial number if applicable 3 ABB instruction manual number page number and reference figure that identifies the part Contact ABB for replacement toroidal conductivity...

Page 21: ...ds the application of pipe sealant Teflon tape or equivalent onto all pipe threads to prevent process liquids from seeping into the conduit piping R 4 Attach the in NPT pipe coupling to the submersible coupling adapter 20 min Number Qty Description 4TB4951 0092 1 Submersible coupling adapter 20 x in NPT CPVC 4TB4951 0093 Submersible coupling adapter 20 x in NPT Kynar 4TB4951 0094 Submersible coupl...

Page 22: ...around the sen sor cable and top of the conduit pipe to prevent moisture from entering the pipe R 7 Position the pipe in the desired location and retain it in a fixed position using a conduit clamp or similar device R 8 Orient the sensor in the flow according to the installation guidelines described in Section 2 Figure PR1 1 Submersible Assembly USER SUPPLIED CONDUIT PIPE USER SUPPLIED COUPLING T0...

Page 23: ...y high temperature pipe sealant onto the outer threads of the in line fitting R 5 Install the in line fitting into the pipe or tank fitting using a two inch open end wrench to tighten the fitting Fig PR2 2 NOTE The pipe or tank fitting must have a female 1 NPT thread 20 min Number Qty Description 4TB4711 0021 1 Nut retaining 4TB4906 0014 1 In line gasket Viton 4TB4951 0085 1 In line fitting 1 in 3...

Page 24: ...ection 2 R 7 While maintaining the sensor orientation with the inch open end wrench use a 1 inch open end wrench to tighten the retaining nut R 8 Slide the Viton gasket over the back of the sensor and onto the retaining nut Figure PR2 1 In Line Assembly Exploded View ASSEMBLED IN LINE SENSOR T00876A 3 4 IN ADAPTER RET AINING NUT NO 2 117 O RINGS IN LINE GASKET 1 1 2 IN IN LINE FITTING TYPETB404 SE...

Page 25: ...ng threads on the sensor R 10 Attach inch flexible conduit or a cable gland to the conduit cable gland adapter Figure PR2 2 In Line Assembly in Pipe or Tank Fitting PEEK 3 4 IN CONDUITADAPTER RET AININGNUT IN LINE FITTING 9 16 IN W RENCH FLA TS VITON GASKET 1 1 2 IN NPTTEE T0087 SIDEVIEW FRONTVIEW ...

Page 26: ...ss steel hardware and EPDM hardware O rings Nos 014 and 132 4TB9515 0070 Hardware kit for high pressure hot tap assembly with 316 stainless steel hardware EPDM hard ware O rings Nos 014 and 132 and ball valve 4TB9515 0071 Hardware kit for high pressure hot tap assembly with 316 stainless steel hardware and Viton hard ware O rings Nos 014 and 132 4TB9515 0072 Hardware kit for high pressure hot tap ...

Page 27: ...follow the procedures outlined in these drawings before installing the sensor into the process piping or tank Low pressure hot tap assemblies can be purchased with many different inser tion rod lengths Different lengths allow for flexibility in positioning the sen sor to the desired depth of the final installed location One difficulty often encountered is the lack of repeatability in positioning o...

Page 28: ...n the compression fitting Fig PR3 1 R 2 Position the sensor against the compression fitting body or extraction housing Fig PR3 2 by pulling the insertion rod until the assembly stops moving R 3 Hand tighten the compression fitting to prevent the insertion rod and sensor from moving during the remaining steps R 4 Apply high temperature pipe sealant to the unused pipe threads of the 1 in NPT nipple ...

Page 29: ... compression fitting is secure Figure PR3 1 Low Pressure Hot Tap Assemblies T00877A HAND TIGHT COMPRESSIONFITTINGHARDW ARE WRENCH TIGHT COMPRESSIONFITTINGHARDW ARE OUTMOST COMPRESSION NUT INNERMOST COMPRESSION NUT 1 1 2 IN FULL PORT BALLVALVE 1 4 IN FLUSHING PORTS 2TYP INSERTION ROD HAND TIGHT COMPRESSION FITTING 1 1 2 IN TEE 1 1 2 IN NIPPLE INSERTION ROD RETRACTED INSERTION ROD EXTENDED 1 1 2 IN ...

Page 30: ...ressure Hot Tap Assembly INSERTIONRODRETRACTED INSERTIONRODEXTENDED T00878A 1 4 IN FLUSHING PORT END CAP 1 1 2 IN FULL PORT BALLVALVE 1 1 2 IN SENSOR GUIDE EXTRACTION HOUSING INSERTION ROD ASSEMBL Y 1 2 IN NPT ELBOWFOR CONDUIT CONNECTION ...

Page 31: ...ensor into the two inch sanitary tri clamp tee R 3 Position the sensor so that the sensing area is perpendicular to the flow path to meet the installation guidelines described in Section 2 20 min Number Qty Description customer supplied 1 Gasket sanitary customer supplied 1 Tri clamp tee sanitary 2 in customer supplied 1 Tri clamp sanitary customer supplied 1 Conduit cable gland adapter in custome...

Page 32: ...r threads R 6 If desired attach inch flexible conduit or a cable gland to the in NPT conduit cable gland adapter Figure PR4 1 Sanitary In Line Flow Assembly SANIT AR Y GASKET TB4043 SENSOR T00879A SUPPLIED BY O THERS 2 IN SANIT ARY TRI CLAMP TEE 85 1 3 35 DIMENSIONS MILLIMETERS INCHES Figure PR4 2 Sanitary In Line Flow Assembly with Tri Clamp 1 2 IN NPT CONDUIT ADAPTER USER SUPPLIED SANIT ARY CLAM...

Page 33: ...on 4TB8006 0025 A R Silicone grease 4TB8006 0045 A R Anti seize compound Customer supplied A R Pipe sealant WARNING 1 Firmly hold the insertion rod when loosening the compres sion fitting When the compression rod is loosened the pres sure against the sensor assembly will cause the insertion rod to retract from the ball valve assembly with great velocity This could injure personnel standing in the ...

Page 34: ...fitting body to the ball valve c High pressure hardware Undo the end cap and withdraw the insertion rod assembly from the extraction housing Figure PR5 1 Low Pressure Hot Tap Assemblies T00877A HAND TIGHT COMPRESSIONFITTINGHARDW ARE WRENCH TIGHT COMPRESSIONFITTINGHARDW ARE OUTMOST COMPRESSION NUT INNERMOST COMPRESSION NUT 1 1 2 IN FULL PORT BALLVAL VE 1 4 IN FLUSHING PORTS 2TYP INSERTION ROD HAND ...

Page 35: ...O rings with silicone grease all straight threads with anti seize compound and all pipe threads with pipe sealant Figure PR5 2 High Pressure Hot Tap Assembly INSERTIONRODRETRACTED INSERTIONRODEXTENDED T00878A 1 4 IN FLUSHING PORT END CAP 1 1 2 IN FULL PORT BALLVALVE 1 1 2 IN SENSOR GUIDE EXTRACTION HOUSING INSERTION ROD ASSEMBL Y 1 2 IN NPT ELBOWFOR CONDUIT CONNECTION ...

Page 36: ...g observe all safety precautions required for handling chemicals When handling chemicals always use gloves eye protection safety shields and similar protective items and consult material data safety sheets 20 min WARNING 1 Consider the material compatibility between cleaning fluids and process liquids Incompatible fluids can react with each other causing injury to personnel and equipment damage 2 ...

Page 37: ...may occur R 4 Rinse the sensor with water Solvent Dip This method removes organic coatings R 1 Verify that any process fluid on the sensor is not incompatible with iso propyl alcohol or other appropriate solvent R 2 Put on gloves eye protection safety shields and other protective items as needed for protection R 3 Dip the sensor into the solvent Do not use a solvent that is known to be incompatibl...

Page 38: ...assembly PR4 1 Submersible assembly PR1 1 Instruction content 1 2 Intended user 1 1 L Location considerations 2 1 M Maintenance sensor cleaning PR6 1 N Nomenclature 1 3 O Orientation requirements 2 3 P Parts spare and replacement 4 1 R Reference documents 1 2 Replacement parts 4 1 S Sanitary assembly installation PR4 1 Sensor Anatomy 2 2 Application 1 1 Cleaning PR6 1 Description 1 1 Orientation r...

Page 39: ...Sales Service ...

Page 40: ... make technical changes or modify the contents of this document without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosur...

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