Carbotec TR-PT

Instruction Manual
CO2 Inline Sensor
Carbotec TR-PT

Version V1.6
December 2012

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 Carbotec TR-PT

Table of Contents

Table of Contents ................................................................................................................ 2

1 General notes for the user ............................................................................................... 3

2 Principle of Measurement ................................................................................................ 5

2.1 General function of the Carbotec TR-PT Sensor .......................................................... 6

3 Technical Data .................................................................................................................. 7

4 Installation Guidelines ..................................................................................................... 8

4.1 General Information...................................................................................................... 8

4.2 Sensor Mounting .......................................................................................................... 9
4.2.1 Horizontal Sensor Installation ............................................................................................... 10
4.2.2 Vertical Sensor Installation .................................................................................................... 12

5 Electrical Connection ......................................................................................................15

6 Handling the sensor ........................................................................................................17

6.1 General handling .........................................................................................................17

6.2 Product selection .........................................................................................................21
6.3 Product calibration.......................................................................................................25
6.4 Analog output ..............................................................................................................27
6.5 Service Data................................................................................................................29

7 Handling the PC software ...............................................................................................34

7.1 installation of the software „Carbotec Oxytec Viewer “.................................................34

7.2 Operation of the software „Carbotec-Oxytec-Viewer“ ..................................................35
7.2.1 General operation ................................................................................................................. 35
7.2.2 Product data administer ........................................................................................................ 41
7.2.3 Firmware actualization .......................................................................................................... 44

8 Cleaning ...........................................................................................................................46

9 Maintenance and Repair .................................................................................................47

9.1 Service ........................................................................................................................47

9.2 Failure analysis ...........................................................................................................47
9.3 Repair .........................................................................................................................48

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 Carbotec TR-PT

1 General notes for the user

In the following chapters detailed information is given for the correct use of the device / sys-
tem.

Should you required any further information, please contact:

Centec GmbH
Wilhelm-Röntgen-Str. 10
D-63477 Maintal
Tel.: +49-(0)6181 1878-0
Fax.: +49-(0)6181 1878-50
e-mail: info@centec.de
Internet: www.centec.de

This instruction manual describes the applications of the device / system and how you can
start it up, operate and service it. Of particular importance are the warning and information
texts. These are separated from the remaining text, specially identified by appropriate picto-
grams (see examples on left), and provide valuable tips on how to avoid mal operations.
⇒
Warning means that death, severe personal injury and/or substantial damage to property
can occur if the appropriate safety precautions are not observed.
Note is important information on the product itself, the handling of the product or the respec-
tive part of the instruction manual to which particular attention should be paid.

Note!

For clarity reasons, this Operating Instructions cannot describe all detailed information on all
versions of the product and cannot cover every possible aspect concerning installation, op-
eration or maintenance.
Should you require further information, or should particular problems occur which are not
handled in sufficient depth in this Manual, help can be requested through your local Centec
office or representative.
Your attention is additionally drawn to the fact that the contents of these Operating Instruc-
tions are not part of a previous or existing agreement, commitment or statutory right and do
not change these. All commitments on the part of Centec GmbH are contained in the respec-
tive sales contract which also contains the complete and solely applicable warranty condi-
tions. These warranty conditions in the contract are neither extended nor limited by the con-
tents of these Operating Instructions.

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Warning!

This device must only be installed and operated if a qualified person has previously ensured
that suitable power supplies are used which guarantee that no dangerous voltages can be
applied to the device in normal operation and also in the event of a fault in the system or in
system components.

The device can be operated with corrosive media and may be under pressure. Therefore
improper use could lead to severe personal injury and/or extensive damage to property.

Correct and safe operation of this device is dependent on proper transport, storage, installa-
tion and assembly, as well as careful operation and maintenance.

Operational safety and protection of the device are only guaranteed if the device is operated
according to the Instruction Manual.
The device / system must only be used for approved applications.

Qualified personnel

A qualified person is one who is familiar with the installation, assembly, commissioning and
operation of the product and who has the appropriate qualifications, e.g.:
- Is trained or authorized to operate and service devices/systems in accordance with
established safety practices for electrical circuits, high pressures and corrosive media.
- Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
- Is trained in first aid.

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2 Principle of Measurement
The Carbotec TR-PT in-line CO2-transmitter measures continuously and exactly the content
of carbon dioxide in carbonated liquids. For determining the CO2-content of a carbonated
liquid, every ca. 20 seconds a 25 ml sample is isolated from the main stream. The pressure
of this taken sample is abruptly reduced to below atmospheric pressure. The resultant pres-
sure will differ from that of a non-carbonated liquid according to the volume of dissolved CO2
in the sampled liquid. This difference in resulting pressure is the basis for calculating the
CO2-content of the liquid. The temperature dependence of the measurement signal is elec-
tronically compensated by PT100. After the measurement the sample is returned to the
product line, the CO2-concentration can be displayed in different units like e.g. g/l. The menu-
driven software includes the product-specific calibration and product selection. Analog and
digital in- and outputs onboard can be used for process controlling and automation. The sen-
sor has a hygienic construction and is cleanable with all in food- and beverage industry typi-
cal CIP-media.

Figure 1: Dimensions of the sensor with DN65 measuring head

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2.1 General function of the Carbotec TR-PT Sensor

- A product flow (beer/beverage) runs through the measuring head of the sensor. Optimal
is a condition of continuous flow in the product line to ensure a proper sensor function.
- A solenoid valve integrated in the sensor drives an air cylinder for the sensor piston in-
side. The piston moves continuously up and down.
- In piston position “Piston Down” the sample is isolated from the main stream and the
pressure abruptly reduced by increasing the chamber volume. Dissolved CO2 in the me-
dium will go into the gas phase and is increased the pressure depending from the amount
of dissolved CO2 in the product.
- With the received values of pressure and temperature the content of CO2 will be calculat-
ed. (the value can be used to provide a Centec PID controller to regulate the valve inject-
ing CO2 into the beverage).
- In the piston position „Piston Up“, the measuring chamber is open, the old sample is flow-
ing back into the product line and replaced by new sample for the next measurement cy-
cle.

In the CIP mode the sensor processes in the same way as described above, means the pis-
ton is moving up and down to ensure proper cleaning. Except of the displayed values and
alarms which are not in function. They are set to zero or any other requested value.

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3 Technical Data

Measuring range: 0 – 10 g/l CO2

Repeatability: ± 0,01 g/l CO2

Flow: >1,5 m/s

Response time: ≤ 20 sec

Temperature compensation: Pt 100

Temperature range:
Medium -10°C - +100°C, +14°F - +212°F
Environment -10°C - +50°C, +14°F - +122°F

Pressure range: Max. 10 bar

Material of parts in contact with medium: Stainless steel 1.4404 (316L),EPDM, PTFE

Seals: EPDM, PTFE

Process connections: compatible to Varivent©-Inline-Housings

DN 65 (2,5“) – DN 150 (6“); others on request

Electrical connections:

Input: - 6x digital (24 VDC)

Output: - 3x digital (24 VDC)

- 2x analog (4-20 mA)

Power Supply: 24 VDC

Enclosure rating: IP 65

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4 Installation Guidelines

4.1 General Information

The sensors are watertight and can be installed in rooms with high humidity. Degree of pro-
tection is IP 65. Correct installation is a requirement for retention of the degree of protection.
The following listed working steps and information must be observed for proper function:
1. The to be measured Carbon Dioxide (CO2) in the medium must be completely dis-
solved (100%), bubbles generally lead to measurement problems.
2. The practical line pressure must be kept always above the required pressure for the
CO2-Equilibrium (CO2-Equilibruium is depending from pressure and temperature) to
avoid measurement problems caused by un-dissolved CO2-bubbles in the medium.
3. The maximum permissible ambient temperature and temperature of the medium must
never be exceeded.
4. If the surface of the sensor tube can become more hot than 70 °C in an application, a
warning must be provided and/or a guard to protect against accidental contact.

5. When installing the sensor outdoors, provide protection from direct rain contact and
solar radiation.

Pipe work

The Carbotec TR-PT should be preferably built into a vertical product line with flow upstream.
For the sensor installation into the product line an Varivent® Inline housing is suitable.

Warning!

Before sensor installation into new welded pipes ensure that all metal particles etc. are
flushed out to avoid damages of the piston seals or other components.

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4.2 Sensor Mounting

To install the Carbotec TR-PT sensor, Centec can optionally supply a Varivent® Inline-
housing. Suitable Clamp-rings as well as tools has to be used by qualified personnel.

Inline-Housing
Typ Varivent®

Carbotec TR-PT
Inline Sensor

Figure 2: Sensor installation

The Carbotec TR-PT can be installed directly into inline housings of type Varivent® for diam-
eters DN 65 – DN 150.

Warning!
This device must be installed and operated by a qualified person who has inspected the fix-
ing connections as well as the static conditions.

Air Supply

A clean dry air supply of 5-6 bars should be connected to the 6mm air connection of the sen-
sor. A special air filter with pressure control filter before the sensor inlet is required to ensure
proper function. An occasional lubrication using a light oil is desirable or a lubricator can be
fitted.

Remark: Centec can optionally supply a suitable pressure air filter with integrated control
valve for pressure adjustment.

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4.2.1 Horizontal Sensor Installation

The Carbotec TR-PT CO2-sensor can be principally mounted in a horizontal and in a vertical
product pipe.

The ideal measuring point which Centec always recommends first is an installation of the
sensor into a vertical pipe with flow direction from the bottom to the top. Therefore the sen-
sors are at state of supply principally pre-adjusted for the vertical configuration (if not before
any other customer requirements are known).

Figure 3: Configuration for horizontal Sensor installation

The flow direction in the pipe is for the sensor head not relevant. Both sides of the sensor
head have the same types of inlets and outlets. In Figure 3 is the sensor shown for horizontal
sensor installation.

To change the position of the sensor head (horizontal ↔ vertical Installation) respective to
check for which installation the sensor is pre-configurated, the following items have to be
considered:

1. Dismantle the sensor from the pipe.

2. Check the positions of the inlet/outlet windows in the measuring head. These win-
dows have to be located in flow direction and ensure that the measuring chamber is
correctly filled with sample. Figure 4 is showing the correct window placement for an
installation into a horizontal pipe.

Window in the
measuring head

8 mounting screws
(M3x16mm)

Figure 4: Position of the window openings for inlet/outlet - horizontal installation

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3. Dismantle the measuring head from the sensor body by removing the 8 screws below
the flange connection. The figure 5 is showing the removed sensor head. Pay atten-
tion of the black O-ring inside of the head. In most cases this O-ring is sticking on
the head. For the later assembly this O-ring has to be cleaned and put back into the
groove of the PTFE-bellows (see also figure 6).

O-Ring

Figure 5: Dismantled Measuring Head with O-Ring

4. Figure 6 shows the sensor with piston after removing the sensor head. Now the posi-
tions of the openings in the piston have to be checked and if required the position
changed in an angle of 90° (see also following poin t 5). The openings in the piston
have generally to be located in the same direction as the window openings in the
sensor head (in flow direction of the medium).

Groove in the PTFE-

2x mounting screws of Bellows for the O-ring
the sensor piston

Figure 6: Sensor without Sensor head horizontal Installation

5. 90°-Rotation of the measuring piston: Remove the two mounting screws below the
measuring piston and below the PTFE-bellows as shown in figure 6 with a 2,5mm Al-
len key (hexagon socket screw key). Remove the screws completely out of the sen-
sor, afterwards rotate the piston about 90°. Is the new position reached, than screw
the 2 screws tightly.

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 Carbotec TR-PT

Figure 7: Removed Screws of the sensor piston (M3x8mm) with used Allen Key

4.2.2 Vertical Sensor Installation

The Carbotec TR-PT CO2-sensor can be principally mounted in a horizontal and in a vertical
product pipe.

The ideal measuring point which Centec always recommends first is an installation of the
sensor into a vertical pipe with flow direction from the bottom to the top. Therefore the sen-
sors are at state of supply principally pre-adjusted for the vertical configuration (if not before
any other customer requirements are known).

Figure 8: Vertical Installation of the sensor (Rising Main)

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The flow direction in the pipe is for the sensor head not relevant. Both sides of the sensor
head have the same types of inlets and outlets. In Figure 8 is the sensor shown for vertical
sensor installation.

To change the position of the sensor head (horizontal ↔ vertical Installation) respective to
check for which installation the sensor is pre-configurated, the following items have to be
considered:

1. Dismantle the sensor from the pipe.

2. Check the positions of the inlet/outlet windows in the measuring head. These win-
dows have to be located in flow direction and ensure that the measuring chamber is
correctly filled with sample. Figure 9 is showing the correct window placement for an
installation into a vertical pipe.

8 Mounting screws Window in the

(M3x16mm) measuring head

Figure 9: Position of the window openings for inlet/outlet - vertical installation

3. Dismantle the measuring head from the sensor body by removing the 8 screws below
the flange connection. The figure 10 is showing the removed sensor head. Pay atten-
tion of the black O-ring inside of the head. In most cases this O-ring is sticking on
the head. For the later assembly this O-ring has to be cleaned and put back into the
groove of the PTFE-bellows (see also figure 11).

Figure 10: Dismantled Measuring Head with O-Ring

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4. Figure 11 shows the sensor with the piston after removing the sensor head. Now the
positions of the openings in the piston have to be checked and if required the position
changed in an angle of 90° (see also following poin t 5). The openings in the piston
have generally to be located in the same direction as the window openings in the
sensor head (in flow direction of the medium).

Openings for sample

flow in the piston

Groove in the PTFE-

2x mounting screws of Bellows for the O-ring
the sensor piston

Figure 11: Sensor without Measuring Head for vertical Installation

5. 90°-Rotation the Measuring piston: Remove the two m ounting screws below the
measuring piston and below the PTFE-bellows as shown in figure 6 with a 2,5mm Al-
len key (hexagon socket screw key). Remove the screws completely out of the sen-
sor, afterwards rotate the piston about 90°. Is the new position reached, than screw
the 2 screws tightly.

Figure 12: Removed Screws of the sensor piston (M3x8mm) with used Allen Key

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5 Electrical Connection

Warning!

◊ The pertinent regulations must be observed for the electrical installation.

To get access to the electrical connections of the Carbotec TR-PT, the right and left covers
of the display have to be removed and the underlying four screws solved. Now the cover
plate of the sensor can be opened (Figure 13: Electronic with electrical connections).

Plug contact for

ribbon cable of
the display

Socket for serial

CENTEC Com-
munication Box
Connector block

Figure 13: Electronic with electrical connections

Table 1: Electrical pin connection

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
+ - - 1 2 3 + - + - - 1 2 3 4 5 6
+24V GND GND D. OUTPUT AO 1 AO 2 GND DIGITAL INPUT

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The supply voltage of the sensor (24VDC) is attached on the electronic board to the connec-
tions 1 (+VCC) and 2 (GND) (see Table 1: Electrical pin connection). The analog outputs 1
and 2 can be used for the output of the signals; e.g. CO2-concentration and temperature or
pressure. The output signals are 4 - 20mA. For the digital product choice the digital inputs
11-16 and/or 17 can be used. The digital input 6 (pin 17) at the electronic can be used either
as freeze signal of the measured value, or for additional product selection (see section 6.2
product selection).

The digital outputs are reserved for alarm messages. The allocation which alarm on which
digital output is, you can see in following Table 2 (Digital Outputs). The voltage level amounts
to 24VDC regarding GND.

Note:
The digital output Dig Out 3 possesses with inverse logic, that means the output is high sig-
nal (24VDC), if no error is present!

Table 2: Digital outputs

3 4 5 6
- 1 2 3
GND Dig. Out 1 Dig. Out 2 Dig. Out 3
General alarm (hu-
High High Limit (HH)
High Limit (H) and midity alarm, pres-
and Low Low Limit
Low Limit (L) Alarm sure measurement
(LL) Alarm
broken, etc)

The following rules are generally valid for the signal cables:
- Use only screened, two-wire cables twisted pair
- Signal cables have to be separated from other cables with voltages >60 V
- Avoid laying near to large electrical installations
- The specifications only apply for properly executed installations.

The serial connection on the electronic board is intended for communication between sensor
and a PC/laptop. On one side the “CENTEC-Communication-Box” is connected to the serial
connection of the electronic board with a serial cable on the other side it is connected with a
USB-cable to the PC/Laptop (chapter 7 handling the PC software).
With the software „Carbotec-Oxytec-Viewer “it is possible to do all settings, calibrations and
adjustments with a PC/Laptop.

Warning!

After sensor connection of power supply and all signal wires are made, take care, that
all cable entries are tighten well and no humidity can enter the electronic housing!

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6 Handling the sensor

6.1 General handling

Figure 14: Standard screen with the measured values

If the power supply of the sensor is switched on, the standard-screen with the measured val-
ues appears on the display (Figure 1).

In the first line the active product number is indicated (in the Figure 1 active product-number
is 1).

The second line shows the current measured absolute pressure in bar. If the sensor is not
installed in the line it will measure the air pressure, approx. 1 bar.

The measured temperature of the sensor is displayed in the third line.

In the fourth line the measured CO2-value is shown, which is only indicated if a measured
value is calculated. That means only after a completed measurement-cycle, a value appears
on the display.

The last line is reserved for alarm messages. If the values of the product are over or under
the adjusted limits, an alarm message is flashing in the last displayed line.

If the sensor display shows the standard-screen, you have to press the ENTER key to get
into the sensor menu. In every screen of the menu with chosen or selected first line, you can
go back with the ENTER key to the standard-screen.

To move through the menu use the 5 keys below the display. With the arrow keys you can
choose or change values, with the ENTER key you select and/or acknowledge the value.

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Figure 15: Product selection

You can reach the screen “Product selection” (Figure 15) if you press the ENTER key in the
“Standard-screen”. This is the first screen in the main menu. With the arrow keys up and
down you can choose the sub items of the menu. If the first line has a gray background, oth-
er screens can be selected by pressing the arrow keys right or left (details to the product
choice in chapter 6.2 product selection). If the ENTER key is pressed when the first line has
a gray background you can go back to the standard-screen.

Figure 16: Product data

The screen “Product data” can be reached by pressing the arrow key right from the screen
“Product selection”. In this screen the different products can be selected by using the arrow
keys up or down. If a product has a gray background, the characteristics of the product will
be shown by pressing the enter key (see 6.3 product calibration).

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Figure 17: Analog output

By pressing the arrow key right again from the screen “Product data” the screen “Analog out-
put” will be displayed. In this screen you can select and scale the two analog outputs (chap-
ter 6.4 analog outputs).

Figure 18: Measurement

Has the first line a gray background in the screen “Analog outputs”, the screen “Measure-
ment” will appear by pressing the right arrow key. In this individual screen measuring settings
can be made. A temperature offset, a damping for the pressure and the CO2 value, as well
as a change of the rinsing and measure time can be adjusted. Any changes of these values
can have extreme effects on the measuring behavior of the sensor, therefore any changes of
these parameters should be done after contact with CENTEC. Further adjustments for the
internal humidity sensor can be made from that screen.

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Information to the humidity sensor:

The humidity sensor in figure 18, visible in the menu „Measuring”, is a control mechanism for
monitoring the process seal and protected the electronics and process hygiene. The mecha-
nism is based on a conductivity measurement, which is integrated in the sensor flange. The
high impedance value at dry (normal) conditions is in-between a dimensionless value of ap-
prox. 100 - 120. If the value, adjustable by the humidity alarm limit, halves itself an alarm is
initiated. After that alarm message the sensor should be removed immediately, in order to
avoid damage of the electronics. Further details you can find in chapter 6.5 service data.

Figure 19: Manufacturer

By scrolling with the arrow key “Right” from the screen “Measurement” the screen “Manufac-
turer” appears. In this screen you can see by pressing the arrow keys up and down the dif-
ferent sub items, which are individual information to the sensor.

Figure 20: Language selection

The screen “Language” you find by simultaneous pressing of the arrow keys right and left
from the standard-screen (Figure 1). You can select the language German or English.

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6.2 Product selection

Figure 21: Product selection

In the screen “Product selection” you can choose between the sub items product group, se-
lect mode, product select, input 6 config and freeze delay (Figure 21). By pressing the arrow
keys up and down the sub items can be selected. If the background of an item is gray it can
be chosen by pushing the ENTER key. The sub menu “freeze delay” is only visible, if under
sub-menu “input 6 config” the freeze-signal is already chosen before respective is active (see
also figure 25).

Figure 22: Product group

In the screen “Product Group“ (Figure 22) the product has to classified into one of 4 main
product groups. If the product has a wrong selection (e.g. the group Beer is selected but
product Mineral water is measured), than it can occur, that the required offset value com-
pared to the lab result can become quite high. Therefore it is recommended to always select
each product to the correct product group.

Remark:
For the sensor commissioning pay attention, that the right product group is selected
for the measured product!

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Figure 23: Select mode

In the screen “Select mode” (figure 23) you can select between manual and digital input. Dig-
ital means that by default binary signal at the digital inputs at the connection block (pin 11-17;
see figure 13 electrical connections) the product number can be selected. Depending from
the adjustment of “input 6 config” (figure 15) products can be selected up to max. 64 (if “input
6 config” on setting “product selection”). In total 32 different products are available if “input 6
config” is chosen for adjusting a “freeze signal”.

Example:
Product 23 should be chosen; product-choice is digitally selected; input 6 config is set on
product selection.

Signals of the digital inputs:

Table 3: Signals of the digital inputs

11 12 13 14 15 16 17
20 21 22 23 24 25 or freeze
signal1
GND digital TRUE TRUE TRUE FALSE TRUE FALSE
signal

23=1*20+1*21+1*22+0*23+1*24

Remark:
Is the product selection set to “Manual”, it is insignificant which signal at the digital inputs is
switched. The product is than only active basing on the manually selected product number.

1
Depends on choice of input 6 config.

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 Carbotec TR-PT

Figure 24: Product selection

If in Figure 21 the sub item “product selection” is chosen, the screen in figure 24 appears by
pressing the ENTER key. At this screen a product can be selected manually by pressing the
arrow keys up or down. You can go back to the preceding screen through by pressing the
ENTER key. If any change is made, the question appears “save changes yes/no”. Only after
selecting “YES”, the product will be changed. By selecting „NO“ you go back to the preceding
screen without any stored modification. If in the sub item “Select Mode” (figure 23) “Digital” is
selected, the manual change of the product does not have any influence.

Figure 25: Input 6 config

If the sub item “Input 6 config” is selected in figure 21, the screen “Input 6 config” will appear
(figure 25). In this screen the configuration of the digital input 6 can be selected. This input
can be used as additional digital product selection, or as freeze signal. Freeze signal means
that the last measured value before the digital input 6 takes the value TRUE (+24V) is stored.
The measured value is than constantly displayed till the digital input takes the value FALSE
(0V). In that Freeze status, the sensor piston is normally working up and down. This signal
has only influence on the software, means only on displayed value and on the analog output.

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Remark:
The installation of a Freeze signal is always than recommended, if many product stops
are expected in the process, e.g. in front of the filler.

Figure 26: Freeze Delay

In Screen “Freeze Delay” (figure 26) the time can be freely adjusted, how long the frozen
value will be still displayed after deactivating the digital input freeze signal. This time should
be chosen depending from the expected stops in process. If this time is relative long, than
the freeze delay should be also chosen relative long. The following figure 27 (signal diagram
freeze delay) should be helpful for the adjustments.

Figure 27: Signal diagram Freeze Delay

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6.3 Product calibration

Figure 28: Product data

In order to calibrate a product, the screen “Product data” (Figure 28) has to be selected. By
pressing the ENTER key the product specific calibration is reached (e.g. product 1 figure 29).

Figure 29: Product calibration

Figure 29 shows the screen “Product calibration”. For each product such an individual screen
will appear. Depending from the made selection in the screen “Product Data” in figure 28
each product can be individually edited. The alarm limits as well as an individual product off-
set can be freely set based on the measured laboratory value for calibration. The offset is
calculated as follows:

Labor value- measured value sensor = product offset

Example:
Sensor indicated 4,38 g/l and the value of the labor is 4,05 g/l

Product offset = 4,05 g/l – 4,38g/l = -0,33g/l

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Figure 30: Product offset

This calculated product offset can be inserted in the screen “Product offset” (figure 30) by
pressing the arrow keys up or down. With the enter key the offset is than set and the product
is calibrated.

In order to enter the Alarm limits of the sensor, the appropriate limit must be selected by the
arrow keys up or down (Figure 29). By pressing the ENTER key the value can be selected
for changing. As an example is in the following figure 31 the selection of the Alarm HH (High-
High) shown:

Figure 31: HH alarm limit

The input of the individual alarm and warning limits can be made in the appropriate screens.
The values can be changed with the arrow keys up and down. Before a modification takes
affect you have to confirm the message with YES. After that the change is stored.

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6.4 Analog output

Figure 32: Analog output

In the screen „Analog output “(figure 32) it is possible to scale the two 4-20mA-signals (pins
7,8 or 9,10 at the connection block; see also table 1: Electrical pin connection).

Remark: If both analog outputs are active, than the whole screen has more than 8 lines (in
figure 32 is analog output 1 not active/is off). Not displayed lines can than be seen by scroll-
ing up and down with the arrow keys.

Figure 33: Analog config

For each analog output you can select between “Pressure absolute”, “CO2-content”, “Tem-
perature”, “Pressure relative” and “Off” (Figure 33). Depending from this choice and scaling
the output signal is between 4 and -20mA.

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The analog outputs can be scaled by selecting the appropriate lines in figure 33. Than the
specific values for 4 and 20 mA can be freely chosen. Figure 34 shows the screen for scaling
the lower limit value which is than assigned to a current of 4 mA. In the figure 35 the upper
current value is assigned to the output 20 mA. The second analog output can be scaled in
the same way.

Figure 34: Analog config 4 mA

Figure 35: Analog config 20 mA

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Figure 36: Analog Config Error

In the screen Analog Config Error (figure 36) it can be chosen, which current in case of error
message should be applied. Possible are to values: <3,6 mA (Selection <3,6mA) or >22mA
(Selection >20mA).

It is possible to set the analog output to simulation, concentrations, temperature or off. De-
pending on the selection and scaling of the analog output corresponding value will be trans-
mitted as a current signal.

The analog input function is customer specific e.g. for CO2 compensation.

6.5 Service Data

Figure 37: Measurement

In the screen “Measurement” (figure 37) elementary values, which are important for the
measurement, can be modified. These values should only be changed carefully and after
contact with CENTEC-personnel. Wrong values can lead to extremely varying measuring
values.

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Figure 38: Temperature offset

In the screen “Temperature Offset” (figure 38), a recognized deviation between the real me-
dium temperature and the displayed sensor temperature can be compensated. The value
can be determined as follows:

Temp-Offset = true temperature value – displayed temperature value

At stage of delivery this value is set to ZERO. After changing the temperature offset the CO2-
content has to be newly calibrated.

Figure 39: Pressure Damping

The screen in figure 39 shows the factor for signal damping of the pressure which can be
freely adjusted. A numerical value of 0,0s is a 100% un-damped measurement of the pres-
sure, the value 20,0s would represent a very strong damping factor. An increase of this factor
can lead to a more stable measurement value. A higher factor however leads to a more and
more slow-acting measurement which directly influence the response time of the CO2-
measurement. A recommended basic adjustment for this pressure dumping is a value of
1,5s.

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Figure 40: CO2 damping factor

The CO2 damping factor (figure 40) can be adjusted between 0,01 and 1,00. The measure-
ment is un-damped with a factor of 1,00. The damping effect increases with reducing this
factor. One receives the maximum absorption with the value 0,01. This value generally indi-
cates, how strong the difference between actual measured value and the previous measured
value is weighted. A recommended basic adjustment for the CO2-damping factor is a value of
0,70.

Figure 41: Rinse time

In the screen “Rinsing time” (figure 41) the time can be adjusted, how long the measuring
piston will stay for rinsing the measurement chamber. As higher this value is chosen, as
longer the piston stays at the position “Piston up”, the time for rinsing the measuring chamber
is than increasing. The time for getting a new calculated CO2-value will increase as well, but
the measurement can become more stable. As recommended basic adjustment for the rins-
ing time is a value of 8s.

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Figure 42: Measuring time

In the screen “Measuring time” (figure 42) it can be adjusted, how long the measuring piston
will stay in the position “Measuring”. As higher this value is chosen, as longer the piston will
stay in the position “Piston down”. This chosen time is directly affecting the calculation of a
new CO2-value. Principally with longer measurement time, the measurement becomes more
stable. A recommended basic adjustment for this time is a value of 12s.

Figure 43: Humidity sensor

In the screen “Humidity-Sensor” (Figure 43) you can make a selection of three menu items.
In first item „Humidity-Config“ can be activated or deactivated the humidity sensor (Figure 44:
Humidity Config). In the second sub-item „actual Humidity“ is shown the actual measured
humidity value, a dimensionless number. If the sensor is dry inside, the value is between ca.
100-120 (figure 45). In the last sub-item an alarm limit can be specified for the humidity
alarm. Recommended is a value of approximately half of the displayed value at dry condi-
tions. Is the value 100 to 120 under dry conditions than an recommended alarm limit is a val-
ue of 50 to 60 (Figure 46).

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Figure 44: Humidity Config

Figure 45: actual humidity

Figure 46: Humidity alarm

The humidity alarm limit should be approximately the half of the value under dry conditions
inside the sensor (i.e. a value of 50 to 60 at a dry condition value of 100 to 120).

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7 Handling the PC software

7.1 installation of the software „Carbotec Oxytec Viewer“

The PC software „Carbotec-Oxytec-Viewer “is installed by starting the Setups (setup.exe) on

the CD. Please follow the requests of the installation routine. After the program is installed,
the hardware driver for the sensor is up-played. In order to install the driver, the connection
between PC and sensor must be made over the Centec box (Figure 47).

Figure 47: Connection of the CENTEC Box

After connecting the USB cable into the USB socket at the PC by Plug and Play a new hard-
ware is recognized. The hardware installation assistant of Windows will be opened. Select
the driver in the folder “USB driver “on the CD and install it.

Subsequently, the before installed software „Carbotec-Oxytec-Viewer“ can be started. As

interface „USB Centec” should be recognized. If this is not the case, it should be examined
whether the sensor is supplied with power and all further connections to the PC and sensor
are correctly. If this is checked and the interface is still not recognized, than the correct driver
must be updated.

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7.2 Operation of the software „Carbotec-Oxytec-Viewer“

7.2.1 General operation

After starting the software the starting picture appears, at which the interface can be selected
for connecting to the sensor. Only one interface is recognized, if a sensor is attached and
supplied with power.
Further the languages German or English can be selected. The button “Exit” closes the pro-
gram again. In order to make a connection to the sensor, the interface must be selected
(blue background) and the button „Connect“ must be selected.

Figure 48: Start up screen

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If the connection with the sensor is successful, the picture shown in Figure 49 is seen. It
shows the device data, like for example type device, serial number, software-version, etc.

In the selection field language can be changed the adjusted language of the sensor display,
not the language of the software. With the button “Disconnect” you can cut the connection to
the sensor and go back to the picture of Figure 48: The start up screen of the software “Car-
botec-Oxytec-Viewer” is than seen again.

With the button “Exit” you can close the program. You can call stored settings with the button
“Open” (Figure 50), the button “Save” (Figure 51) stores made settings in a file. By selecting
other tabs you can chose further adjustment possibilities of the sensor.

In the right part of the program window actual data of the sensor can be seen, as well as fault
signals and alarm messages. The bars READ and WRITE indicate whether data are red or
written by the sensor. The current alarms, if limit values of the selected product are exceed-
ed, can be seen within the range status flag.

Figure 49: Device data

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Figure 50: Button open

Figure 51: Button save

In the tab calibration (Figure 52) the general calibration data of the sensor are shown. These
internal values can only be modified by Centec personnel in case of e.g. any hardware modi-
fications. Therefore you can not make any changes in this tab.

Figure 52: Tab calibration

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Figure 53: Tab products

In the tab “Products” it is possible to modify all settings for the max. 64 different products
comfortably. The 4 alarm limits and the product offset can be individually entered (all these
settings can be also made directly at the sensor via the menu).

Over the switching surface „Product data read “, the data from the sensor into the software
are transferred. In the top of the tab the settings for the product setting (manual or digital),
„input 6 config. “(input 6 can be set as freeze product signal) and further the product selec-
tion can be adjusted. The settings are only transferred to the sensor if the switching surface
or button „Save“ (product select mode and product selection) and/or (input 6 config.) is se-
lected.

Without operating these buttons the settings are not sent to the sensor.

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Figure 54: Tab measurement

Values, which have crucial influence on the measurement, as well as the configuration of the
analog outputs, can be administrated in the tab “Measurement” (Figure 54). The values
„Pref“, „Tref“ and „CO2-Offset “cannot be modifed. With these values the internal calculation
polynomials are calibrated and can only be adjusted by Centec personnel during basic facto-
ry calibration.

At the area Measuring / Rinsing time, the sequence of the measuring piston is specified. The
value “Measuring time”, indicates, how long the piston stay at the position measure (piston
down), the rinsing time indicates, how long the piston stays at the position rinsing (piston up).
As bigger the adjusted value of the measuring time is, as longer it takes till a new CO2-value
is calculated, however the result of the measurement can become more stable. Basic setting
for the measuring time is recommended with a value of 12 s.

As bigger the value of the rinsing time is, as longer the measuring chamber with medium is
rinsed. Rinsing out of not dissolved CO2-bubbles (can disturb the measurement) becomes
better at high values and the result of the measurement can become more stable. Basic set-
ting for the rinsing time is recommended with a value of 8 s.

The adjustment range for both values (measuring and rinsing) is generally possible within
values from 2s to 30s.

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 Carbotec TR-PT

The setting of the pressure-damping-time causes a slower-acting behavior during the pres-
sure measurement. A numerical value of 0,0s means an 100% un-damped measurement of
the pressure, 20,0s means a very strong damping effect on the calculated pressure. An in-
crease of the damping time can lead to a more stable measuring value, a too high dumping
factor however can lead to a very slow-acting measuring behavior.

In the input field „Temperature offset “the temperature value can be corrected with an offset,
if the indicated temperature level deviates from the real medium temperature. The offset is
determined as follows:

Temperature offset = displayed temperature - sensor temperature

After a change of the temperature offset the CO2-content must be calibrated newly.

In the sub item CO2 damping factor, the calculated CO2 value can be directly damped. The
CO2 damping factor can be adjusted between a value of 0,01 and 1,00. The measurement is
un-damped with a factor of 1,00. The maximum effect is reached with a value 0,01. This val-
ue generally indicates, how strongly the difference between actual measured value and pre-
vious measured value is weighted.

All values in the area pressure-damping-time are only taken over by operation of the
respective buttons “Save” behind the input fields!

Further the analog outputs 1 and 2 can be selected and scaled in this tab. In the two drop
down menus „Analog Config 1” and “Analog Config 2 “ all settings can be made.

These values are only taken over by operating the respective buttons “Save” below
the input fields

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7.2.2 Product data administer

Figure 55: File save with parameter data

The software „Carbotec-Oxytec-Viewer “offers the possibility for storing the adjusted data of
the sensor in a parameter file (*.par). In this file also the analog output calibration and the
attenuation factors are stored, further the measuring time, the rinsing time and the product
data (alarm limits, offsets). For storing the data simply the button “Save” (Figure 56) has to
be selected. A window, in which the memory place must be assigned will be opened and one
has to appoint a file (at figure 57 “Parametersatz_1.par”). After the button „Save” is activated
the file is provided. The data of the sensor are now in the file stored.

Figure 56: Button save

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 Carbotec TR-PT

Figure 57: Opened stored parameter data

In order to open a stored parameter data file, the button „Open“ (Figure 58) must be operat-
ed. The window „please select a parameter file“ will than be opened. At this window you have
to select the parameter file, the stored file (*.par) and opened the file by activating the button
“Open”.

Figure 58: Button open

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If the stored file was selected, the parameters are in the window „saving parameter“ (Figure
59). If the selected file is correctly chosen, the parameters can be taken over by pushing the
button “Send”. However not all parameters are written on the sensor. The data, which are
sensor-specifically dependent, like for example the calibration data of the pressure cell, are
stored in the parameter file, but are never overwritten by sending anything to the sensor. This
has the reason that these values are firmly bound to the sensor hardware, wrong values
would lead to a wrong measurement. Since each sensor is supplied calibrated, these values
are always present in each individual sensor.

Figure 59: Send parameter data to the sensor

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7.2.3 Firmware actualization

In the process of the firmware actualization it is necessary to separate the sensor from
the power supply. Check before that this is also possible before you start updating.

Figure 60: Start up screen

An actualization of the sensor firmware is only possible if no connection to the sensor is ac-
tive. Either the connection to the sensor is disconnected over the switching surface „Discon-
nect “or the software is started again.

If no connection to the sensor exists, the starting picture of the software will be seen at Fig-
ure 60. In order to update a new firmware on the sensor, the switching surface firmware up-
date (Figure 61) must be operated.

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Figure 61: Button firmware update

Figure 62: Firmware update

After operation of the switching surface „firmware update“, the window „firmware update “ will
appear. In this window by selecting the button “Firmware auswählen (Choose Firmware)”, a
new window will be opened. At this window you have to select which file with the firmware
(*.hex) you want to update. The path of the selected file is in the window „firmware update“ at
the line „Ausgewählte Datei (Chosen file)“ indicated.

After the file is selected, the switching surface „Firmware Update starten“ can be operated.
You are led on basis of dialogues through the actualization. During the update you will be
requested to set the jumper. Figure 63 shows the position of the jumper on the electronic
board.

When the message „firmware update successfully “appeared, the made update is finished.

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 Carbotec TR-PT

Figure 63: Jumper setting

Position of the two pins used for the jumper

8 Cleaning

⇒ For Cleaning of the sensor only liquid media are allowed.

A sufficient sensor cleaning is normally achieved with the standard CIP process for the com-
plete production line.

Warning!

◊ Before starting the cleaning procedure ensure that the cleaning liquid is not aggressive
against the material of the product contact parts of the sensor.

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9 Maintenance and Repair

Warning!

To avoid damages of the Carbotec TR-PT, the sensor should not run longer time under com-
plete dry conditions, means no liquid media in the line resp. measuring chamber. The sensor
function (piston sequence up /down) can be stopped by selecting product number 0. Under
this product number, the pistons stops in position “Piston up” (Rinsing position).

9.1 Service

Servicing is at least depending from the process conditions. However we recommend a

monthly visual inspection checking

- that there are no product leakages

- that no air is in the measuring medium
- that behind the display window no humidity is visible inside

If there are no obvious problems then no action has to be taken and an bi-annual mainte-
nance service is under standard conditions sufficient.

In case of any visible leakages, the Carbotec TR-PT should be taken immediately from the
process, in order to avoid severe damages.

Generally all service activities should be done by Centec or other trained personnel.

Note: For sensor maintenance a separate service kit with manual is existing.

9.2 Failure analysis

Problem Solution
Dark display
Check power supply and fuses of the sensor

Frozen or no CO2-value displayed
Check values for pressure and temperature

Check air pressure and supply

Check correct function of digital freeze signal
(if in connected and in use)

Frozen or to high temperature
Check temperature and flow through sensor

Unsteady CO2-values
Too much un-dissolved bubbles in the pipe

Piston seals are down, have to be changed
according to the service manual

Drifting CO2-value
Piston seals are down, have to be changed

according to the service manual

Measurement piston is not moving
Check air pressure and supply

up/down
Check if product number is different to “0”

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9.3 Repair

If you have to return the sensor to Centec for repair, please enclose a note with the following
information:
- Description of application (type of measurement)
- Description of fault
- Chemical and physical properties of medium

Warning!

◊ All product residues of the medium must be removed before shipment. This is particularly
important if the medium is dangerous to health, e.g. corrosive, toxic, carcinogenic, radioac-
tive, etc.

Please return to:

Centec GmbH
Wilhelm-Röntgen-Str. 10
D-63477 Maintal

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