Mettler Toledo InPro6000G Series Gas Phase Oxygen Sensors Mode d'emploi

Taper
Mode d'emploi
InPro 6000G Series 
Gas Phase Oxygen Sensors
Instruction manual
Bedienungsanleitung
Instructions d’utilisation
InPro 6000 G Series
52 206 477 E
2 InPro 6800G/6850iG/6900iG/6950iGO
2
12 mm
InPro 6000 G Series © 12 /18 Mettler-Toledo GmbH
52 206 477 E Printed in Switzerland
English                           Page      3
Deutsch                          Seite    45
Français                          Page    85
© It is forbidden to reprint this Instruction Manual in whole or part. No part of this
manual may be repro duced in any form, or modified, copied or distributed using
electronic systems, in particular in the form of photo copies, photographs, magnetic
or other recordings, without written consent of Mettler-Toledo GmbH, Process Analytics,
CH-8902 Urdorf, Switzerland.
All rights reserved, in particular reproduction, translation and patenting/registration.
InDip, InFit, InPro, ISM, and InTrac are registered trademarks
of the Mettler Toledo Group in Switzerland and a further twel-
ve countries.
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1 Introduction.....................................................................4
2 Important notes ...............................................................5
2.1 Notes on operating instructions ..........................................5
2.2 Intended use ....................................................................6
2.3 Safety instructions.............................................................6
2.4 Correct disposal of the sensor ............................................9
2
.5 Examples of some typical applications................................9
2.6 Use in Ex-zones ...............................................................9
2.7 Ex-classification ATEX .....................................................10
2.7.1 Introduction....................................................................10
2.7.2 Rated data .....................................................................10
2.7.3 Special conditions...........................................................11
2.8 Ex-classification – FM approved .......................................12
2.8.1 Introduction....................................................................12
2.8.2 Rated data ....................................................................13
2.8.3 Special conditions...........................................................13
3 Product description........................................................15
3.1 General information ........................................................15
3.2 Principle ........................................................................15
3.3 Enhanced diagnostics (only for ISM types available) ..........17
3.4 Scope of delivery ............................................................18
3.5 Equipment features .........................................................19
4 Installation....................................................................20
4.1 Mounting the sensor........................................................20
4.2 Connection ....................................................................20
4.2.1 Connecting the sensor to a AK9 cable ...............................20
4.2.2 Connecting the cable to the transmitter ..............................21
5 Operation......................................................................22
5.1 Start-up and polarizing....................................................22
5.2 Calibration .....................................................................23
5.2.1 Purpose of calibration .....................................................23
5.2.2 What you have to know for calibration ..............................23
5.2.3 Single point calibration....................................................24
5.2.4 Dual point calibration......................................................24
6 Maintenance .................................................................25
6.1 Inspection of the sensor...................................................25
6.1.1 Visual inspection ............................................................25
6.1.2 Using the METTLER TOLEDO O2 sensor master ..................26
6.1.3 Testing the sensor via a transmitter...................................27
6.1.4 ISM design.....................................................................28
6.2 Changing the electrolyte,
the membrane body or the interior body ............................29
7 Storage.........................................................................32
8 Product specification .....................................................32
8.1 Certificates .....................................................................32
8.2 Specifications.................................................................33
9 Ordering information .....................................................35
9.1 Sensors .........................................................................35
9.2 Transmitter.....................................................................35
9.3 Accessoires....................................................................35
9.4 Spare parts ....................................................................36
9.5 Cables...........................................................................36
9.6 Recommended housings .................................................36
10 Theory of the polarographic sensor.................................37
10.1 Introduction....................................................................37
10.2 Principle of the design of an oxygen electrode....................38
10.3 Parameters determining current ........................................42
10.4 Polarization voltage ........................................................42
10.5 Temperature...................................................................43
10.6 Dependence on flow........................................................43
10.7 Oxygen partial pressure – oxygen concentration.................43
Contents
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1
      Introduction
Thank you for buying the InPro
®
6800G/6850 iG /
6900 iG/6950 iG sensor from  METTLER TOLEDO.
The construction of the InPro series employs leading
edge tech nology and complies with safety regula-
tions currently in force. Notwithstanding this, improp-
er use could lead to hazards for the user
or a third-party, and/or adverse effects on the plant
or other equipment.
Therefore, the operating instructions must 
be read and understood by the persons involv ed 
before work is started with the sensor.
The instruction manual must always be stored close
at hand, in a place accessible to all people working
with the InPro sensor.
If you have questions, which are not or insufficiently
answered in this instruction manual, please contact
your METTLER TOLEDO supplier. He will be glad to
assist you.
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2
      Important notes
2
.1    Notes on operating instructions
These operating instructions contain all the information
needed for safe and proper use of the InPro 6800G /
6850iG/6900 iG/6950 iGsensor.
The operating instructions are intended for personnel
entrusted with the operation and maintenance of the
sensors. It is assumed that these persons are familiar
with the equipment in which the sensor is installed.
Warning notices and symbols
This instruction manual identifies safety instructions
and additional information by means of the following
symbols:
This symbol draws attention to safety instructions
and warnings of potential danger which, if neglect-
ed, could result in injury to persons and/or damage
to property.
This symbol identifies additional information and
instructions which, if neglected, could lead to
defects, inefficient operation and possible loss of
production.
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2.2    Intended use
METTLER TOLEDOInPro 6800G/6850iG/6900iG/
6950 i G sensors are intended solely for inline
measurement of the oxygen partial pressure in 
liquids and gases, as described in this instruction
manual.
Any use of these sensors which differs from or ex-
ceeds the scope of use described in this instruction
manual will be regarded as inappropriate and incom-
patible with the intended purpose.
The manufacturer/supplier accepts no responsibility
whatsoever for any damage resulting from such
improper use. The risk is borne entirely by the user/
operator.
Other prerequisites for appropriate use include:
compliance with the instructions, notes and
requirements set out in this instruction manual.
acceptance of responsibility for regular inspection,
maintenance and functional testing of all asso ci -
ated components, also including compliance with
local operational and plant safety regulations.
compliance with all information and warnings
given in the documentation relating to the products
used in conjunction with the sensor (housings,
transmitters, etc.).
observance of all safety regulations governing the
equipment in which the sensor is installed.
correct equipment operation in conformance with
the prescribed environmental and operational con-
ditions, and admissible installation positions.
consultation with Mettler-Toledo Process Analytics
in the event of any uncertainties.
2.3    Safety instructions
The plant operator must be fully aware of the
potential risks and hazards attached to operation
of the particular process or plant. The operator is
responsible for correct training of the workforce, for
signs and markings indicating sources of possible
danger, and for the selection of appropriate, state-
of-the-art instrumentation.
It is essential that personnel involved in the
commissioning, operation or maintenance of
these sensors or of any of the associated equip-
ment (e.g. housings, transmitters, etc.) be proper-
ly trained in the process itself, as well as in the
use and handling of the associated equipment.
This includes having read and understood this
instruction manual.
The safety of personnel as well as of the plant
itself is ultimately the responsibility of the plant
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operator. This applies in particular in the case of
plants operating in hazardous zones.
The oxygen sensors and associated components
have no effect on the process itself and cannot
influence it in the sense of any form of control
system.
Maintenance and service intervals and schedules
depend on the application conditions, composi-
tion of the sample media, plant equipment and
signi ficance of the safety control features of the
measuring system. Processes vary considerably,
so that schedules, where such are specified, can
only be regarded as tentative and must in any
case be individually established and verified by
the plant operator.
Where specific safeguards such as locks, labels,
or redundant measuring systems are necessary,
these must be provided by the plant operator.
A defective sensor must neither be installed nor
put into service.
Only maintenance work described in this operat-
ing instruction may be performed on the sensors.
When changing faulty components, use only
original spare parts obtainable from your
METTLER TOLEDO supplier (see spare parts list,
“Section 9.4”).
No modifications to the sensors and the acces-
sories are allowed. The manufacturer accepts no
responsibility for damages caused by unautho-
rised modifications. The risk is borne entirely by
the user.
When using cables for sensor connection not
supplied and recommended by the manufacturer
the following standards need to be considered:
• US National Electrical Code
®
(ANSI/NFPA 70
[NEC
®
]), where applicable.
Canadian Electrical (CE) Code
®
(CEC Part 1,
CAN/CSA-C22.1), where applicable.
For guidance on US installations, see ANSI/ISA-
RP12.06.01, Installation of Intrinsically Safe
Systems for Hazardous (Classified) Locations.
Control room equipment connected to intrinsically
safe associated apparatus in the US should not
use or generate more than the specified Um of the
associated apparatus.
Care must be taken during installation to avoid
impacts or friction that could create an ignition
source.
Tampering and replacement with non-factory
components may adversely affect the safe use of
the system.
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Insertion or withdrawal of removable electrical
connectors or modules is to be accomplished only
when the area is known to be free of flammable
vapors.
– WARNING – 
INTRINSICALLY SAFE APPARATUS CAN BE A
SOURCE OF IGNITION IF INTERNAL SPACINGS
ARE SHORTED OR CONNECTIONS OPENED.
– WARNING – 
DO NOT OPEN WHEN AN EXPLOSIVE ATMOS-
PHERE IS PRESENT.
– WARNING – 
SUBSTITUTION OF COMPONENTS MAY IMPAIR
INTRINSIC SAFETY.
– WARNING – 
SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY OF THE EQUIPMENT.
– WARNING – 
FOR CONNECTION ONLY TO NON-FLAMMABLE
PROCESSES.
– WARNING – 
TO MAINTAIN THE ENCLOSURE IP66 RATING,
THE CONNECTOR MUST BE FULLY ENGAGED.
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2.4    Correct disposal of the sensor
When the sensor is finally removed from service, ob-
serve all local environmental regulations for proper
disposal.
2.5    Examples of some typical applications
Below is a list of examples of typical fields of
application for the oxygen sensors. This list is
not exhaustive.
Measurement in gases:
CO
2
recovery
CO
2
purity
Product storage
Inert production
Offgas monitoring
2.6    Use in Ex-zones
Attention!
For an installation in Ex-zones please read the
guidelines following hereafter:
1258
Ex-classification ATEX:
Ex ia IIC T6/T5/T4/T3 Ga/Gb
Ex ia IIIC T69°C/T81°C/T109°C/T161°C Da/Db
Number of the test certificate:
SEV 14 ATEX 0169 X
IECEx SEV 14.0026X
Ex-classification FM approved:
IS/ I, II, III /1/ABCDEFG / T6 Ta = 60 °C
- 53 800 002; Entity
Project ID: 3021227
FM certificate number: FM16US0034X
FM18CA0021X
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2.7    Ex-classification ATEX
2.7.1  Introduction
According to Directive 2014/34/EU (ATEX 95)
Appendix l, lnPro 6XXX*/*/*/*/* oxygen sensors are
devices group ll, category 1/2G and according to
RL 99/92/EG (ATEX 137) may be used in zones
0/1 or 1/2 or 1 or 2 and gas groups llA, llB and llC
that are potentially explosive due to combustible
substances in above stated temperature classes.
For use/installation, the requirements of
EN 60079-14 must be observed.
According to Directive 2014/34/EU (ATEX 95)
Appendix l, lnPro6XXX*/*/*/*/* oxygen sensors are
devices group ll, category 1/2D and according to
RL 99/92/EG (ATEX 137) may also be used in zones
20/21 or 21 or 22 that contain combustible dusts.
The digital sensor circuit is part of a common intrinsi-
cally safe system and is for operation connected to a
separately certified transmitter.
The digital sensor circuit as part of an intrinsically
safe system is isolated from the not-intrinsically safe
electric circuits up to a maximum rated voltage of
375 V and from grounded parts up to a maximum
rated voltage of 30 V.
2.7.2  Rated data
Measuring circuit
Fail-safe ignition protection class Ex ia IIC only for
connection to a certified fail-safe circuit.
Analog O
2
oxygen sensor maximum values
U
i
16 V
I
i
190 mA
P
i
200 mW
L
i
= 0 (effective internal inductance)
C
i
= 900 pF (effective internal capacitance)
Digital O
2
oxygen sensor maximum values
Two-wire current circuit:
U
i
16 V
I
i
30 mA
P
i
50 mW
L
i
= negligible
C
i
= negligible
Note: The above maximum values are each the total
of all individual circuits of the associated intrinsically
safe power supply and transmitter.
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.7.3  Special conditions
The relationship between the maximum permissi-
ble ambient or media temperature and tempera-
ture class, for category 1G applications, zone 0, is
shown in the following table:
   Temperature class          Max. ambient or
                                       media temperature
T 6 68 °C
T 5 80 °C
T 4 108 °C
T 3 160 °C
The relationship between the maximum permissi-
ble ambient or media temperature and tempera-
ture class, for category 1D applications, zone 20,
is shown in the following table:
    Temperature class          Max. ambient or
                                        media temperature
T 69 °C 68 °C
T 81 °C 80 °C
T 109 °C 108 °C
T 161 °C 160 °C
The capacitance and inductance of the connecting
cable has to be considered.
The O
2
Oxygen sensor type InPro 6XXX can be
used in / with the fittings InFit
®
76*-*** or
InTrac
®
7**-***, or in / with other suitable fittings
in potentially explosive areas.
The metal body of the O
2
Oxygen sensors, or the
fittings InFit 76*-*** or InTrac 7**-***, or other
appropriate fitting is optionally included in the
routine pressure test of the system.
The independent fitting used for installation of O
2
Oxygen sensor must be conductively connected to
the equipotential bonding system.
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2.8     Ex-classification – FM approved
2
.8.1  Introduction
T
he following FM control drawing and the standards
l
isted in section 2.8.4 must be observed, where
applicable:
aapappapprapproapprovapproveapprovedapprovedaapappapprapproapprovapproveapprovedapproved
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2.8.2 Rated data
For rated data please observe section 2.7.2
2.8.3 Special conditions
In type of protection intrinsically safe apparatus, the
analytical probes (InPro 6000 Series with InFit 76X/Y
and InTrac 7XX/YY Series housings) equipment is
designated with the following specific conditions of
use.
1. The oxygen sensor shall be installed in compli-
ance with the enclosure, mounting, spacing and
segregation requirements of the ultimate applica-
tion, including a tool removable cover, and is suit-
able for use with FM Approved InFit 76X/Y and In-
Trac 7XX/YY Series Housings.
2. Process temperature no greater than +130 ºC.
3. Maximum permissible working pressure is
12 barg (174 psig).
4. Potential Electrostatic Charging Hazard
To prevent the risk of electrostatic sparking, the
non-metallic surface should only be cleaned with
a damp cloth.
5. Enclosures containing titanium constitute a poten-
tial risk of ignition by impact or friction. Care must
be taken into account during installation and use
to prevent impact or friction.
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2.8.4 Applied standards:
United States Standards
Canadian Standards
Title Number  Issue 
Date 
Approval Standard for
Electrical Equipment for Use
i
n Hazardous (Classified)
Locations – General Require-
ments.
FM Class 3600 2011
Approval Standard for
Intrinsically Safe Apparatus
and Associated Apparatus for
Use in Class I, II & III,
Division 1, Hazardous
(Classified) Locations.
FM Class 3610 2015
A
pproval Standard for
Electrical Equipment for
Measurement, Control and
Laboratory Use.
FM Class 3810 2005
Explosive Atmospheres –
Part 0: Equipment –
General Requirements.
ANSI/ISA-60079-0
(12.00.01)
2005
Explosive Atmospheres –
Part 11: Equipment
Protection by Intrinsic
Safety ”i”.
ANSI/ISA-60079-11
(12.02.01)
2009
Safety Requirements for
Electrical Equipment for
Measurement, Control,
and Laboratory Use –
Part 1: General Requirements.
ANSI/ISA-61010-1
(82.02.01)
2004
Title Number  Issue 
Date 
Explosive Atmospheres –
Part 0: Equipment –
General Requirements.
CAN/CSA-C22.2
No. 60079-0
2005
Explosive Atmospheres –
Part 11: Equipment
Protection by Intrinsic
Safety ”i”.
CAN/CSA-C22.2
No. 60079-11
2009
Safety Requirements for
Electrical Equipment for
Measurement, Control,
and Laboratory Use –
Part 1: General Requirements.
CAN/CSA-C22.2
No. 61010-1
2004
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3
      Product description
3
.1    General information
The oxygen sensor series InPro 6800G/6850iG/
6900iG/6950iG with integrated temperature probe
are used for meas ure ment of oxygen at low and
medium concentrations.
InPro 6xxxiG sensors with ISM
®
functionality offer
Plug and Measure as well as enhanced diagnostics
features.
3.2    Principle
Amperometric oxygen sensors:
The amperometric oxygen sensors of METTLER
TOLEDO base all on the same mearuring principle
according to Clark. However different series are of-
fered, which clearly differ in the number and arrange-
ment of their electrodes and thus in their specifica-
tions:
The measurement system of the InPro sensors
consists of a working electrode (cathode), a
counter electrode (anode), a reference electrode
and a guard ring electrode. The measurement
system is separated from the process medium by
an oxygen permeable membrane.
The measuring technique in principle is alike with
all sensors.
The transmitter supplies a constant voltage be-
tween cathode and anode.
The electrolyte creates a conductive connection
between the electrodes.
The oxygen molecules migrate from the measure-
ment medium through the membrane to the
cathode to which the voltage is supplied and are
reduced. At the same time, oxidation takes place
at the anode.
This causes a current to flow between the anode
and cathode which is directly proportional to the
partial pressure of oxygen (pO
2
) in the process
medium. With digital ISM sensors, the sensor it-
self converts the current into oxygen concentration
and communicates the value to the transmitter.
The guard ring electrode of the InPro 6900iG and
6950i G built into the sensor reduces the oxygen
that migrates to the side of the cathode and can
affect the measurement. The guard ring electrode
therefore enables traces of oxygen to be precisely
determined at even the lowest concentrations.
Note: Please refer to “Section 10Theory of the po-
larographic sensor” for further information.
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ISM Sensors:
All oxygen sensors with the index “i” (6850iG,
6900i G, 6950iG) are equipped with ISM, Intelligent
Sensor Management.
Principle: In the sensor head a chip is integrated,
which takes over the entire monitoring and control of
the sensor and, beyond that, stores all sensor data.
This chip is responsed via the transmitter.
The following data are available permanently in the
sensor:
type of sensor
serial no.
software version
hardware version
order no.
operating time
calibration time and calibration date
calibration table
To check the system, the following indicators are
monitored:
temperature
slope
zero current
air current
polarization voltage
cathode current and voltage
Based on these informations, the transmitter calcu-
lates a wear monitor and displays it depending upon
transmitter type differently. (see the respective in-
struction manuals)
ISM enables the connection of the digital sensor to
the iSense™ Asset Suite. The user-friendly software
allows to manage all sensor information and store it
in a data base. Furthermore, the sensor can be cali-
brated via the iSense software.
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3.3    Enhanced diagnostics 
(
only for ISM types available)
DLI Dynamic Lifetime Indicator The dynamic lifetime
indication allows an estimation, when the sensor in-
ner body is at the end of his lifetime, based on the
actual stress it is exposed to. The sensor permanent-
ly takes the averaged stress of the past days into
consideration and is able to increase/decrease the
lifetime accordingly.
T
he following parameters affect the lifetime indicator:
Dynamic parameters:
Temperature
Oxygen value
Static parameters:
Calibration history
Zero and Slope
The sensor keeps the information stored in the built-
in electronics and can be retrieved via a transmitter
or the iSense asset management suite.
The alarm will be resetted if the Lifetime Indicator is
not 0 days anymore (e.g. after connecting a new
sensor or changes on the measurement conditions)
For amperometric oxygen sensors, the lifetime indi-
cator is related to the inner-body of the sensor. After
exchanging the inner-body, reset the lifetime indicator
in the ISM setup menu (Menu Configure).
TTM Time to Maintenance:                                     
This timer defines when the next electrolyte or mem-
brane replacement should be done to maintain the
best possible measurement performance. The timer
depends on the DLI parameters.
The sensors InPro 6850iG / 6950iG are equipped
additionally with an electrolyte level monitor, ELM.
The electrolyte level monitor, ELM, automatically
sets the TTM to zero as soon as a critical electrolyte
level in the sensor tip is reached.
The alarm needs to be reset in the menu ”ISM setup”.
For oxygen sensors, the time to maintenance indi-
cates a maintenance cycle for the membrane and
electrolyte.
Note: The recommended initial value for the mainte-
nance interval will be uploaded from the sensor to
the transmitter and can be adapted according to the
application experience of the user.
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2
12 mm
InPro 6000 G Series © 12 /18 Mettler-Toledo GmbH
52 206 477 E Printed in Switzerland
ACT Adaptive Cal Timer:                                        
This timer estimates when the next calibration should
be performed to keep the best possible measurement
performance. The timer is influenced by significant
changes on the DLI parameters.
Note: The recommended initial value for the calibra-
tion interval will be uploaded from the sensor to the
transmitter and can be adapted according to the ap-
plication experience of the user.
3.4    Scope of delivery
Each sensor is supplied fully assembled and factory-
tested for correct function together with:
a quality control certificate
inspection certificates 3.1
(complying with EN 10204)
Digital sensors must be filled with electrolyte before
use.
See electrolyte order details at section „Spare Parts“,
9.3.
InPro 6800G/6850iG/6900iG/6950iG O
2
12 mm 19
© 12 /18 Mettler-Toledo GmbH InPro 6000 G Series
Printed in Switzerland 52 206 477 E
3.5    Equipment features
12 mm sensor
METTLER TOLEDO ISM O
2
sensors are supplied with
fitted membrane body but without electrolyte
and covered with the protection cap and have been
checked for proper function.
Anode (Pt)
Cathode and Guard Ring
Protection Cap
Cap Sleeve (N-type)
O-ring (silicone FDA/USP VI)
Membrane Body
Retainer Nut
Reference (Ag/AgCl)
Interior Body
O-ring
(9.0 3 1.0 mm, silicone FDA/USP VI)
Pg 13.5 Threaded Sleeve
AK9 Connector
20 InPro 6800 G/6850i G/6900i G/6950i GO
2
12 mm
InPro 6000 G Series © 12 /18 Mettler-Toledo GmbH
52 206 477 E Printed in Switzerland
4
      Installation
4
.1    Mounting the sensor
Important! Remove the protection cap before
mount ing the sensor.
Mounting the sensor in a housing
Please refer to the instruction manual of your housing
explaining on how to mount the sensor in place.
Mounting the sensor directly on a pipe or a vessel
The 12 mm sensors can be mounted directly through
a socket with inside thread Pg 13.5 and securely
tightened via the Pg 13.5 threaded sleeve.
4.2    Connection
4.2.1  Connecting the sensor to a AK9 cable
Note: The sensor is connected to the transmitter via
a AK9 cable. The AK9 cable ensures a secure con-
nection between the transmitter and the sensor under
harsh industrial conditions. The robust watertight
IP68 connector housing guarantees maximum
process safety.
Do not touch the sensor at the AK9 connector plug!
Tightly screw the plug to fasten the two parts.
Admissible mounting position
Zulässige Einbaulage
Positionement de montage admis
Inadmissible angle
Unzulässiger Winkel
Angle non admissible
5
2910094ME
15 ° 15 °
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