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Service Manual

CO2 Inline Sensor


Carbotec TR-PT

Version V 1_1
Mai 2011

Table of Contents
Table of Contents ................................................................................................... 2
1 Copyright............................................................................................................. 3
2 General notes for the user.................................................................................... 4
3 Content of the Servicekits .................................................................................... 6
3.1 Content of Servicekit I for Carbotec TR-PT (12203130) .................................. 6
3.2 Content of Servicekit II for Carbotec TR-PT (12203100) ................................. 8
4 Maintenance Intervals .......................................................................................... 9
4.1 Maintenance every 6 months (750.000 cycles) .............................................. 9
4.1.1 Back pressure valve in the measuring head ............................................. 9
4.1.2 Replacing the seals of the measuring head ............................................ 12
4.1.2.1 Disassembly of the measuring cylinder ............................................ 12
4.1.2.2 Replacing the PTFE piston seal rings .............................................. 14
4.1.3 Exchanging the Desiccant cartridge ....................................................... 20
4.2 Maintenance cycle every 2 years ................................................................. 21
4.2.1 Maintenance step by step...................................................................... 21
4.2.2 Overview of the air cylinder Seal set ...................................................... 32
4.2.3 Exploded pictorial view of the Air cylinder maintenance .......................... 32
4.3 Maintenance cycle every 4 years (3.000.000 cycles) .................................... 33
4.3.1 Disassembly of the sensor piston........................................................... 33
4.3.2 Assembly of the Sensor piston............................................................... 35
5 Reset of the maintenance counter ...................................................................... 36
5.1 Maintenance counter Piston seals (cycle every 6 month) .............................. 37
5.2 Maintenance counter Piston Bellows (cycle every 4 years) ........................... 38
5.2.1 Rest of the maintenance counter ........................................................... 38
5.2.2 Input of the Constants ........................................................................... 39
6 Addendum Maintenance Manual ........................................................................ 41

2007 Centec GmbH

1 Copyright
This system and this operating instruction are protected author-legally.
The illegal manufacture of the device is pursued legally. All rights at the
operating instruction are reserved, also the rights for any kind of copies,
photomechanical, printed, or on any storage media or also in translated
form. A reprint of this service manual, also in extracts, is only with permission by Centec allowed.
This operating instruction contains a maximally exact description of the
product, however no assertion of specific qualities or commit successes. The operating instruction was checked carefully before it was published. The editors do not take over any liability for damages or follow
up damages neither explicitly nor silently, that result from the application of the operating instruction. For hints on mistake or suggestion and
criticism we are at any time thankful!
Decisive is, not indicated so far differently, the technical state to the
date of the common delivery of product and operating instruction
through Centec GmbH. Technical changes without separated announcement remain reserved, previous operating instructions lose their
validity.
Centec GmbH terms and conditions of sales and delivery apply.

Maintal, 17.06.2011

2 General notes for the user


In the following chapters detailed information is given for the correct use of the device / system.
Should you required any further information, please contact:
Centec GmbH
Wilhelm-Rntgen-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 pictograms (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
respective 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, operation 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
Instructions 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 respective sales contract which also contains the complete and solely applicable warranty conditions. These warranty conditions in the contract are neither extended nor limited by the contents of these Operating Instructions.

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,
installation 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, corrosive media.
- Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
- Is trained in first aid.

3 Content of the Servicekits

3.1 Content of Servicekit I for Carbotec TR-PT (12203130)


The content of the Servicekit I for the Carbotec TR-PT CO2-Sensor is consisting of:
1x Blue Carrying Case Centec with foam plastic (2 pieces)
1x Tool for Piston Seal Assembly
1x Tool for Air Cylinder Assembly
1x Tool for Check Valve Assembly
1x Allen Key 2,5mm
2x Piston Seal Kit (each 1x Plastic Bag 100x150 mm)
Set consisting of:
- 3x PTFE-Seal ring FDA 22x25.2x3 mm
- 3x EPDM-O-Ring 70sh FDA 17x2.5 mm
- 1x O-Ring EPDM FDA 56x2 mm
- 1x O-Ring EPDM FDA 8x2 mm
- 1x Spring Stainless Steel 6x3.8 mm
2x Air Cylinder Seal Kit (each 1x Plastic Bag 120x170 mm)
Set consisting of:
- Axial Face Seal NBR/POM 50x40x11mm
- Rod Seal TPU-PU (26x36x10 mm)
- Clamping Ring (Seeger) I36x1.5 (Stainless Steel)
- O-Ring EPDM 50x2 mm
- O-Ring EPDM 59x3 mm
2x Thread Bolt M4x35 mm
2x Allen Head Screw M4x35 mm
1x 4ml-Bottle Thread Sealant, removable

Figure 1: Content Servicekit I

All components from Servicekit I can be ordered separately as follows:


Table 1: Article numbers of single components

Description
Servicekit I (complete Servicekit)
Piston Seal Kit
Tool Piston Seal Assembly
Air Cylinder Seal Kit
Allen Key 2,5 mm
Tool for Air Cylinder Assembly
Tool for Check Valve Assembly
EPDM O-Ring 8x2 mm with stainless Steel spring
Thread Sealant, removable
Desiccant Cartridge (not shown in figure 1)
4x Thread Bolt M4 (2xBolt+2xAllen Head Screw)

Article number
12203130
12203131
12203132
12203134
12203135
12203136
12203137
12203138
12203139
12203140
12203141

3.2 Content of Servicekit II for Carbotec TR-PT (12203100)


The content of the Servicekit II for the Carbotec TR-PT CO2-Sensor is consisting of:
1x Measurement Piston, pre-assembled with Piston Seal rings,
PTFE-Piston Bellows and upper PEEK-Part
1x Calibration Data Sheet
1x O-Ring EPDM FDA 56x2 mm
1x 4ml-Bottle Thread Sealant, removable
2x 4-edged Ring 1/8

Figure 2: Content Servicekit II (Measurement Piston Set)

4 Maintenance Intervals
To ensure a highly precise CO2-Measurement, Centec recommends to follow the
regular maintenance intervals and to do the maintenance by qualified personnel. In
case of any questions contact Centec. The required maintenance steps have to be
done in a frequency of every 6 months and every 2 years, respectively if displayed in
the sensor screen as alarm messages. The single steps are described in detail in the
following.

4.1 Maintenance every 6 months (750.000 cycles)


4.1.1 Back pressure valve in the measuring head

Figure 3: CO2 Sensor Carbotec TR-PT

In the measuring head of the Carbotec TR-PT is installed a back-pressure valve.


During the maintenance after 6 months, the seal and spring in this valve has to be
exchanged. In figure 3 the position of this valve is marked with red color. For this
maintenance step is a special tool required which is included in the servicekit I together with the required EPDM O-ring 8x2 mm and the stainless steel spring in size
6x3.8 mm.

Figure 4: Opening operation of the back-pressure valve

At first the safety screw of the back-pressure valve must be opened (figure 4). Please
pay attention to the right mounting direction of the screw! The front side has a small
bunch (figure 5.)

Auen

Innen (zur
Messkammer)

Figure 5: Safety screw of the back pressure valve

When the safety screw is removed, the pressure spring and the sealing body can be
seen (figure 6). Remove the stainless steel spring and the PEEK-body. On the body
on the backside is positioned an O-ring 8x2 mm .This O-ring together with the spring
have to be renewed.

10

Figure 6: Measuring head with opened back pressure valve

Exchange the O-ring 8x2 mm, if required clean before the sealing body and the nut.
During installation of the O-ring, care about a proper position in the nut before inserting it back into the measuring head. Install all components in opposite direction, start
with the sealing body, than the spring and as last step the safety screw. Tighten the
safety screw with the tool just by hand, do not use any additional tool like a gripper.
Warning!
Use for tighten the safety screw just the special tool from service kit I, not any additional tool like a gripper! If you would tighten with the additional tool too strong, the
special tool can be damaged or at next service it can become a problem to remove
the safety screw again.

Figure 7: Safety screw with pressure spring, sealing body and O-ring

11

4.1.2 Replacing the seals of the measuring head


To replace the seals of the sensor piston, an Allen key 2.5 mm is required, further a
piston seal set (consisting of 3 white PTFE seal rings and 3 black EPDM O-rings)
and the special tool for the piston seal assembly. All mentioned components of tools
and seals are in scope of supply of the service kit I, or can be ordered separately.
4.1.2.1 Disassembly of the measuring cylinder

Milled slots for the


flat spanner 30mm
to loosening the
housing for the
desiccant cartridge
Figure 8: Measuring head of the Carbotec TR-PT

Before it is possible to disassemble the measuring cylinder of the Carbotec TR-PT,


the stainless steel housing of the desiccant cartridge has to be removed. It can be
unscrew by using a flat spanner 30 mm (figure 8). After that all Allen head screws
M3x16 mm have to be removed, which fix the sensor cylinder to the sensor body
(figure 9).

Figure 9: Unscrew the Allen head screws of the measuring cylinder

12

If all 8 Allen head screws M3x16 mm of the sensor cylinder are unscrewed, the cylinder can be carefully removed. During removing the cylinder from the sensor body,
often the O-ring 56x2 mm sticks in the cylinder head inside. This O-ring has to be
removed from the measuring cylinder. This O-ring has also regularly replaced and is
part of the service kit I. Please care about, that the renewed O-ring is located correctly in its nut of the PTFE-bellows before assembling the sensor cylinder.

Remark!
Before unscrew the Allen head screws of the measuring head, the cylinder of the
desiccant cartridge has to be removed. This can be achieved by using a flat spanner
30 mm.
If the sensor head of the Carbotec TR-PT is removed for renewing the piston seals,
the O-ring 56x2 shown in figure 10 should be always replaced as well. Remind that
the correct position of this O-ring before re-assembling the head is in the nut of the
PTFE-bellows as shown in figure 22.

EPDM O-ring
56x2 mm

Figure 10: Dismantled measuring head, interior view

13

Figure 11: Measuring head with spacer ring

Spacer ring

4.1.2.2 Replacing the PTFE piston seal rings

Figure 12: Carbotec TR-PT sensor with dismantled measuring head or measuring cylinder

Is the measuring head dismantled, the old piston seals can be removed. The easiest
way is to use for this step a knife to cut the old piston seals carefully (figure 13). For
every maintenance, replace always both seals in all three piston nuts, means next to
the 3 white PTFE-piston ring also the 3 black O-rings below (figure 14).

14

Figure 13: Removing the old PTFE piston seal rings

Figure 14: Removing the old EPDM-O-rings

If all old seal rings are removed, the new seals can be assembled by support of the
special fitting tool for the piston seal assembling. This tool as shown in figure 15 is in
the scope of supply of the service kit I or can be ordered separately. Start with inserting the black EPDM-O-ring into the lower piston nut, than into the middle and finally
the upper nut.
Remark:
Always insert first the black EPDM O-rings by using the bottom-up method, than the
white PTFE-rings in the same direction: 1st the lower nut, than the middle nut and
finally the upper nut of the piston.

15

Figure 15: EPDM O-ring fixed on the special tool for the piston seal assembly

Figure 16: Assembling of the EPDM O-ring in the lowest piston nut

16

Figure 17: All 3 EPDM O-rings are assembled on the sensor piston

If all black O-rings are mounted, the white PTFE seal rings can be mounted by support of the same special fitting tool (figure 18). Start by fitting the white PTFE-seal
ring on the special tool as shown in figure 18, than mount the seal ring into the lower
nut of the sensor piston as shown in figure 19. Due to the fact that the PTFE-seal
ring is fairly extended by applying on the fitting tool, the seal ring must be than carefully compressed after positioning in the piston nut. For this step start by carefully
pressing the seal ring in the nut by hand, than follow up with the special fitting tool.
Change the direction of the special fitting tool and compress the seal with the inside
of the special fitting tool till the seal is optimally placed in the nut (figure 20).

Figure 18: Applying a PTFE-Piston seal ring on the special fitting tool

17

Figure 19: Mounting the PTFE-seal ring into the lower nut of the sensor piston

Figure 20: Compressing the PTFE-seal ring with the special fitting tool

Warning!
Mount the white PTFE-rings with the bottom-up method, means start with seal installation in the lower nut, than the middle and finally the upper nut of the sensor piston.

18

Figure 21: Measurement piston with mounted seals

Upper PTFE ring


Warning: During
mounting the sensor
head there is the danger to damage the
upper seal ring by
shearing-off material
of the seal ring!

Seal ring for


the sensor
head (56x2
mm)

Long hole in the


sensor piston
(Opening to replace the sample
in the measuring
chamber)

Figure 22: Sensor piston with all seals ready for mounting the head again

If all piston seal rings are correctly mounted (3x EPDM O-ring and 3x PTFE-seal
ring) is finally the EPDM O-ring 56x2 mm in the nut of the PTFE-bellows to be renewed. Important is, that the old O-ring is removed before. The old O-ring is often
ticked inside of the measuring head (figure 10). After that is done the measuring
head can be imposed on the piston. Care about the right position for the correct flow
direction. The 3 holes in the head must be positioned in the same direction than the
long hole in the piston. Finally bolt down the 8 Allen head screws M3x16 mm into the
measuring head to fix it on the sensor body. The screws must be tightened well.

19

Warning!
During assembly of the sensor head on the piston, take care that the PTFE-piston
seals are not damaged by shearing-off PTFE-material from the seals.
Warning!
Care about that the position of the holes in the head (cylinder) are in same direction
than the long hole in the piston.
The 3 holes in the head (cylinder) and the long hole in the piston must be always located in same direction than the flow in the product pipe. For additional information
please also look into the general user manual for the Carbotec TR-PT).

4.1.3 Exchanging the Desiccant cartridge

Figure 23: Indicator for exchange of the desiccant cartridge

The desiccant cartridge has to be replaced when the blue indicator colour has
changed to a pink colour (figure 23). To exchange the cartridge, the complete black
plastic cartridge has to be unscrewed. In the same way a new cartridge can be
placed by screwing it into the stainless steel cylinder of the sensor.
Remark!
After the made maintenance a calibration of the sensor is in most cases required.
Due to this a comparison to the lab is recommend and if necessary to modify the
product related offsets.

20

4.2 Maintenance cycle every 2 years


With the maintenance cycle every 2 years the seals in the air cylinder have to be renewed. This procedure is extensive and should be done only by qualified personnel.

4.2.1 Maintenance step by step

Figure 24: Opening of the sensor cover plate

The opening of the bottom cover plate can be achieved by using an Allen key 2.5
mm and unscrewing all 6 Allen head screws M3x12 mm. The cover plate is sealed
with an O-ring 59x3 mm, therefore it is not easy to remove the cover plate without
any extra tools. To remove this plate, 2 Allen head screws M4x30 mm are required
which are in scope of supply of the service kit I. Bolt in the 2 screws into the visible
holes on the plate by using an Allen key 3 mm till the plate is loose and can be removed from the sensor housing (figure 25). Care about that the 2 screws are equably
screwed, to avoid any jamming of the cover plate.

21

Figure 25: Removing of the cover plate

After removing the blue cover plate of the sensor bottom, behind is visible the stainless steel cover plate of the air cylinder. Unscrew the visible 6 Allen head screws
M3x12 mm with an Allen key 2.5 mm and remove the screws from the plate.

Figure 26: Removing the screws of the air cylinder plate

22

To seal the cover plate of the air cylinder an O-ring 50x2 mm is in use. Therefore this
plate cannot be easily removed without any tools. To remove the plate a special tool
for the air cylinder assembly is required which is in scope of supply of the service kit
I. Screw the tool into the hole in the middle of the plate with M6-thread (figure 27)
and dismantle the cover plate by careful pulling at the tool. If the plate is sticking to
the air cylinder housing you can dismantle the cover plate by moving and hitting the
metal weight of the tool to the top of the tool till the plate is removed.

Remark!
During removing the air cylinder cover plate care about, that the plate is not jamming.
If the plate is jamming just try to resolve the problem by careful moving of the tool by
hand. Do not use strong force with any other tool to remove the plate. In worst case it
can damage the air cylinder and later the proper function of the sensor.

Figure 27: Disassembly of the air cylinder cover plate with support of the special tool

Inside of the removed cover plate is located an EPDM O-ring 59x2 mm. This O-ring
has to be replaced within this maintenance step as well (see figure 28).

23

Remark!
Use a little bit grease before inserting the new O-ring into the cover plate. This activity would increase the lifetime of the O-ring and the tightness.
Advice:
The used grease should be suitable in food.

EPDM O-ring
50x2 mm

Figure 28: O-ring in the cover plate of the air cylinder

Figure 29: Disassembly of the Air Cylinder Piston

24

When the cover plate of the air cylinder is removed, you can see the piston of the air
cylinder inside which is fixed with 3 screws (figure 29). Unscrew these 3 Allen head
screws M4x20 mm and remove the screws from the piston. The piston is trapped by
the piston seal and cannot by removed easily. For this step is again used the special
tool for the air cylinder. Screw the end of the tool into the visible hole with M6-thread
(see figure 30) and pull by slight hits of the movable tool weight the piston out of the
air cylinder.

Figure 30: Removing the piston from the air cylinder

The air cylinder piston seal has to be renewed and is in the scope of supply of the
service kit I. Care about the right direction of the orange slide ring! The orange slide
ring has inside a nose-piece, which must be directed to the black seal ring. In figure
32 is shown a cross section of the orange slide and black seal ring for your support.
Insert this seal in the right direction to avoid any jamming of the piston during reassembly.

25

Figure 31: Disassembled air cylinder piston with piston seal

Warning:
For mounting the piston seal do not use any sharp tools which can damage the seal.
Remark:
Use a little bit grease before inserting the new piston seal O-ring on the piston. This
activity would increase the lifetime of the piston seal. Care about the right position of
the orange slide ring!
Advice:
The used grease should be suitable in food.

Figure 32: Cross section of the black seal ring and the orange slide ring

26

When the piston is removed out of the cylinder you will have a direct view on the piston rod of the sensor. To replace the piston rod seal (figure 33), the measuring cylinder (head) must be dismantled. The procedure how to dismantle the sensor head
can be seen in detail in chapter 4.1.2.1 Disassembly of the measuring cylinder.

Piston rod seal

Figure 33: Sensor with disassembled piston

After removing the measuring head as described in chapter 4.1.2.1, the piston rod
can be pushed outside of the cylinder. If this is done, the piston rod seal can be renewed, not before.
Warning:
Push the piston rod slowly and carefully to avoid any damages of the measurement
cable inside of the rod. The maximum position of the piston to be pulled out to the top
is shown in figure 34.

27

Figure 34: Pushed back piston rod

Figure 35: Sensor with pushed back piston rod

28

Figure 36: Disassembly of the piston rod seal

After the piston rod is pushed back, the piston seal can be removed. For this maintenance step remove the Seeger ring at first as shown in figure 36. The Seeger ring is
fixing the piston seal in the right position. After the Seeger ring is disassembled, the
old seal can be removed by support of a screw driver.
For the assembly of the new piston seal use the special tool for the air cylinder assembly with screwed termination insertion tool piece on top. Fit a new piston seal on
the termination insertion tool (care about the right direction!) and put a little bit grease
on the seal to make the installation easy. Afterwards - as shown in figure 37 - insert
the new seal with support of the special tool to the final position in the cylinder. Finally fix the position of the seal with a new Seeger ring. All required components are in
the scope of the service kit I or can be ordered separately.

Warning!
Push the piston rod seal with the tool in the final position, so that the Seeger ring can
be correctly fixed in its nut. Is the Seeger ring not correctly positioned in the nut, it
can later damage the sensor during function.
Remark:
Use a little bit grease at position of the piston rod and piston rod seal, where these
two parts are in contact. This activity would increase the lifetime of the piston seal.
Advice:
The used grease should be suitable in food.

29

Correct insertion
direction of the
piston rod seal

Figure 37: Installation of the piston rod seal with the special tool for air cylinder assembly

To assemble the sensor piston afterwards correctly, the piston rod has to be pushed
down again. For this step arrange the sensor on a table and push by hand on top of
the measurement piston. During this procedure the piston rod will slowly go back into
the starting position.
After that screw the two threaded bolts M4x35mm of the service kit I into 2 of the 3
visible holes of the air cylinder piston and position the piston with support by the special tool for the air cylinder assembly. Is the piston correctly positioned and in the
guide on the piston rod, push the piston down into the cylinder (see figure 38).
Is than the piston located in the final position, the 2 threaded bolts can be removed
and the piston fixed with the 3 Allen head screws M4x20 mm. Tighten these 3 screws
well.

30

2x Guiding
bolts M4x35

Figure 38: assembly of the air cylinder position with guiding bolts

After the 3 screws of the air cylinder are tighten well, the air cylinder cover plate can
be fixed with its 6x M3x12 mm Allen head screws. Finally put the blue housing plate
on top and screw this plate as well with its Allen head screws M3x12 mm.
Warning!
Insert the plates carefully and slowly to avoid any jamming. It is recommended to
torque down the plate screws cross-over.

31

4.2.2 Overview of the air cylinder Seal set

2
1

4
5

Figure 39: Overview components of the air cylinder seal set

Component
Component
Component
Component
Component

1:
2:
3:
4:
5:

Air cylinder piston seal


Air cylinder piston rod seal
50x2 mm EPDM O-ring for the air cylinder cover plate
Seeger-Ring J36 to fix the air cylinder piston seal
59x3 mm EPDM O-ring for the blue housing cover plate

4.2.3 Exploded pictorial view of the Air cylinder maintenance

Figure 40: Exploded pictorial view of the air cylinder

32

4.3 Maintenance cycle every 4 years (3.000.000 cycles)


The 4 years maintenance cycle requires the exchange of the sensor piston with integrated pressure and temperature transmitter, further the PTFE-bellows. For this
maintenance step is the service kit II Replacement Piston (art-no.: 12203100) required. The service kit II is including a complete measuring piston with preassembled PTFE-bellows. Required tools for this assembly are a 10 mm socket key
and a 2.5 mm Allen key.

4.3.1 Disassembly of the sensor piston


Start with disassembling of the sensor cylinder (sensor head) with a 2.5 mm Allen
key, before as shown in chapter 4.1.2.1 Disassembly of the measuring cylinder the
stainless steel body for the desiccant cartridge has to be removed.

10mm lock
screw

Figure 41: Position of the 10 mm lock screw

After dismantling the sensor cylinder, the sensor piston is visible as shown in figure
41. The sensor piston is including in a combined pressure and temperature transmitter. To remove the old piston, start to unscrew and remove the two 10mm lock
screws at both sides of the sensor neck. Behind these two lock screws are now two
Allen head screws M3x8 mm visible, which have to be unscrewed as well with a 2.5
mm Allen key. These two screws are fixing the sensor piston on the piston rod and
are secured with removable thread locker. Due to this the required force to loosen
these two screws might be higher than expected (figure 42).

33

Allen key 2.5 mm

Figure 42: Removing the 2 Allen head screws M3x8 mm

Important!
Before the new piston is bolt down with the 2 M3-8 mm Allen head screws, clean the
thread from the old thread locker and put some new thread locker (removable version!) on the screw threads. The right removable thread locker is part of the servicekit I and II and filled in a small white 4ml- bottle.
Are the 2 Allen head screws M3x8 mm are completely removed, the piston can be
pulled out from the piston rod. Please care about the measurement cable inside of
the rod, therefore pull the piston by hand carefully and not with strong force max. 3-5
cm out of the piston rod.

Figure 43: Removing the coupling device

34

4.3.2 Assembly of the Sensor piston


To insert the new sensor piston, make the assembly in reverse order. Please do not
forget to tighten the screw which is fixing the measurement cable underneath the
sensor piston before inserting it into the piston rod.
Care about the right position of the sensor piston. The two Allen head screws M3x8
mm to fix the piston in the rod have to be treated with removable thread locker.
Depending from the sensor position in process two installation options are possible
(installation in a horizontal or a vertical pipe). This is described in detail in the general
user manual of the Carbotec TR-PT.
Important!
Attend the later sensor position in the process line, depending from this the sensor
piston and head has to be adjusted. The procedure therefore is described in the
general user manual of the Carbotec TR-PT.
Further do not forget to use removable thread locker for the 2 Allen head screws
M3x8 mm which are fixing the sensor piston. This is important that any unscrewing of
these 2 screws during the normal sensor function is avoided.
After the measuring cylinder and the stainless steel housing with desiccant cartridge
is mounted again, the sensor is ready again for installation in the process.
Remark!
After the maintenance a sensor calibration is in most cases required. Therefore it is
recommended to cross check the products with corresponding lab values.

35

5 Reset of the maintenance counter


After made maintenance (exchange of the piston seals or exchange of the complete
piston) the respective maintenance counter have to be set back. This is required, that
also the warning messages on the sensor display will disappear again. For setting
back the counter, the menu point Maintenance has to be opened (figure 44) and the
settings modified.

Figure 44: Menu Screen Maintenance

36

5.1 Maintenance counter Piston seals (cycle every 6 month)


The maintenance counter for the piston seals exchange can be set back in the menu
Maintenance (figure 44) by selecting the menu point Piston seals. When you have
selected the menu point Piston seals (figure 45), press the arrow key up or down,
the question Piston seals Exchange? will than appear automatically. Choose the
respective answer Yes or No and confirm your choice with the blue Enter-button.
The counter is than automatically reset.

Figure 45: Reset of the maintenance counter Piston Seals

Remark!
In case you get into this menu point just by mistake respectively you have not made
a maintenance, confirm the question with the answer No. In case you would confirm
here with Yes the counter would be reset. The danger will than arise, that the sensor will not run properly with the time or in worst case it will become any damages.
Important!
After renewing the piston seals all product specific calibration factors have to be rechecked with corresponding lab-values for each product.

37

5.2 Maintenance counter Piston Bellows (cycle every 4 years)


5.2.1 Rest of the maintenance counter
The maintenance counter for the piston bellows (boot) which is automatically replaced with a new sensor piston can be set back in the menu Maintenance (figure
44) by selecting the menu point Boot. When you have selected the menu point
Boot (figure 46), press the arrow key up or down, the question Boot Exchange?
will appear automatically. Choose the respective answer Yes or No and confirm
your choice with the blue Enter-button. The counter is than automatically reset.

Figure 46: Reset of the Maintenance counter Boot

Remark!
In case you get into this menu point just by mistake respectively you have not made
a maintenance, confirm the question with the answer No. In case you would confirm
here with Yes the counter would be reset. The danger will than arise, that the sensor will not run properly with the time or in worst case it will become any damages.

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5.2.2 Input of the Constants


When the sensor piston is replaced, the constants of the pressure measurement
which is integrated in the sensor piston have to be modified as well. The sensor constants you will find on the calibration data sheet which is always added to a new sensor piston (service kit II). For inserting the new constants you have to choose the
menu point Maintenance (figure 44), further the sub menu point Pressure Sensor
(figure 47). Insert the new constants into the menu and confirm with the blue Enter
button. An example for such a calibration data sheet is shown in figure 48.

Figure 47: Menu Screen Pressure Sensor

Remark!
After made exchange of the sensor piston with bellows (boot), the sensor constants
have to be modified as well. The new sensor constants you will find on the calibration
data sheet which is added to the new sensor piston.
Remark!
After inserting the new sensor constants into the menu of the Carbotec TR-PT, the
sensor has to restart (reboot) again. If this is not done, the sensor will calculated still
with the old constants and can lead to wrong calculated CO2-values.
Important!
After renewing the sensor piston all product specific calibration factors have to be
rechecked with corresponding lab-values for each product.

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Figure 48: Example for a calibration data sheet

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Serial number: _____________________

Sensor Piston

Performer

Air cylinder Seals

Date

Piston Seals

6 Addendum Maintenance Manual

Signature

Date of the next


maintenance