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1. EI 4 00 sc Print Off START 20 ig 204 int 390 Se Angle 392 Feedback 256 5 AUX 1023 C Offset adjustment see section 3 7 1 on page 127 This function is accessed in the main menu Offset If you have made a fine calibration and subsequent checking reveals that it is not correct you can use the Offset function Note that the setting should not be altered until the erroneous reading has been confirmed by sev eral laboratory samples The function operates by displacing the whole calibration curve and lo cating it with a laboratory sample You store the cons value in the memo ry at the same time taking a laboratory sample and then load the resulting data in the normal way Ifthe offset adjustment needed is already known the value can be directly entered Any compensation currently applied can be read directly from the Offset display and erased or altered at the next check A valuable way to use this function is to compensate for coating of the sensing element as for example happens in certain types of bleach plants Coating on the sensor causes the signal to rise It is possible to tell from experience when the sensing element has become so thickly coated as to interfere with the functioning of the transmit
2. sample gt and coll xD E S EE F Cali ial SE This function will be found under Sate EZ The function is used for manual loading of various feedback values for calibration for example when replacing a card or if you have lost or want to alter a feedback value gt For training in the operation of the transmitter this function together with entering lab values is a very useful aid See section 3 13 Training F Calibration curve see section 3 7 5 on page 136 a 3 E Calib The function is found in the main menu under ration To assess the calibration it is possible to see directly how well the cali bration points entered agree with the calculated calibration curve The three calibration constants KO K1 and K2 and the correlation factor D constanta Blears ejer 1 38 H 83 2 r can also be seen Bi The resolution ofthe display can be adjusted to zoom in an area for better readability G Trend see section 3 7 6 on page 136 This function is found in the main menu under Here you can see directly the output signal s trend and stability This is important when setting the right time constant damping The resolution ofthe display can be adjusted by varying the trend display from 0 5 minutes to 0 55 minutes Thi
3. xw 0 61 7 100 Cons 3 35 ch 01218 56 3en MEK 2300 Operating instructions 81 BTG 2004 3 4 Operating the transmitter SPC 1000 Communication Terminal 1 1s Calib ration curve Send data mmm 0 61 7 100 Cons 3 35 i SPC 1000 Communication Terminal Offset Calib Ka a a SPC 1000 Communication Terminal SPC 1000 Communication Terminal SPC 1000 Communication Terminal Setting the maximum consistency of the measuring span Setting the time constant damping 1 99 seconds Used for zero point offset of the calibra tion curve directly or against a laboratory sample Sends the terminal settings to the transmitter The transfer can be protect ed against unauthorized action by using a code lock Other functions Factory settings code protected Back up data from the termi nal s second memory if the editing memo ry data is lost or when using the back up card Simulation function for manipulation of the settings without disrupting the output signal 82 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 4 Operating the transmitter a Prints all calibration data and tr
4. 50 MEK 2300 Installation instructions BTG 2004 11218 56 3en 2 6 Installing the junction box type JCT 1100 2 6 Installing the junction box type JCT 1100 For information regarding Installation instructions for the JCT 1100 junction box see the Installation instruction section of the JCT 1100 manual included in this manual 2 Quick start checklist When you are confident your MEK 2300 has been correctly installed and you are ready to power up the system for calibration and or testing you should run through this brief check list before powering up Using this list can help ensure trouble free initialization of your system gt To ensure that the measuring vessel weld in bulb and the transmitter is correctly installed and free from leakage it is recommended to pressure test the system with water The pressure should be kept higher than the rating according to applicable regulations 1 Check that the inspection cover if any is properly tightened 2 Where applicable check that there is a supply of flushing water to the mechanical seal and that the water is draining as it should 3 Ensure that the system is turned OFF before attaching the sys tem cable to the transmitter Note Tighten the system cable contact hard 4 Check all wiring 5 Switch on the main power supply 6 Connect the hand held terminal to the junction box Switch it on and check that the display lights up 7 Switch on the electri
5. Action Empty the line and adjust FEEDBACK IN AIR to the correct val ue Enter the relevant value for FEEDBACK IN WATER in the pro gram gt In case of very low consistencies it may be advantageous to measure the actual FEEDBACK IN WATER at actual operating temperature and enter the result as sample 0 This is then made at 58 check that the value is activated and calculate the new calibration Symptom 4 Wide scatter of calibration points round calibration line low correlation factor Action Check the sampling equipment and quality of sampling methods This is the commonest cause of lack of precision in calibration You can also try deactivating the most deviant samples Does the feedback signal fluctuate wildly If so the probable reason is that the transmitter is measuring in non homogenous badly mixed pulp Check transmitter location it may not be located correctly refer to the Installation instructions for advice on relocation 01218 56 3en MEK 2300 Operating instructions 121 BTG 2004 3 6 Calibration Symptom 5 Insensitive signal The calibration line has a low gradient Action Replace the sensor with a larger one The size of the sensor is the primary factor with regard to sensitivity so replacing it is always the first thing to do If this is not possible an alternative is to re adjust the Feedback resolution An MC transmitter which brakes 100 feedback at a torque of
6. max ca 2m 6 6ft 134 5 3 SEC ec unication Terminal 2 3 2 4 Materials All the materials used in the exposed surfaces of the MEK 2300 system are designed and manufactured for use in pulp and paper mill environ ments The system cable is sheathed in PVC The transmitter housing is made of cast aluminum painted with epoxy poly urethan paint Materials used in the submerged parts of the transmitter i e the transmit ter itself any measuring vessel used and any weld in stud are selected based on process conditions and may be of either stainless steel 254 SMO or Hastelloy C 11218 56 3en MEK 2300 Installation instructions 11 BTG 2004 2 4 Planning the installation 2 4 Calculate the dilution water control valve correctly and use a high quality precision actuator Make sure that the dilution water pressure is stable and that the water is injected at high velocity into the pump suction Correct dilution is essential to ensure reliable transmitter operation Planning the installation 2 4 4 Advice and recommendations The MEK 2300 is a precision instrument designed to provide accurate and reliable measurements over a long period of time To make sure of obtaining the best possible results please note the following recommen dations and advice when planning your installation Dilution Dilution water should be pressure controlled or otherwise protected from ma
7. 108 3 6 4 Updated calibrauons 48h aww Sedes e DEE ena 110 3 6 5 Calibration with given constants 111 3 6 6 Evaluation and documentation of calibration 112 3 6 6 1 Print out documentation 112 3 6 6 2 Documenting calibrations see Fig 58 with printer or manually 112 M218 56 3en MEK 2300 Table of contents II BTG 2004 3 6 6 3 Documenting calibration using the back up card 117 3 6 6 4 Documenting calibration using a personal computer PC 119 3 6 6 5 Evaluating calibrations EE 120 3 6 6 6 Manual calculation of calibration constants KO K1 and K2 124 3 6 7 Setting time constant damping 125 3 6 8 Setting measuring span and alarm limits 126 3 7 Special calibration functions 127 3 7 1 Offset adjustment EECH 127 3 7 2 Compensation for varying Temperature 129 3 7 3 Manual loading of feedback settings nunana aaea 132 3 7 4 Altering Feedback resolution annaua aaau 133 3 7 5 Ree EE 136 3 7 6 TIS EE 136 3 7 7 Simulation DEE ee EE ln ege Rane ie Week Sw ER eoe tetas 137 3 8 Production calculation x geet EN og box ER n2 138 3 9 Code protection eg daa oun QU RUROE a eee a Ce ares ae 140 3 10 Back up memory 2 2 3 T Ee Be SRG EG edu Pl ede ewe 142 3 11 Trouble shooting functions 2 esee pee pedum Ee de ds 143 3 11 1 Checking measured set values nnna anaana 143 3 11 2 Service functions and signal calibration
8. 3 12 Altering sensor transmitter data Fig 64 guidance Sensing elements are made in a number of basic designs A B C etc each of a certain size 1 Sensing elements are available with a choice of fastening systems see Service Manual 2 Different materials are also available The standard material is SS 2343 AISI 316 stainless steel Other options are Hastelloy C 276 254 SMO and rubber clad types for abrasive media 3 Different sensing elements fit different models of transmitter 4 Each sensing element is adapted to a given range of consistencies but the type of fiber also influences the choice The figures given for maximum and minimum consistency are only approximate Consult BTG about the choice of sensor because there are many variables to be taken into account 5 Sensing elements type D and E are not recommended as first choice If possible use type G J Test shows that the transmitter is less influenced by flow velocity changes and other non consistency related factors using type D and E Always consult BTG about the choice of sensing elements and propellers c The Tables in Fig 65 Fig 64 refers to the MEK family and is available in MEK MPK 2000 series MEK MPK 2200 series and in the MEK 2300 series Example sensing element G is valid both for MEK 2210 and MEK 2310 Ordering nos Propellers for the MEK family Fig 65 Choice of MEK prope
9. ON TE ZHOS 19 8AA YIVQPI J 9T CIXX 0IXX 9o91 CIXX 0IXX CIXX DINN Koll CIXX OLXX OCXX OVXX FINN 00XX VIXX 00XX 9 90 01 VIXX 00XX OCXX AGS OVXX FTXX 80XX 00XX OCXX OVXX FINN 00XX VIXX 00XX 9 FINN DUNN OCXX O S OVXX FIXX 00XX S OCXX ST OL OVXX FINN 00XX VIXX DUNN AST FINN DUNN OCXX AST OVXX FIXX 00XX ywy roddn yuy 4oA40 00 c 00cc 000c IFUL 2uojsisuo od A 193jrursueJ AIS EPET SS AIS EPET SS Our Teqqmi OWS FS AIS EPET SS EPET SS Our Kee Kl OWS FS AIS EPET SS EPET SS PAMA PAMA ONS vSC AIS EPET SS EPET SS Terje ATI EL AIA Sjuauro o SuIsUaS 60 90 vL LTS89TYL P IC 99CSOOEL Sir Salz TOSP6T el 6vv6CTET cIC8IeL 9099L0 L TCL81TEL T666v0 L Correll LOV6ETET 660C8T EL VS9cLOEL L8680T EL L99 00 L X S8rV6TET LLVYV6TET III M L6981I L PO98SOEL suluajsey INSLIO IVIeYD M S PIA ou SULPpIO ILT ISIV peoejdoz sey OWNS PST i9 0N eotoqo ISJ se popuoururooo1 JOU o1e pue F A 939N xx pesn jou A jyeuurou St 3uounsn pe uonnjoso1 xoeqpooj sm p 930N x 69vv6TET S68V000V L68861 L CC886T EL ISpporel L887000V 688861 EL VI886I L brbroleL 6L87000V TL886T EL 908861 EL suluajsey A999s sauids OU SurLiopJ OI218 56 3en MEK 2300 Operating instructions BTG 2004 146 3 12 Altering sensor transmitter data
10. 144 3 12 Altering sensor transmitter data 145 3 13 Eo Ae elt kat ee oe ba cot oe pel ee 149 3 14 Trimming the controller i225 RE RR Sii etu eee ous Hs 150 3 15 Using the HART communication 151 3 15 1 Digital communication according to the HART protocol 151 3 16 Software revisions EE 152 3 16 1 SPC 1000 hand held terminal nonna anaana aaa 152 3 16 2 SPC 1000 PCMCIA sensor can 152 3 16 3 MEK 2300 sensor processor card E prom 00 0005 152 3 17 Maintenance Planning and Quality Assurance 153 3 17 1 Inspection of the accuracy calibration of the consistency transmitter 153 3 17 2 Recommendation concerning transmitters used for simpler measurements e g for indicating purposes 154 3 17 3 Recommendation concerning transmitters used for measuring control function of vital importance to the process 154 3 17 4 Recommendation concerning transmitters used for measuring control function of vital importance to the process or used for debiting purposes 154 3 17 5 Maintenance of the transmitter 154 3 17 6 Maintenance of the junction box 155 IV MEK 2300 Table of contents M218 56 3en OBTG 2004 4 JCT 1100 Junction box appendix 157 4 1 PROGUGE IMIFOCUCHION 4 3 223 2 3 2 0 4 Caen ROC EE 157 4 1 1 System description ssis per EE 157 4 1 2 Technical data Ehe EE Ee 158 4 1 3 Ke Le EENEG 160 4 2 REVISION information ius EEN
11. 3 Then load the corresponding laboratory sample value cm xx The consistency according to the original curve appears in the display and after pressing the offset consistency ap Offset pears inthe xx key in the main menu 4 Press ages to transfer the offset adjustment to the transmitter 5 The offset adjustment can be cancelled at 8668 if you give the input the value zero OI218 56 3en MEK 2300 Operating instructions 127 BTG 2004 3 7 Special calibration functions B Offset adjustment based on a deviation that is detected A deviation can be entered directly if a deviation from the laboratory val ues is detected during regular monitoring of a transmitter s display for example Note however that the deviation should be verified by several laboratory samples before carrying out zero point adjustment Procedure Offset X Xx5 1 Goto the main menu function 2 Press SEE inthe sub menu and enter the deviation that is detect ed 3 Transfer the value to the transmitter using ZE Clearthe value by going back to the function and entering 0 128 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 7 Special calibration functions 3 7 2 Compensation for varying temperature See section 3 6 1 2 on page 96 item D This function will be found in main menu sub menu gure button as signed 29
12. AN et OW 6L T AN 9606C OIN 949 ON Lx OIN L ON 9464 OW 01 ON 96914 OIN ZI1 ON 0Z ZH09 J93EAA 9E qpo9 1 ON O OIN 96 T4 ON ST OIN 966 ON 9494 OIN 9 ON Lx OIN 948 ON 95 T4 OIN OT ON LT ZHOS 19 8AA YIVPI2 J yuy Aaddn yu 13m0 IFUL 2uojsisuo CIXX OIXX CIXX OIXX iAUO STXX TIXX SIXX CIXX HXX 01XX CIXX OIXX CIXX VIXX iAUO STXX TIXX SIXX CIXX HIXX 01XX CIXX OLXX CIXX VIXX iAUO STXX TIXX SIXX CIXX TIXX OXX CIXX OIXX CIXX VIXX iAUO STXX TIXX SIXX CIXX 1IXX 00XX 00 c 00cc 000c ad Aj 1ojrusue EPET SS EPET SS OWS vSC AIS Epez SS EPET SS OWS YST AIS Epez SS EPET SS OWS br AIS Epez SS EPET SS OWS vSC AIS Epez SS EPET SS EPET SS E 8 SIT 8ETLTITL SL 6STEL 8 007 St V E E cu JDSLEI9JOEIEW 3 VPPOLIEI LLLESTEL 66 6 1 l 9T 6 I I SSE8TTEL 90SOZTET ELEOETEL S8ZIPIEL SOLOETET OLIPEIEL PLESTTEL B6rOZTET 98LTOOEL suluajsey A992S PIA ou SULPpIO 0 886I L 19 9000V IA S6L6StVL 9000V 0986S rL L8LOSEPL 9v 9000V CS86S EPL 6LLOSEVL 8 9000V SP86SEPL T9LOS EPL suluajsey A999Ss sauids OU SurLiopJ 147 instructions ing ins MEK 2300 Operat BTG 2004 OI218 56 3en
13. Ensure that the transmitter is anchored solidly during installation A transmitter weighs approximately 40 kg 88 Ib Construct a platform if the transmitter is located high up This platform will make it easier to fit and start up the transmitter and carry out service in the future The rubber quality of the transmitter flange seal O ring should be selected to suit the current medium The O ring supplied is suited to the current criteria Fit the transmitter using the 15 screws nuts and washers supplied Lubricate and tighten the screws alternately using a torque wrench Tightening torque for 8 mm screws nuts 24 Nm 2 4 kpm 17 7 Ibf ft Tightening torque for 10 mm screws nuts 47 Nm 4 7 kpm 34 7 Ibf ft Original screws are secured against vibration by means of nylon locking devices When the transmitter has been installed test pressurisation should be carried out using water in the pipeline The test pressure is adapted to standards and regulations in each country In some lines for which inspection is required pressure test must be carried out before the product can be commissioned A hazardous voltage is used to drive the electric motor The motor may only be connected by a qualified electrician in accordance with instructions The motor earth should be connected correctly and checked A safety switch should be located in the immediate vicinity of the transmitter in order to facilitate work on the motor and trans
14. For more information see section 3 3 5 on page 73 All transmitter settings calibration data and transmitter data can be stored on a special SRAM memory card This is the back up card The card replaces the standard sensor card which holds the transmitter pro gram The back up card can store up to 125 complete different transmit ter settings for all four measuring ranges For practical reasons it is preferable to store only one mill section s transmitters Tag No on one card A Storing the transmitter s data on the back up card Store data 1 Make a standard complete calibration and adjustment of the relevant transmitter 2 Switch off the hand held terminal and replace the sensor card with the back up card 3 Switch on the hand held terminal Press BACKUP CARD The message for this function is displayed only in English 4 Select the relevant storage position For example in the case of stor 10 age position No 34 of 125 press three times 30 and four times 4 30 4 34 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD 10 1 STORE DATA SPC 1000 gt BACKUP CARD READ DATA BACKUP CARD gt SPC 1000 1 125 0 STORE 10 1 READ DATA DATA SPC 1000 Communication Terminal STORE Backup card SPC 1000 74414152 5 Then press tara to
15. Position the new card with the front fac ing the front of the terminal and insert the card fully into the slot The two types of cards are used as required The memory card must be handled with care and protected from mois ture extreme temperatures and direct sunlight Do not bend or twist the card c Handle the memory card with care Store it in its plastic wallet if it is not fitted in the terminal 3 3 6 Setting Display All normal settings are made via the hand held terminal s touch screen All displays are provided on the touch screen The touch screen s LCD read angle can be adjusted when necessary via a covered hole at the back of the terminal marked DISPLAY CON TRAST The read angle is set by the factory for normal room tempera ture but may need to be changed particularly at very high ambient temperatures c The read angle need not be adjusted for normal use 3 3 7 Operating and cleaning the hand held 74 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 3 Hand held Terminal SPC 1000 terminal 3 3 7 1 Operating As mentioned earlier the terminal should be handled with care and not subjected to mechanical damage immersed in or sprayed with water When communicating with the sensor the hand held terminal is normal ly placed in the special terminal holder installed on a wall close to the junction box c To prevent the terminal being sprayed with water when in the wall holde
16. The resulting calibration is good within a wide range about 1 consis tency from the calibration point This method can be used only with sensor B O1218 56 3en MEK 2300 Operating instructions 93 BTG 2004 3 6 Calibration B Single point calibration see section 3 6 3 2 on page 105 This method is used to get started quickly and obtain a output signal and in cases where the consistency is not allowed to vary for purposes of cal ibration This method is used to get started quickly and obtain an output signal and in cases where consistency must be stable due to calibration A single point calibration is based on one single calibration value A cal ibration point is achieved by entering the topical raw signal feedback and simultaneously extracting a lab sample The calibration will now be correct at that point but may deviate to a greater or lesser degree at other consistencies depending on the type of pulp and the sensor fitted c Since single point calibration is based on a single sample the output signal cannot be linearized and will therefore not be so exact Multi point calibration is preferred to get an exact calibration with a linearized output signal The measuring span is adjusted to the desired interval later via the 4 mA and 20 mA buttons in the main menu c Single point and Multi point calibration are combined in the program where they are simply called CALIBRATE but are treated
17. e Use sealing water of a good quality standard for the flushing water for the mechanical seal Make sure the flushing sealing water pressure is maintained at all times This is especially important for the MEK 2320 variant e The main power voltage frequency must be within acceptable limits and be protected against transient sources such as electrical storms or other electrical equipment Make sure the signal cables are located far away from the power cables 11218 56 3en MEK 2300 Installation instructions 5 BTG 2004 2 2 Before you start 2 2 e Ifthe transmitter must be installed high up or in some other position where it will be difficult to reach a platform should be built to provide easy unit access for service and inspection A platform is also a good solution for positioning the sampling valve Install the sampling valve a BTG valve is recommended close to the transmitter This way the lab sample will be identical to the sample measured by the consistency transmitter Before you start 2 2 1 Introduction This manual contains instructions for planning and implementing the in stallation of the BTG MEK 2300 in line consistency transmitter The MEK 2300 is the basic model in a series of highly specialized trans mitters optimized for their individual application ranges If you are in doubt about whether the model you plan to install is the same in all respects as the model described in this
18. operational pressure depends on the temperature Max medium temperature is 120 C at max approved operational pres sure 8 bar 248 F at 116 psig 3 Material 54 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 8 Type sign explanation AISI 316 SMO 254 Hastelloy C 276 Actual material qualities AISI 316 SS 2343 See also data sheet D750 01 4 VO VO is the BTG internal manufacturing number 5 DN Connection Pipe size connection and flange standard for measuring vessel DN 100 4 in 125 5 in 150 6 in 200 6 in 250 10 in Flange standard DIN 2642 AISI 150 lbs and other standards 6 Text When using the weld in stud make strength calculations Guidance is given in section 2 5 2 2 11218 56 3en MEK 2300 Installation instructions BTG 2004 55 2 9 Miscellaneous 2 9 Miscellaneous 2 9 1 Dimensioning of the dilution water valve for consistency control Calculation of dilution water quantity Q Required data Production t h P Uncontrolled consistency C1 Desired controlled consistency 9o C2 2 9 1 1 Calculation formula for dilution water flow Px100 C1 C2 _ C1x C2 Qh Example Production 8 t h Uncontrolled consistency 3 Desired controlled consistency 2 5 2 9 1 2 Dimensioning of the dilution water valve Calculation formula for the capacity factor K X p KY 1000 x Ap NOTE C K x 1 155 Ky Capacity factor m h Q
19. separately in the instructions c When you select Calibrate in the main menu the display gives you calibration functions Fig 56 Calibration functions MEMORY CARD 4 20mA MODEMPRINTER PWR ON OFF EJECT menu Calc S Take E new gpecial sample S const c ae tiop lt Take san le gt and Ee ct sample 2 n m lab gvaluatio ion push vale d lab 3 Push PEST Mom Geese calculate the new SE EE func gt _are used to manually raw signals or cal constants Communication Terminal L 94 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration C Multi point calibration see section 3 6 3 3 on page 108 Multi point calibration is used to obtain high precision it takes full ad vantage of the potential of the software Multi point calibration is based on the proposition that the consistency may be changed signals for different consistencies are stored in the sys tem memory When laboratory consistency data are later entered the mi croprocessor can use the input data and a mathematical formula See below to compute the linearized output signal Formula Feedback KO K1 x cons K2 x cons 2 The calibration curve is now determined by three CALIBRATION CONSTANTS KO K1 and K2 see section 3 6 5 on page 111 mm The more points you have and the wider they are spread within the E measuring spa
20. 100 240 V AC 50 60 Hz 85 264 V AC 47 63 Hz max 50 VA automatic setting Output voltage 24 V DC regulated Or Customer provided 24 V DC regulated voltage 24 V DC 10 max ripple 240 mV peek to peek total regulation 2 Maximum 50 VA for AC supply or Maximum 600 mA including hand held terminal 200 mA for 24 V DC supply Standardization and approvals Standardization Quality assured in accordance with ISO 9001 Designed in accordance with relevant CE standards Low Voltage Directive 73 23 CEE EN61010 1 April 93 EMC Directive 89 336 CEE EN 50081 2 Aug 93 EN 50082 2 Mar 95 Approvals GR C Equipment type Permanently connected equipment The product is designed for industrial use Installation category HI Shock protection Class I Pollution degree 2 Insulation category I IP Code IP65 NEMA 4X Installation altitude lt 2000m MSL AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 159 BTG 2004 4 2 Revision information 4 1 3 Type sign explanations gt Always refer to the type sign when ordering spare parts Fig 67 Type sign for junction box 2 3 4 5 1 Manufacturer 2 CE marking BTG Pulp amp P S AB D 3 C Tick ma rking Indusingsten Dog SE 4 CSA marking cae C 4 ER N N 5 Warning sign wu bigppcom Q P 6 Product 7 Voltage DE No 9 8 Apparent power 6 JCT 1100 A
21. 1100 Junction box appendix BTG 2004 183 4 8 Service instructions Fig 82 Fuses and test points TP on the main circuit board Pos oN O o A O N TP TP TP1 TP2 TP3 TP5 Bel ICT REEREGEEREER 1120 goooooOpe rs ex UUUUUE d itrmmm UHT o Wn m 2 Min Max 2 2 2 2 23 5 24 5 11 5 12 5 4 95 5 05 1 20 1 25 Unit lt gt gt gt lt lt V Comment Fuse for AC power supply 250V 2AT Fuse for AC power supply 250V 2AT Fuse for 24 V DC power supply 250V 2AT Fuse for DC DC converters 250V 2AT Ground reference for all voltages test points Output voltage from 24 V DC power supply SPC 1000 supply voltage from DC DC converter Regulated system supply voltage from DC DC converter Reference voltage for HART mod
22. 12345 9 Manufacturing number VOLTAGE FREQUENCY 10 Frequency 7 100 240 VAC 50 60 Hz 10 1 1 Installation category APPARENT POWER INSTALLATION CATEGORY FACTORY IDENTIFICATION 12 Production Factory 8 60 VA TT F1 12 11 Warning sign The device is designed for industrial use Installation handling and service must only be carried out by trained and authorized personnel and according to relevant standards and legislation Read the manual for detailed information and pay special attention to the warning signs 4 2 Revision information The following changes have been made in the JCT 1100 A compared with the JCT 1100 e The language setting for the JCT 1100 is stored in the transmitter memory instead of the JCT 1100 memory na standard delivery the isolation amplifier has been replaced with a HART filter in the 4 20 mA output signal The extra 250 ohm resistor for HART communication is not required as long as the HART filter is mounted e The RS 485 terminal block has been made smaller 160 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 3 CE Declaration of conformity 4 3 CE Declaration of conformity BTG s CE Declaration of Conformity is only valid when the junction box is used in combination with other BTG equipment Manufacturer s Name Manufacturer s Address declares that the product Product Name Model Number conforms with the following Product Standards LVD EMC and complies with the req
23. 141 3 10 Back up memory 3 10 Back up memory The transmitter is equipped with a memory in which all data is stored for this specific transmitter according to the Tag No There are two separate memories in the hand held terminal one editing memory where all the programming is normally stored and a back up memory When data is transferred from the transmitter to the terminal Read data the transmitter data is stored in both the editing memory and the back up memory Fig 63 Storing menu Transmitter Read data CN Send Back up Back up card data memory Misc Backup data Nc ow SPC 1000 We b Read data Store data The back up memory data is not affected by the different actions per formed on the terminal except when data is entered press aes c When pressing Read data all previous data both in editing and the backup memory are erased and replaced by the new data entered from the transmitter memory The back up memory can be used to retrieve the original transmitter data even when changes were made via the terminal The terminal does not need to be connected to the transmitter Misc Press Es When back up range 1 is pressed the back up memory data is transferred to the editing memory on measuring range 1 Implement the correspond ing action for the remaini
24. 150 kpmm can be adjusted to brake 100 kpmm at the same feedback i e made 33 more sensitive or equal in sensitivity to the standard model The setting should pref erably be made with the aid of a torque brake See section 3 7 4 on page 133 gt Bear in mind that the increase in sensitivity is illusory the difference in feedback is greater but signal resolution and accuracy of measurement are not enhanced Your first corrective action should always be to replace the sensor Symptom 6 Feedback signal too high 7210094 Action Replace the sensor with a smaller one Alternatively set the feed back resolution to a higher torque up to 150 kpmm see Symptom 6 and section 3 7 4 on page 133 Symptom 7 Poor precision outside normal working range Calibration points are too few or too closely grouped Action Enter more calibration points making sure that they cover as much as possible of the measuring span FEEDBACK IN WA TER sample 0 should be included as it stabilizes the whole cal ibration curve 122 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration Symptom 8 Abnormal calibration constants KO should normally be the same as FEEDBACK IN WATER sample 0 This value shows where the calibration line inter sects the Y axis at 0 consistency Some deviation is normal K1 shows the slope of the calibration line which is normally pos itive K2 shows the exponential deflection
25. 16 3 below for further information 3 16 3 MEK 2300 sensor processor card E prom Two different hardware types of sensor processor cards have been deliv ered with the MEK 2300 The older version has traditional electronic components and is encapsu lated in a metal cover The software on this circuit board has versions 1 1 1 2 In All versions A F and forward of the PCMCIA sensor card software can be used with this circuit board The new type delivered today has surface mounted electronics and is not encapsulated in a metal cover The software on this circuit board has versions 2 1 2 2 2 n This type of circuit board requires version E F and forward of the PCMCIA sensor card software 152 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 17 Maintenance Planning and Quality Assurance 3 17 Maintenance Planning and Quality Assurance In April 1993 BTG K lle Inventing AB attained ISO 9001 certification concerning development design and production among others for pro cess control equipment for the pulp and paper industry Repair at the fac tory is made in accordance with appropriate demands from new production every transmitter is e g tested according to a specified pro gram The result is documented and included in the delivery 3 17 1 Inspection of the accuracy calibration of the consistency transmitter Inspection can be made in two ways 1 By means ofa special torque brake with the tr
26. 2 5 3 2 Installation with weld in stud Fig 22 The weld in stud is available in two sizes 1 To be fitted in pipes gt 200 250 mm 8 in 10 in see Fig 23 2 To be fitted in pipes gt 300 mm 12 in see Fig 22 c The small 200 250 mm 8 in 10 in stud should not be used at consistencies higher than 8 10 in a long fiber pulp and 10 12 in a short fiber pulp Pulp may plug inside the cavity and in the long run damage the mechanical seal If any doubt use the measuring vessel Before commencing the work of installation check that the thickness of the pipe wall is sufficient for the pressure rating required See Fig 24 and Fig 25 The length of the measuring chamber M is 60 mm 2 4 in for installation in consistencies gt 496 For installations with consistency lt 4 M should be 150 mm 6 in Contact BTG for further advice Always check that this dimension agrees with the dimension stated for the position number and in the order copy gt Note the length of measuring chamber M Installation in the pipe a Cut a hole with a diameter of 220 mm 8 6 in in the pipe and Warning Assure yourself grind and bevel the edge to receive the weld that the pipe is empty before opening it up b Weld the three deflector rails supplied upstream of the stud with their sharp ends facing upstream This will have the effect of pro tecting the sensing element which will be in the main stream c Ifitis im
27. 250 Q Superimposed signal over 4 20 mA current loop according to standard HART protocol and BELL 202 modem Follows HART universal commands 0 420 mA Four separate individually programmable externally connectable using a binary coded switch Also accessible via the communications link Communication Junction box Hand terminal DCS OPC Fieldbus Display for viewing and buttons for adjusting span offset damping and calibration constants Using the BTG SPC 1000 hand held terminal jack plugs into the junction box The communication is superimposed over the 4 20 mA current loop Directly with the DCS HART universal commands RS 485 for connection to OPC server OPC program provided by BTG Note Only for DCS OCS system with OPC capabilities Prepared for fieldbus communication e g Profibus PA or Fieldbus Foundation MEK 2300 JCT 1100 Junction box appendix BTG 2004 AX218 56 3e 4 1 Product introduction Connections Transmitter connection Cable fittings LIYCY 5x2x0 5 twisted pair shielded 10 m 33 ft cable with connector is included in the delivery This cable is connected to the terminal strip in the junction box Other cable lengths are available on request max 100 m 328 ft Brass nickel coated For US and Canada no fittings are included Supply voltage Supply voltage options Power consumption Built in multi voltage power supply
28. 54 Enter your code 2300 and press Enter 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD SPC 1000 Communication Terminal See Fig 54 for the following menu with the Auto Preset and Check choices 4 20mA MODEMPRINTER PWR ON OFF 2 MEMORY CARD SPC 1000 Communication Terminal 01218 56 3en MEK 2300 Operating instructions BTG 2004 89 3 5 Starting the transmitter Adjustment can be done in one of two ways 1 Automatic feedback adjustment Auto SE or Auto gt Preset It can be checked at Check Set 2 Pre set set point Preset point Angle Feedback Check The function operates so that the arrow is stepped to EN by pressing the button then press SS c Note that the transmitter s basic setting will be changed The terminal and the transmitter will now exchange data with each other and adapt the adjustment to the correct value The Set point Angle and Feedback values will be displayed after about halfa minute Set point is the set point value ofthe feedback system con troller Angle its actual value and Feedback its output signal AUX is an input for special functions The value should be 0 if these functions are not used If the adjustment is correct the Set point and Angle values should agree A typical nominal Set point value is 1600 and Angle can be permitted to vary by 10 units max 20
29. 56 2 1 Important information The Consistency Transmitter is a precision tool and must be properly in stalled to ensure reliable service So please read the following instruc tions and user information before installing the transmitter This instruction manual contains installation instructions for the entire range of BTG in line rotating consistency transmitters Installation and operating conditions The transmitter is designed and manufactured to provide accurate and re liable measurements over a long period of time gt Correct installation and regular maintenance according to the Service Manual will ensure maximum utility of the transmitter s capacity Install the transmitter so that it is protected from direct mechanical damage If there is any risk of it frequently being sprayed by water or pulp ensure it is adequately protected by an enclosure e To protect the junction box from water or pulp spray install under a roof above the box If installed outdoors the roof will also protect the unit from direct sunlight and rain Protect the transmitter from heavy vibration sources such as cavitation or unbalanced pumps Install the transmitter at the correct distance from a pump pipe elbow or valve The measuring vessel weld in stud sensing element propeller etc must be of the correct type and in accordance to the PED for the specific application Contact your BTG representative for information and advice
30. Be wk A ears RS 160 4 3 CE Declaration of conformity 161 4 4 Safety recommendations EEN 162 4 5 Installation instructions 25452 S Evo een EST uA 163 4 5 1 Mounting WEE 163 4 5 2 Junction box with external 24 V DC power supply 165 4 5 3 Cabling rca xiu Pa Nea fete A ae 166 4 5 3 1 Cable types are Ee geb AER 166 4 5 3 2 Guidelines for cable connections 166 4 6 die Le We TL E ou th ee x Gee crc OY eee suco Pad 168 4 6 1 HAR T communication x 92 2 eebe ae ae Eee ones eg 169 4 6 1 1 Range select iNp t e EE genee ger eg 169 4 7 Operating instructions 170 4 7 1 Starting the junction BOX 22 0 2 secge Se ee eae eee ie Peete eee 170 4 7 2 Transmitter configuration from the junction box 170 4 7 2 1 General information MEET 170 4 7 2 2 E DR 172 4 7 3 Collecting samples and changing settings 173 4 8 Service instructions uu sedis Ges Rta cin DONG oi es usd 177 4 8 1 Maintenance routines 1x uc e ERU praebe RERO RE e Dope bb des 177 4 8 2 Service hardware Sege E reiege ie e ed oe da acido added da ge 177 4 8 3 Handling of circuit boards for output signals 178 4 8 3 1 Replacing the power supply unt 179 4 8 3 2 Replacing the front panel 180 4 8 3 3 Replacing the main circuit board 000000 eee 181 4 8 4 Service SoftWare e eebe eebe A e 182 4 8 5 Trouble SHOOUNG x sokeaa ka ESI EE 182 4 9 Paris Sl 5450905 20 odd ge D en
31. Excluded in cal gt Calibration can be improved by entering additional calibration points i e by making a multi point calibration according to section 3 6 4 on page 110 All previous calibration values should be deleted during sin gle point calibration Press calib and accept deletion by pressing Press Zale and take representative laboratory samples The feedback signal will then be stored in the memory for sample 1 mean value over 40 seconds Sample 0 is the feedback in water value entered at the factory see section 3 6 2 2 on page 101 Single point calibration will be based on a single feedback value and the corresponding laboratory sample and calculated to a special adapted formula to give a good correspondence to Mem the actual curve Press is Evaluate the laboratory samples Calculate the mean value Load lab cons in water and sample No 1 should be activated during single Press Sample 0 the feedback value during rotation Active O 2 On for sample no 00 Press point calibration Press Edit saple until the arrow reaches sample No 1 Press r On Press Lb and enter the laboratory value Off Enter Menu mean value Press Menu Calc new const Press to allow calibration to be performed The rel evant calibration curve and the calibration const
32. Setting 1 Calibrate the flow transmitter against the consistency transmitter The flow transmitter should produce an output signal of 4 20 mA A Go to ge Va B Enter the code 1945 C Step down to Prod by pressing the E button D Determine the measuring span over which the flow may vary e g 120 450 m h Adjust the flow meter for a slight wider span e g 100 500 m h i e 4 mA output signal 100 m h and 20 mA output signal 500 m h E Enter the minimum limit of the flow span at 4 mA m h XX e g 100 Enter the maximum limit at 20 mA m h xx e g 500 F Calibrate the flow transmitter against the consistency trans mitter Connect a simulator capable of supplying the appro priate mA signal to the AUX in terminals in the JCT 1100 junction box See the wiring diagram in the Installation in structions section of the JCT 1100 manual included in this manual G First adjust the minimum signal for the measuring span e g 4 mA at 100 m h and press PaT H The raw signal AUX input should now be displayed Press Sien when the raw signal is stable 138 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 8 Production calculation I Then adjust the maximum signal for the measuring span e g 20 mA at 500 m h and press fawsion when the raw signal is stable 2 The flow transmitter is now cali
33. She Wa emt EECHER 6 2 2 1 troduction ssia xc aboard deut pa x s RR dte oye to ans Aca 6 2 2 2 Visual inspection 2 1o deo de our rh eer ee tee Sa o Ge Gag Yol Ur Sod 7 2 3 Basic system description 00 cc cee eee eee eee 8 2 3 1 TEH SVSIQITI eh Ca xcacd EE Ee ak ate 8 2 3 1 1 Conformity to CE directives and CSA approval 9 2 3 2 Working space and installation clearance requirements 9 2 3 2 1 Bee 10 2 3 2 2 Junction box type JCT 2100 2 0c eee eee 10 2 3 2 3 Hand held terminal type BTG GbPCG 2000 aaaea 11 2 3 2 4 EE EE 11 2 4 Planning the installation 42 1 5 5 ge died aca be utut dud 12 2 4 1 Advice and recommendations 000 cece cece eee 12 2 4 2 Choosing a site for the transmitter 15 2 4 3 NOLO RCA TEEN EE cea apo Reh egy Popes 18 2 4 4 Choosing a site for the JCT 1100 junction box 18 25 Installing the transmitter cios ee be ceeds es 19 2 5 1 Operating principle 0 eee eee eee 19 2 5 1 1 Positioning the transmitter A seg er ER Se Ne NEE 19 2 5 2 Low pressure pipe installations PN10 0 0000 19 2 5 2 1 Installation with measuring vessel n n naana aaea 20 2 5 2 2 Installation with weld in stud 0 000 cece eee eee 25 2 5 2 9 Installation with shut off valve 29 2 5 3 High pressure pipe installations 25bar 226 C 30 2 5 3 1 Installation with measuring vessel illii 30 M218 56 3e
34. and may be either 70 100 or 150 mm 2 75 4 or 6 in It may only be Measuring chamber length longer than this if a shut off valve is also to be installed Always check M is determined by BTG that this dimension agrees with the dimension stated for the position Correct length is vital for number and in the order copy the transmitter s function HS Installation in pipe a Turn the vessel so that the flow direction arrow points in the actual direction of flow see Fig 10 Fig 13 b Align the vessel and any gaskets before welding it to its stud join ing the flanges If welding use a full penetration weld Do not turn the vessel c Fitthe 8 mm stud bolt supplied into the upper hole in the transmit upside down Air may ter flange and lock it in position with thread sealant accumulate in its upper part and disturb d Check the inspection cover to ensure that it is correctly positioned measurement and tightened e Ifthe transmitter and any sampling valve are not to be installed im mediately screw a blank flange onto the transmitter Blank flang es are available as accessories from BTG 20 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 9 Measuring vessel with weld ends for low pressures and vertical mounting left hand design Min M 500 La P ra 308 20 012 2 1 Measuring vessel 2
35. calibration It can be further refined by an updated cali bration see section 3 6 4 on page 110 Note that if you have previously made a single point calibration it will now be erased If you want to save the value sample 1 select UPDATED CALIBRATION Does the temperature normally fluctuate widely by more than approxi mately 10 C If so and you want to achieve greater precision in mea surement connect compensating equipment see section 3 7 2 on page 129 Criteria a Transmitter started up as per section 3 5 on page 86 Feedback in water should be set see section 3 6 2 2 on page 101 for a multi point calibration b The transmitter s data must be entered in the hand held terminal as per section 3 5 on page 86 items 4 5 amp Procedure Go to MAIN MENU Compare with section 3 6 3 2 on page 105 which describes similar steps in somewhat more detail 1 Select actual range with Range button range 1 4 2 Start by setting the desired measuring span under MAIN MENU mA 4 20 mA 1 0008 option and 4 00 See also section 3 6 8 on page 126 3 Setthe controller to MAN Close the dilution water so that the con sistency rises to the maximum permissible limit Let it stabilize If feedback now approaches or exceeds 100 the sensing element should be replaced by a smaller one If feedback is very low close to the value for water the sensing element should be repla
36. from the Set point value The Set point value can be adjusted between approximately 1440 1680 units The nominal value depends on the torque wheel s toothed wheel and optical sensors adjustment Refer to section 3 2 of the service manu al c The feedback value when rotating in air should be 4 8 The A change to the feedback Feedback signal in this part of the menu is first shown as a raw adjustment changes the signal and the actual one 6 2 Note that to obtain the actual one setting of the transmitter Sensor sensitivity adjustment must be performed first see This must be done only when the transmitter rotates in air not in pulp section 3 7 4 on page 133 If the feedback value at rotation in air is outside its limit fine tuning can Auto gt Preset be performed at c Automatic feedback adjustment can be regarded as a rough adjustment and the setting often needs fine tuning 90 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 5 Starting the transmitter 2 Pre set set point Preset BEES gt Preset It is possible to reach the control point quickly by directly adjusting the feedback controller s set point On the MEK 2300 this function is gener ally used for fine tuning of the feedback adjustment GE Pr t This is done by pressing setpoint Then enter the required set point value on the keyboard which now ap pears The previous value will be disp
37. gt To simplify and improve the regularly follow up routines the BTG Smart lab sampler SLS 1000 is an useful aid 3 6 2 Criteria for calibration 1 The transmitter rotates and has been started up as per section 3 5 on page 86 2 The hand held terminal must be connected to the junction box and switched on and the transmitter data read into the terminal as per section 3 5 on page 86 3 The pulp flow must be turned on and must pass the transmitter in the pipe The pulp must have representative consistency and flow val ues 3 6 2 1 Adjusting Tag no Serial no Sensing element no Propeller no Tag no The Tag no is the transmitter identification no in the process It can have different shapes in practice In the terminal max 6 identifica tion numbers can be entered Example Tag no is 12 NT 1234 Enter it the following way Press 12 Enter 1234 Enter NT will be displayed as a point l e the total Tag no will be 12 1234 Serial no The serial number is entered at the factory It can also be read at the transmitter type sign and reentered if being lost Example Serial no is 123456 01 01 Sensing element no Propeller no The part numbers for the sensing element and propeller supplied are entered at the factory c When replacing sensing element propeller with another type the relevant new part number must be entered so the transmitter is correctly documented c When changing the sensing element to an
38. installed in a horizontal or inclined pipe care should be taken in locat ing it so that it does not measure large bubbles trapped in the pulp Measuring vessels for use in low pressure installations may be of left hand or right hand design Fig 6 shows a typical installation Your BTG sales engineer will be pleased to assist in selecting the location that will give the best results consistent with your specific control strategy 11218 56 3en MEK 2300 Installation instructions BTG 2004 15 2 4 Planning the installation Important recommendations There are a number of considerations to take into account l The transmitter should be installed as close as possible to the point where the dilution water is injected to ensure minimum time lag Recommended minimum distances See Fig 7 See Fig 7 and Fig 8 Proximity to bends or elbows in pipes is to be avoided due to turbulence and dewatering For optimum results when the transmitter is positioned downstream of a pump or pipe el bow it should be located at the theoretical outer turn of the pulp stream Ifthe transmitter is to be installed at a height where it will be difficult to reach build a platform that will make it more easily accessible for service and inspection It is important to choose a location with sufficient room for insertion and removal of the transmitter and o
39. menu The function is used to change the adjustment of the calibration setting for example without the actual output signal being affected Simul ation mode When the function is enabled displays the simulated output signal under the main menu s Trend button where in this case the button displays imula ion on Note that the transmitter s actual output signal is displayed in the main menv s standard window for the output signal display Transfer the change to the transmitter by pressing 2 The simula tion function will then be disabled automatically If you wish to go back to the original setting you can do this directly on the terminal since this has two separate memories see section 3 10 on page 142 Goto BEE and transfer the relevant measuring range data back to the editing memory range Another option is to re read the transmitter data to the terminal by pressing data 01218 56 3en MEK 2300 Operating instructions 137 BTG 2004 3 8 Production calculation 3 8 Production calculation This function is available as an option from BTG and cannot be accessed until a special code is entered The program is prepared for the function which can be accessed when a special code is entered gt To obtain this function the transmitter must be equipped with a special version of the Sensor processor card Order no 74457607
40. minimum of 250 mm SS2343 OD 800 mm PN16 respectively 320 mm SS2343 OD 800 mm PN25 on each side of the weld in stud counted from its center 11218 56 3en MEK 2300 Installation instructions 35 BTG 2004 2 5 Installing the transmitter Fig 24 Material thickness in main pipe to 25 bar tein mm o pressure For high pressure weld in studs pipe size 300 mm 12 in tmin mm Minimum mate rial thickness in main pipe for PN 25 OD mm Outer diameter of main pipe A Stainless steel to SS2343 AISI 316 B Stainless steel to 254 SMO C Hastelloy C 276 Installation data Pressure 25 bar 360 psi Temperature 226 C 440 F 14 0 13 0 12 0 11 0 10 0 9 0 8 0 7 0 6 0 5 0 300 400 500 600 700 s00 D mm Calculation values for weld in stud Outer diameter D 240 mm Material thickness t 10 mm Omax Max permitted stress value N mm 882343 Omax 95 N mm 254 SMO Omax 122 N mm Hastelloy C 276 Omax 127 N mm 36 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 25 Material thickness in main pipe to PN16 For high pressure weld in studs for PN 16 Pipe size gt 250 mm 10 in tmin mm Minimum mate rial thickness in main pipe for tmin mm PN 16 OD nm O
41. redrawn calculated to a straight line with K2 0 The output signal in this case is not linearized By checking the calibration curve or running a printout you can check which calibration point is distorting the result and correct the calibration by deactivating that point O1218 56 3en MEK 2300 Operating instructions 95 BTG 2004 3 6 Calibration D Updated calibration see section 3 6 4 on page 110 Updated calibration works just like the normal multi point calibration with ge one exception when you make a multi point calibration the previous DEEN calibration is erased from the memory whereas an updated calibra E port Load lab Eur tion adds new points to the curve without erasing the existing points the valt jSpecial func are used to manually load raw signals or cal constants E Calibration constants see section 3 6 5 on page 111 As previously mentioned the calibration curve is defined by three cali PEE bration constants KO K1 and K2 It is also possible to make a calibration E NE 3 by loading manually calculated values for these constants KO is the value of the calibration line where it intersects the Y axis K1 is the inclination coefficient of the calibration line K2 is the exponential rate of increase of the inclination line c K2must not be negative see section 3 6 5 on page 111 and section 3 6 6 on page 112 3 6
42. section 3 6 6 2 on page 112 ANGLE When the feedback function is working correctly the ANGLE reading should be equal to the SETPOINT reading within a tolerance of 5 units If feedback is more than 100 the feedback system is overloaded and ANGLE will be greater than SETPOINT Feedback resolution Feedback raw signal The adjustment of the Feedback resolution setting will influence the above settings OI218 56 3en MEK 2300 Operating instructions 143 BTG 2004 3 11 Trouble shooting functions The Feedback resolution setting is also observed at adjust Select Sensor sens FB 100 o St calib rawsig This value is named Feedback raw signal The H original setting can be read in the attached test protocol Refer to section 3 7 4 on page 133 for adjustments 3 11 2 Service functions and signal calibration A Factory settings There is a Factory settings sub menu under the heading Misc This is where a certain signal calibration can be done Since the calibration nor mally requires special equipment this work can be done only at BTG The function is protected by a code and is therefore not accessible An instruction is available from BTG on request at emergency cases 144 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 12 Altering sensor transmitter data 3 12 Change the transmitter specification data when rebuilding the transmitter t
43. simulation and docu mentation for instance when the terminal is used at a desk A portable AC adapter is supplied with the hand held terminal The AC adapter is available for 110 V AC or 220 V AC The output supply is 12 V DC Check before connecting to the main power supply that the AC adapter is made for the correct supply voltage The AC adapter is supplied with a cord for plugging in to the mains pow er supply In some cases the molded plug may not fit your outlet Re place the plug with a suitable standard plug if this is the case The AC adapter s 12 V connection is connected to the socket on top of the terminal This is marked PWR 12 V DC 0 4 A AC adapter DC jack with 2 mm connection pins The connection goes to the casing and the connection goes to the center pin t The display lighting also comes on when the 12 V power supply is used 01218 56 3en MEK 2300 Operating instructions 69 BTG 2004 3 3 Hand held Terminal SPC 1000 Minimum circuit resist ance 250 Q C 9VDC supply from an integral battery The battery power supply is used for example when the terminal is con nected to the 4 20 mA signal loop at a location other than at the junction box An internal standard 9 V DC battery is located behind a cover on the back of the terminal To provide maximum operating time a type 6F22 high power alkaline 9 V DC battery should be used A battery of this type will operate for approxim
44. size is 2 x 0 75 mm 2 x AWGI8 c BTG recommends that separate cables be used for analog and digital signals Multiconductor cables can be used 4 5 3 2 Guidelines for cable connections Do not place signal cables and power supply cables close together This may cause interference Always avoid loops of cable leads in the junction box and make the leads as short as possible The shields for the Alarm AUX in and Range select cables should not be connected in the junction box unless the mill standard specifically requires it Normally these shields are grounded to instrument earth at the mill end BTG recommends that the shield for the output signal cable is connected to CONN21 in the junction box CONN21 is connected to PE via a capacitor 166 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 5 Installation instructions Fig 73 Grounding of cable shields Power supply or transmitter cable Nut Sealing ring Insert ring Cable shield Socket Free wires NOOB WD Fig 74 Connection of signal cable shields BTG BTG Mill 1 System cable transmitter JCT 1100 equipment The cable shield must be connected to PE at both ends CONN 21 2 Output signal cable In the JCT 1100 the shield is connected to CONN21 and in the mill equipment the shield is connected to instrument earth PE Protective earth t Instrument earth It is important to tighten the cable connecto
45. store the terminal s transmitter adjustment for the relevant transmitter TAG No on the back up card Then Verify press for storage to be executed 01218 56 3en MEK 2300 Operating instructions BTG 2004 117 3 6 Calibration c Note the relevant TAG No and the number of the storage position on a separate identification list gt All four measuring ranges will be stored so each one must be clearly identified in the identification list 6 Switch off the terminal and replace the back up card with the sensor card c Store the back up card in a safe place protected from moisture The card is an object of considerable value c The back up card can be protected against accidental or unwanted data input by using its write protect Set the write protect button to the activated position to prevent input When the write protect is activated the text Card write protected or Low card battery appears on the display B Retrieving transmitter data stored on the back up card l dta Repeat Items 1 4 in A described earlier Read Press data to access the relevant transmitter setting from the back up card and transfer this to the terminal s memory The rele vant Tag number is shown in the identification list as per Item 5 above Press Verify Switch off the hand held terminal and replace the back up card with the sensor card Switch on the han
46. the total pressure drop in the dilution water line The valve and its actuator must operate with the least possible backlash and smallest possible dead zone The valve must be tight when in its closed position See Fig 5 c See section 2 9 1 How to calculate the dilution water valve 12 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 4 Planning the installation Fig 5 Dilution water supply at consistency control Ap Dilution water pressure difference up stream downstream of the dilution wa ter valve 1 Velocity 3 5 m s 10 16 5 fps V2 See Dimensioning the pulp line G Min 15 50 mm 0 6 2 inches depending upon suction pipe size Ap min 0 5 bar 7 psi L See Fig 7 A Recommended design B C Not recommended Location of the dilution water valve The conventional method is to install the valve above the highest pulp level in the chest to prevent pulp from entering the valve during a shut Do not use saddles in down With modern large chests it is not always possible to meet this re dilution water piping see quirement Pig 918 Valve location as close as possible to the suction pipe wall is recommended 11218 56 3en MEK 2300 Installation instructions 13 BTG 2004 2 4 Planning the installation Dimensioning the pulp line See Fig 5 V The transmitter is designed for installation in a pulp line d
47. to Trend Feedback xx It is a good idea to remove the cover of the transmitter s measuring part and brake the rotating brake ring for a few seconds by hand This helps the feedback circuit to start up faster The feedback value when the transmitter rotates in air should at normal operation be between 4 and 8 when the transmitter is warmed up and settled gt If the FB value is wrong lt 1 gt 12 a new basic setting must be made Proceed to section 3 5 1 on page 88 gt The transmitter is now ready for calibration against pulp samples Proceed to section 3 6 3 on page 103 OI218 56 3en MEK 2300 Operating instructions 87 BTG 2004 3 5 Starting the transmitter Warning rotating parts Do not allow the transmitter to rotate for more than 5 minutes in air if the mechanical seal is not flushed It is better to retard it manually 3 5 4 Feedback adjustment in air 3 5 1 1 Function gt Incorrect adjustment of feedback in air can cause the signal to become unstable and drift The purpose of this adjustment is to set the outer torque wheel so that it centers between the end position stops while the transmitter rotates in air refer also to section 3 1 of the Service manual When the transmitter rotates in air and is stabilized the feedback signal should be reset if it is less than 4 or greater than 8 When the transmitter s motor is started there may be a delay of a few minu
48. 0 years of operation Replacement of motor ball bearings recommended after 8 years of operation Cleaning lubrication or replacement of rotating ball bearings of drive unit and measuring unit two for the drive shaft one for the moment shaft after approximately 10 years of operation Replacement of mechanical seal after typically 5 years of operation depending on the operating condition Replacement of rubber seals after typically 10 years of operation For further information see also the Service instruction for the respective transmitter type 3 17 6 Maintenance of the junction box For information regarding routine service for JCT 1100 see the Service instruction section of the JCT 1100 manual included in this manual OI218 56 3en MEK 2300 Operating instructions 155 BTG 2004 3 17 Maintenance Planning and Quality Assurance 156 MEK 2300 Operating instructions 01218 56 3en BTG 2004 4 1 Product introduction 4 JCT 1100 Junction box appendix 4 1 Front panel overview Single line LCD display Keys for access to basic settings Front cover LED indicating 24 V DC power on SPC 1000 connector Terminal connection box Product introduction This instruction manual is valid for JCT 1100 A junction boxes 4 1 1 System description The JCT 1100 junction box is delivered as a complete unit from BTG and is always delivered together with a transmitter It has the following functions Loc
49. 00 Documentation program for Windows Version 1 0 e Copyright 1995 BTG RB All rights reserved 3 3 4 Connecting a PC Also a PC can be connected to the hand held terminal socket marked Printer The hand held terminal is connected according to RS 232 standard with either a 25 pin Fig 58 pos 2 or a 9 pin Fig 45 pos 1 serial connector depending on the PC you have A suitable connecting cable is available from BTG and fits both 9 and 25 pin connector See parts list Accessories for hand held terminal If you use Windows 3 1 or later versions you can use the SPC 1000 Documentation program This program is available at disk Documenta tion program for Windows from BTG See section on page 119 You will receive all data for the range you send to the PC so if you want all four ranges you just repeat the procedure for each range If you have sev eral BTG smart transmitters this is a very useful way of storing all trans mitter data within the same file Pressing the print button will transfer the data to your text file for one range at the time Fig 58 gt The PC can only be used for storing the transmitter calibrations They cannot be transferred back from the PC to the SPC 1000 transmitter 72 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 3 Hand held Terminal SPC 1000 Sensor card SPC 100 English Ver C 14457675 3 3 5 Memory cards 3 3 5 1 Functi
50. 09 1 2 342310 3 7037 10 7 2330 9 2949 10 4 1868 103 1 16310 426 94 1 1 5812 10 3 0880 10 3 9683 2 6478 106 0 73550 0 27 10 632 42 1 1 9529 10 2 5096 10 1 3558 0 37662 10 0 13826 0 32383 10 0 51206 10 1 1 25851 10 1 0551 103 0 29307 10 107 59 0 25200 0 39847 10 718 17 1 1 erg 0 1 10 6J Effect Ww kpm s kcal s kcal h hp metr hp ft Ibf s BTU h Horse Horse power power 1 0 10197 0 23885 10 0 85985 1 3596 10 1 3410 10 0 73756 3 4121 9 8066 1 2 342310 8 4322 13 333 107 13 151 10 7 2330 33 462 4 1868 10 426 94 1 3 6 103 5 6925 5 6146 3 0880 10 14 286 10 1 163 0 11859 0 27778 10 1 1 5812 10 1 5596 10 0 85779 3 9683 735 50 75 0 17567 632 42 1 0 98632 542 48 2 5096 10 745 70 76 040 0 17811 641 19 1 0139 1 550 2 5444 10 1 3558 0 13826 0 32383 10 1 1658 1 834 10 1 8182 10 1 4 6262 0 29307 29 885 10 69 999 10 0 25200 0 39302 10 0 39302 10 0 21616 1 64 MEK 2300 Installation instructions 11218 56 3en BTG 2004 3 1 Important points to note 3 Operating instructions Safety Recommendations see relevant section in manual 3 1 Important points to note The transmitter is a sensitive piece of precision equipment Handle it with care When installing the transmitter in the line or removing it from the line use the handle to lift it and take special care to avoid any damage to the unit Do not rotate the sensing element by hand as this can overload the measuring sys
51. 1 2 Other functions that affect calibration These functions are Damping measuring span offset adjustment tem perature compensation load feedback calibration curve trend and sim ulation mode c The basic settings of the transmitter also affect the calibration A Damping see section 3 6 7 on page 125 A time constant damping factor usually needs to be inserted to stabilize the output signal Its value can range from 1 to 99 seconds Damping is ac complished by filtering the signal through a software controlled low pass filter ee When making the setting you should try to make the time constant as short as possible in order to avoid the risk of filtering out actual changes in consistency By doing so you also take maximum advantage of the transmitter s precision B Measuring span limits see section 3 6 8 on page 126 This setting can be accessed directly in the main menu e ze Measuring Span can be set as desired but is limited by the measuring span of the sensing element If the calibration is of single point type or if the output signal is not linearized K2 0 the span setting should be as small as possible since in these cases the calibration is correct at one point only but may be more or less off at other points 96 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration
52. 1 4 Faulty 24 V DC supply Check TP1 If out of limits replace the power supply unit See section 4 8 3 1 1 5 Faulty DC DC converters Check TP2 and TP3 If out on main circuit board of limits replace the main circuit board See section 4 8 3 3 2 There is no informa 2 1 No power to the junction See point 1 above tion on the display box 2 2 Faulty or incorrectly Check the display wiring 8 connected display wiring and the groundling strap 12 2 3 Display is faulty Replace the front panel See section 4 8 3 2 3 Nothing happens 3 1 Faulty or incorrectly Check the display wiring 8 when the push but connected display wiring and the grounding strap tons are used 12 3 2 One or more push Replace the front panel buttons are faulty See section 4 8 3 2 182 MEK 2300 JCT 1100 Junction box appendix BTG 2004 AX218 56 3e 4 8 Service instructions Symptom 4 There is no output signal 5 The SPC does not work 6 The analog output signal from the junc tion box is lower than what the display dis play shows 7 Language changes to English after pow er down 4 2 4 3 4 4 4 5 4 6 Probable cause 4 1 No power to the junction box Transmitter not in operation Improperly mounted HART filter or isolation amplifier Open loop for 4 20 mA output Incorrect transmitter analog out configuration Faulty HART filter or isolation amplifier Incorrect pr
53. 1000 Fig 41 Hand held terminal SPC 1000 1 Telephone jack to 3 3 junction box JCT 1100 2 Touchscreen 3 Rubber casing 1 8 c Hand held Terminal SPC 1000 3 3 4 General information All of BTG s smart transmitters are programmed using the BTG special hand held terminal type SPC 1000 SPC Smart Portable Communica tor This terminal communicates with the sensor via a special protocol Other makes of hand held terminals cannot be used to program BTG transmit ters even though they may operate using the HART protocol min ca 0 3m 1ft max ca 2m 6 6ft 5 3 10 The hand held terminal is designed in accordance with CE s personal safety and interference requirements This means that it is harmless to the user and does not cause interference to other equipment and is not affect ed by interference from other equipment It is protected by a thick rubber casing and can therefore withstand reasonable mechanical shocks and a small amount of splashing with water Since the terminal is an electrical instrument it should be treated with care and not subjected to abnormally rough treatment Treat the terminal with care Do not abuse it physically submerge it or spray it with water Avoid storing it in a humid environment for long periods 01218 56 3en MEK 2300 Operating instructions 67 BTG 2004 3 3 Hand held Terminal SPC 1000 Fig 42 MEK 2300 system typical contro
54. 12 in the transmitter should be connected to the pulp line via a weld in stud See Fig 15 and section 2 9 2 A slide gate shut off valve may also be fitted in a low pressure installa tion of this type The valve makes it possible to remove the transmitter while the pipe is filled with pulp 11218 56 3en MEK 2300 Installation instructions 19 BTG 2004 2 5 Installing the transmitter Note that shut off valves should only be used in low pressure installa tions and with non hazardous media as a complete seal over the valve cannot be guaranteed Shut off valves should only be used with the standard model of the MEK 2300 and where consistency does not exceed approximately 4 2 5 2 4 Installation with measuring vessel Standard measuring vessels are designed for welded connection See Fig 9 Fig 12 gt The dimensions for the welded in measuring vessel weld ends are given in section 2 9 3 Measuring vessels designed for flange connection conforming to DIN 2642 ANSI 150 Ibs or other standards are available to order See Fig 13 c The measuring vessel s pressure class rating determines the choice of flange despite the fact that some flanges will accept higher pressures Standard measuring vessels for vertical pipe installations are left hand see Fig 10 Measuring vessels for horizontal or inclined pipes may be either left hand or right hand The length ofthe measuring chamber M in Fig 9 is determined by BTG
55. 2 5 Installing the transmitter Fig 13 Flanged measuring vessel available to order gt See also Fig 9 for other dimensions 11218 56 3en 24 MEK 2300 Installation instructions BTG 2004 2 5 Installing the transmitter Warning Assure yourself that the pipe is empty before opening it up A Measuring chamber length M is determined by BTG Correct length is vital Proper M dimension is shown on the label attached on the weld in stud No part of the weld in stud may extend into the pulp line Align it to the vertical line 2 5 2 2 Installation with weld in stud Before starting installation check that the thickness of the pipe wall is sufficient for the pressure rating required See Fig 14 The length of the measuring chamber M is determined by BTG and may be either 70 100 or 150 mm 2 75 4 or 6 in It may only be longer than this if a shut off valve is also to be installed Always check that this dimension agrees with the dimension stated for the position number and in the order copy The dimension is also stated on the weld in stud See Fig 15 Fig 16 for weld in stud for PN10 Installation in pipe a Cut a hole with a 308 mm 12 13 in diameter in the pipe and grind and bevel the edge to receive the weld b In installations where the length of the measuring chamber is 70 mm 2 75 in and there is a possibility of the presence of solids in the pulp
56. 25 and the valve size 50 is sufficient Example to Fig 39 Q 6000 m 24 h Pipe diameter 300 mm What is the velocity in the pipe line 4 17 m min In the nomogram Fig 39 we can see that the flow velocity is 0 98 m s 3 2 fps 11218 56 3en MEK 2300 Installation instructions 59 BTG 2004 2 9 Miscellaneous Fig 39 Nomogram for flow velocities in pipes Flow m min a AU 9 o a Velocity m s TAM SSSRSSINSS NSONSNNSNNITI AM SS SS NNNN SS Kate ANN CN NS NN SN SS E VANAN Flow m min X BW Ken KK NS S NN AN aw ES ek NW NN NN Si N BY N o SS N N eu Son Voce KAN Wai x VIN NN CNN WAAR NN Gs Veen NS CN ER Kee AANA AANA AAA Sint CNN SSSSINS VER X X NA 15 dk KMA SU GC ROTI POA KINN ANTAA A MAAN AA NRW ERR NAN SSNNCS ANE AAT At ASSN ANAN NNN EAA ANNMAN NNT ANANTA NNNNA AACA AAR TAN OEY AN AB AAD AY WA A AANA A NVANAANN RE WAAAY CH Fe Me Klee ate Ki SORT OAL CE E SRM EES LN NL NA A Ne AAT ao NSW SHE N Venez A VAN OY OANA WANN DE GE SC Gei esche AE S SS SOT SANS og AECH MANDATE ISCAS NWN ATNA AT RRR SRE AATA ANANN TAN CECE ETAT LAKE DEE EECHER EE TATRA g N RRR ARS VC UNN e SS amp AA AIAN ANM AAA EA AAA ALAA ANY MRNA S NIS AN Creche ANNE A RAA CSS SONS EEN KEN AW AAA gt ANAM AAA SS AAA YAR Kuel et EN AA 100 w 800 T IDE diameter mm ex Gs 60 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 9 M
57. 3 3 on page 108 c To improve the calibration Make an updated calibration and an multi point calibration is obtained Criteria 1 Transmitter started up as per section 3 5 on page 86 2 Feedback in water should be set see section 3 6 2 2 on page 101 3 The transmitter s data must be entered in the hand held terminal as per section 3 5 on page 86 items 4 5 d s Procedure 1 Set the controller to MAN and adjust the dilution water valve until the consistency is judged to be normal i e as close to the intended SETPOINT as possible Let it stabilize 2 Select the relevant measuring range Range No 1 4 3 Start by setting the desired measuring span under main menu 4 mA 20 mA option 1 008 and 4 00 see also 3 6 8 Cali Take 4 Press brate followed by sample Toad raw six Or cal constants ial ed to manually iSpgcial func are us y OI218 56 3en MEK 2300 Operating instructions 105 BTG 2004 3 6 Calibration Keep 0000000 M voc 10 oto oooooooon 33333333 EE z RE S 8 2B 20000000 oooooocon 833333335 EH eseu eosscoootty 120000008 Et 20030 0030 f On Included Off
58. 4 Trimming the controller Once a transmitter has been calibrated the controller should be trimmed PI controllers are the type traditionally used in consistency transmitter circuits the following is a brief description of the standard trimming pro cedure l LA ud Ch Nn A 10 Set the controller to MAN and adjust the set point value which is normally set at 50 Example Consistency measuring span 2 4 normal consistency 3 present consistency signal 42 which means that the present consistency is 2 84 To obtain a set point of 3 the set point value is set at 50 see also step 9 below Set the controller to AUTO Set I time to infinity Gradually reduce the P band until the controller begins to oscillate spontaneously Increase the P band to twice the width Allow operation of the circuit to stabilize Keep the P band as it is or increase it slightly Reduce the I time slowly until slow sine curve spontaneous oscilla tion Is detected Increase the I time to give an adequate margin e g twice the sponta neous oscillation value Study the regulating process in disturbed conditions If changes in operating conditions cause spontaneous oscillation adjustment is necessary If flow conditions change e g if the flow velocity is re duced the width of the P band must be increased Do not make the P band setting too wide as this will adversely affect the response time of the controlle
59. 54 59462110 1 1 2010 3 78510 231 0 13368 4 951110 0 83268 1 Velocity Force mis knot kilopond Ibf 1 l 1 9438 Ndyn Tee kg 0 27778 0 53996 1 0 22481 0 3048 mors E 0 59248 e 5 0 44704 er 0 86898 10 10 2 248110 0 51444 1 9 8066 1 f1 L ns 1kn 1 mile h 4 4482 1 11218 56 3en MEK 2300 Installation instructions BTG 2004 63 2 9 Miscellaneous Pressure mechanical tension Density Pa bar kp cm at kp mm dry atm Ibf in kg m alem Ib in Ib ft mm Hg psi 1 10 36 127 107 62 428 10 1 10 10 10 197 10 0 10197 10 7 5006 10 9 8692 10 10 1 36 127 10 62 428 14504 10 27 680 10 27 680 1 1 72810 100 10 1 1 0197 10 197 10 750 06 0 98692 14 504 16 109 6 019 10 0 57970 10 1 98 066 10 0 98066 1 10 13 735 56 0 96784 14 223 9 8066 10 98 066 100 1 73 556 10 96 784 1 4223 10 133 32 1 333240 13 595107 13 59510 1 1 3158 107 19 337 10 101 32 10 1 0132 1 0132 10 332 10 760 1 14 696 6 8948 10 68 948 10 70 307 10 3 0 70307 10 51 715 68 046 10 1 1 mm water column 9 81 Pa 1 inch water column 249 09 Pa 1 inch Hg 3386 4 Pa Temperature Kelvine Celcius Rankine Fahrenheit Phys
60. 63x0 25 200 8 219 1x3 8 63x0 12 219 1x8 8 63x0 31 250 10 273x3 10 75x0 12 273x10 10 75x0 39 The pipe dimensions refer to the pipe weld end Outer diameter x pipe thickness OD x t 2 9 3 2 Pipes according to ID metric Inner Diameter standard dimensions Pipe connection Pipe dimension Pipe dimension Low pressure High pressure PN 10 150 psi 25 bar 360 psi mm inch mm inch mm inch 100 4 100x3 3 94x0 12 mE 125 5 125x3 4 92x0 12 mE 150 6 150x3 5 91x0 12 150x6 3 5 91x0 25 200 8 200x3 7 87x0 12 200x8 7 87x0 31 250 10 250x3 9 84x0 12 250x10 9 84x0 39 The pipe dimensions refer to the pipe weld end Inner diameter x pipe thickness ID x t 62 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 9 Miscellaneous 2 9 4 General dimensional units Sl Basic Units Derived and additional units Area me Square meter Volume n cubic meter Angles i degree minute second Electric current Time min minute hi hour d day Temperature Frequency Hz herz s Luminance Velocity ms Material length Acceleration m s Recalculation K n C 273 15 Density kg m C n K 273 15 Force N newton kg mie Pressure mech Tension Pa Pascal N m Pressure bar bar 100 000 Pa 0 1 Mpa Dynamic viscosity Pa s Pascal second Torque Kinetic viscosity m s Nm kpm Ibf
61. 84 Various types of compensation transmitters can be connected A PT 100 transmitter with mA output is normally used for temperature compensa tion Since the compensation input is a universal input for 4 20 mA it can also be used for other types of compensation equipment The function should be used only with multi point calibration which should preferably be performed before compensation is calibrated c Record the temperature during multi point calibration The temperature transmitter is connected to the AUX in terminals in the JCT 1100 junction box See the wiring diagram in the Installation in structions section of the JCT 1100 manual included in this manual Setting 1 Calibrate the transmitter against the consistency transmitter Confi A Press gure inthe main menu B Enter the code 1945 20 m Rawsig 1023 C Step down to temp by pressing the ES button Temperatures in C F or any other temperature system D Determine the temperature span within which the process may vary e g 25 55 C Calibrate the transmitter for a somewhat wider measuring span e g 20 60 C Calibrate the temperature transmitter in workshop to re quired measuring span e g 20 C 4 mA and 60 C 20 mA output signal Note It is not necessary to make a complete and precise cal ibration but you must verify that the transmitter s output sig nal actually c
62. B max feedback raw signal Both the Feedback raw signal as well the Feedback value can be dis played after pressing i according to point 4 above O1218 56 3en MEK 2300 Operating instructions 135 BTG 2004 3 7 Special calibration functions SEE 3 7 5 Calibration Curve See section 3 6 1 2 on page 96 item F EON Calib This function is in the main menu under ration The feedback signal 0 100 is displayed as a function of the set mea suring span xx xx The calibration points within the predetermined measuring span are displayed but note that activated calibration points outside the measuring span affect the shape of the calibration curve A valuable application for the function is showing in a simple and clear manner how well the calibration points agree with the calculated curve The three calibration constants KO K1 and K2 and the special correla tion factor r also provide a guide Refer also to section 3 6 6 5 on page 120 Note that the feedback signal is displayed for the entire span 0 100956 This means that the slope of the curve and thus the resolution can be small This is particularly the case if a small measuring span is selected or at low consistencies and pulp grades with low shear force such as re cycled fibres If other measuring criteria are good i e the transmitter is correctly installed the 4 20 mA signal can be modulated f
63. DANGER High voltage operation motor Connection must be carried out by authorized personnel Where the transmitter s mechanical seal is not water flushed the motor must be interlocked with the pump motor 2 5 8 Connection of electric motor 2 5 8 1 General The motor can either be 3 phase or single phase Instructions for the connection of the transmitter s electric motor are to be found in the cover of the junction box See Fig 34 Fig 35 The motor should preferably be connected using a plug to ensure easy service acces sibility 2 5 8 2 Connecting a 3 phase motor a The pulp line must be empty while this work is being carried out b Check that the motor voltage connected at delivery is correct If it is not adjust the jumpers in the junction box for the correct voltage according to the data on motor type designation plate See Fig 34 Fig 35 c Always check that the motor voltage connected at delivery is correct If not switch over to the correct voltage c The direction of rotation is indicated by an arrow on the motor housing As soon as the motor has been connected check that the direction of rotation is correct by starting and stopping the motor momentarily See Fig 35 d Set the overload protection to the same value as the rated current for the motor indicated by the rating plate If the overload protec tion shows a tendency to trip it may be raised by a maximum of 20 but in no case must the external mo
64. EP rm i Rod acts 52 2 8 2 Junction box type Sigh 2 Gard Bebe 8s fes uar Rer tbetso gres 54 2 8 3 Measuring vessel weld in stud low pressure models type sign 54 2 9 Miscellaneous 2 500 Vr dee drei e O85 dui e atl weder d arde e deque Va 56 2 9 1 Dimensioning of the dilution water valve for consistency control 56 2 9 1 1 Calculation formula for dilution water flow 56 2 9 1 Dimensioning of the dilution water valve saaana nnn 56 2 9 2 Pressure and temperature limits for piping pipe flanges and fittings of stainless steel according to Swedish Standard SMS 1233 61 2 9 3 Measuring vessel with weld ends Dimensions of the vessel s weld ends 62 2 9 3 1 Pipes according to ISO standard dimensions 62 2 9 3 2 Pipes according to ID metric Inner Diameter standard dimensions 62 2 9 4 General dimensional units GI 63 II MEK 2300 Table of contents M218 56 3en BTG 2004 3 Operating instructions 65 3 1 Important points to note EE Kee ee ce 65 3 2 Routine servicing general remarks 00 eee eee eae 66 3 3 Hand held Terminal SPC 1000 2 2 0 0 0c 67 3 3 1 General Infortiatiort 2 ox odium hve RUE Fenice ks 67 3 3 2 Connecting the SPC 1000 EN 68 3 3 2 1 Power TEE 68 3 3 2 2 Real Ile Lee WEE 70 3 3 3 CONNSCING a printer cer tea ETDSU 4e Eee wee adu ee ws 71 3 3 4 Connecting EE 72 3 3 5 Memory CAS e 5 0s Anite eed fondre e
65. Flushing water for mechanical seal Where applicable the supply of flushing water for the transmitter s me chanical seal must be of good quality and pressure must be maintained at all times See section 2 5 7 for detailed recommendations as to the de sign of the water supply system MEK 2300 Installation instructions 11218 56 3en BTG 2004 Fig 6 2 4 Planning the installation MEK 2300 system typical control circuit for consistency control Consistency transmitter MEK 2300 Junction box type JCT 1100 Hand held terminal SPC 1000 3 System cable to transmitter Controller and recorder DCS Dilution water valve Pulp chest with sufficient mixing Stock pump BTG Sampling valve type MPS 1000 Transmitters with mechanical seals that are not water flushed must have their motors interlocked with pump motors to ensure that the transmitter stops when the pump stops However it must still be possible to run the transmitter s motor under manual control by jogging it and to lock it in this position MEK 2320 With this model it is vital that the flushing water pressure is maintained at all times If pressure is lost fibers may clog below the sens ing element and affect measurements 2 4 2 Choosing a site for the transmitter Careful siting of the transmitter is essential for optimum performance and ease of maintenance The transmitter can be installed in a vertical horizontal or inclined pipe If
66. Measuring chamber in A the measuring vessel 3 Inspection cover 4 Stud bolt Note Fit bolt in the upper hole 5 Flow direction arrow 6 Inspection area 1 A Ga 2 I L 3 l S en 6 A SE LJ 5 Offset measure x D x Conn mm Imm 100 106 71 4 114 3 67 Y 125 131 58 5 139 7 53 a E e E 150 156 45 OD e 1983 2 D Outer diameter of pipe 200 206 20 8 219 1 13 5 250 256 0 10 273 0 11218 56 3en MEK 2300 Installation instructions 21 BTG 2004 2 5 Installing the transmitter Fig 10 Measuring vessel with weld ends for low pressures and lt Flow direction horizontal mounting left hand design standard 1150 la 475 675 18 7 26 6 Fig 11 Measuring vessel with weld ends for low pressures and Flow direction L horizontal mounting right hand design on request 22 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 12 Measuring vessel with stud for sampling valve available to order 1 Vertical mounting 2 Horizontal mounting left hand design A For more information see drawing 5329015 included in reference A gt State in order to BTG if sampling valve type FVS 1100 or MPS 1000 is going to be installed 3 Weld in stud for sampling valve type FVS 1100 or alternatively MPS 1000 11218 56 3en MEK 2300 Installation instructions BTG 2004 23
67. Operating the transmitter Read data FU Reads the sensor s setting to both mu memories in the hand held terminal and deletes all previous programming in the terminal 61 7 1008 Cons 3 35 oeh The function flashes normally when reading should be carried out but it may also flash under other circumstances SS Choice of measuring range No 1 of 4 mis for editing Note that the present actual TUM SH output signal is controlled by the exter Goo nal measuring range setting This output pem signal is the one displayed in the main menu 61 7 3 35 cons in example Setting and control of the transmitter s mus basic functions locations in the process Si TAG no temperature compensation and calculation of the production option al functions Tag no 282234 For calibrating the transmitter against o A the consistency in the process i NE Can also be used as a training and simula tion function 25 234 LN Shows the differences between the c pum stored calibration points and the cali M cm bration curve as well as the calibration constants and the correlation factor 25 234 Setting the minimum consistency of the SS measuring span Send data is Tag no 282234
68. Quantity of liquid m h p Density of liquid kg m Ap Pressure drop across the control valve bar When the dilution water density normally is 1000 kg m the formula can be simplified to EON V JAp The pressure of the dilution water should not vary more than 15 In 56 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 9 Miscellaneous Fig 36 Example of traditional dilution before pulp pump case of large pressure variations we recommend a pressure control of the dilution water see directions in section 2 4 1 Example When the installation is traditionally made according to Fig 36 where the dilution water is injected before the pulp pump the pressure drop across the control valve is equal to the difference between the dilution water pressure and the height of the pulp chest This pressure difference should be min 0 4 0 5 bar 6 7 5 psi In this case the pressure difference is 0 8 0 3 bar 0 5 bar 12 4 5 psi 7 5 psi With all other data in accordance with the examples above the required K will be The BTG ball sector valve type VBG 30 according to data sheet D521 60 65 is a suitable control valve Choose a valve size 40 or 50 mm l5 or 2 in depending on the pipe dimension The velocity of the dilution water at the point of injection should be 3 5 m s 10 16 5 fps see also section 2 4 1 According to the nomogram in Fig 37 a pipe size of 60 80 mm 2 5 3 2 i
69. R High voltage within the junction box Connections may only be carried out by qualified personnel applies to version with 100 240 V AC power supply 4 8 3 3 Replacing the main circuit board If the main circuit board is faulty it needs to be replaced Tools required Screwdriver medium size Star screwdriver medium size c Break and secure the AC power supply voltage to the junction box before the front panel is removed it is not sufficient to turn it off with the power supply switch in the terminal box All numbers within below refer to fig 80 on page 4 177 1 Check that the 24 V DC LED 7 and the display are off 2 Unscrew the terminal box cover 1 3 Detach all screw clamp connectors with cables connected to them Note that the terminal screws do not need to be fully removed the contact can be pulled out of the screw clamp connector on the main circuit board 4 Unscrew the front panel 2 and carefully lift the front panel plate aside 5 Detach the display connector 8 by pushing the two levers aside and pulling the connector straight out from the main circuit board 6 Detach the SPC connector 9 by pulling it straight out from the main circuit board It might be necessary to loosen the locking flap using a flat screw driver 7 Unscrew the front panel grounding strap 12 from the main circuit board 8 Unscrew the fifteen screws 10 that attach the main circuit board to
70. The difference is that a different torque required for 100 feedback is set during Item 3 e g 50 kpmm This means double the resolution as at a torque of 100 kpmm Enter this value as per Item 4 C Direct input for required feedback resolution c This adjustment is not as accurate as the previous adjustments but works quickly and simply The transmitters cannot be interchanged The standard Feedback in water setting may not be valid 1 Refer to item A 1 and 2 134 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 7 Special calibration functions FB 100 2 Press wsig Enter the raw signal as per the following table xx Fig 62 Feedback torque curve MEK 2300 Feedback Raw signal Torque 3400 1085 50 3200 1200 60 3000 1320 70 2800 1423 80 S 2600 1565 90 2400 1694 100 2200 Torque 1880 110 2000 2110 120 Eden 2350 130 iib 2725 140 1400 3180 150 Ga 1000 r t t r t 40 60 80 100 120 140 160 Torque kpmm gt This feedback torque curve is only valid for the latest versions of MEK 2300 See section 3 16 Software revisions r FB 3 As a reminder also enter the torque value at Es 4 Press to transfer the values to the transmitter 5 Exit by pressing iade c To obtain the actual feedback value in Feedback in air x 100 max FB Feedback in air Feedback value raw signal when sensor rotates in air max F
71. User manual MEK 2300 with JCT 1100 Smart Rotating Consistency Transmitter Sample Pie M218 56 3en BTG 2004 06 09 Disclaimer The contents of this document are subject to revision without notice due to continued progress in methodology design and manufacturing BTG shall have no liability for any error or damages of any kind resulting from the use of this document OBTG 2004 BTG Pulp amp Paper Sensors AB P O Box 602 SE 661 29 S ffle Sweden Phone 46 533 426 00 www btg group com Table of contents 1 Safety recommendations 1 1 1 Safety recommendations for consistency transmitters in the MEK 2300 Family ikea petu up RA Yen RE tus 2 1 2 General 35 33 2 02 22 8 50 CER ROC ae eee a EN 2 1 3 Selecting a transmitter model and assembly parts 2 1 4 Installing mounting details 5255 2 1 5 Installing the transmitter eee IBI 3 1 6 Installing the junction box lisse 4 1 7 Starting up and servicing the transmitter 0000005 4 2 Installation instructions 5 2 1 Important information e 4 d bb dr dere vete et lue bdo ace oer es 5 2 2 Before youstatt x ate veni iiie
72. accordance with Swedish industrial safety and pressure vessel standards Do not accept parts which have not been manufactured by BTG and follow the current instructions and stan dards during installation Selecting a transmitter model and assembly parts Pressurized parts must be suited to the current maximum pipe pressure in relation to the temperature see the data sheet Select a material for the parts which come into contact with the medium so that corrosion does not occur see data sheet CAUTION The shut off valves see II 218 56 section 4 2 3 should be used only in low pressure installations and with non corrosive media as we cannot guarantee complete tightness over the valve Installing mounting details Welding or bolting and subsequent inspection should take place in accor dance with current standards and regulations Use approved lifting gear MEK 2300 Safety recommendations SR218 56 3en BTG 2004 06 09 1 5 Installing the transmitter Assure yourself that the pipe is empty before opening it up DANGER High voltage operation motor Connection must be carried out by authorized personnel 1 5 during installation to prevent injury Anchor the parts well during installation A measuring vessel weighs ap proximately 40 kg 88 Ib Brace this vessel if it has a shut off valve weight with shut off valve 120 kg 265 Ib Installing the transmitter Use approved lifting gear during installation
73. according to the HART protocol and BELL 202 modem standard The communication takes place as a superimposed signal over the 4 20 mA output signal loop The following functions are available e Output signal In percentage of output signal and in mA e Identification Instrument supplier BTG and instrument identification TAG no e Alarm information Present signal above or below the set measuring span 4 mA 220 mA e Damping Adjustable setting e Measuring span Adjustable setting c For details please contact the HART Communication Foundation or BTG OI218 56 3en MEK 2300 Operating instructions 151 BTG 2004 3 16 Software revisions 3 16 Software revisions 3 16 1 SPC 1000 hand held terminal There are two models available the original model SPC 1000 and an up graded model SPC 1000 A Both models can be used with all types of MEK 2300 transmitters and all versions of PCMCIA sensor cards 3 16 2 SPC 1000 PCMCIA sensor card Today s MEK 2300 product requires PCMCIA sensor cards versions E or F depending on language version or later The MEK 2300 software version in these PCMCIA sensor cards is 1 3 or later These sensor cards can also be used with all older sensor processor card software versions See section 3 16 3 below for further information Older PCMCIA sensor card software versions A D have restricted us age in combination with sensor processor card software versions See section 3
74. ake a new calibration c The word New calibration must appear to make a new calculation 5 Press daca to enter the calibration to the transmitter 132 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 7 Special calibration functions 3 7 4 Altering Feedback resolution See section 3 6 6 5 on page 120 symptom 6 and 7 compare with sec tion 3 6 2 2 on page 101 All transmitter models for normal or low consistency MEK 2300 2308 2314 2320 2340 have a standard setting for feedback in rela tion to the torque Standard setting NC 100 feedback at a torque of 100 kpm The medium consistency models MEK 2310 2311 2312 2315 have a stronger setting MC setting 100 feedback at a torque of 150 kpm These settings are incorporated before delivery using a special torque brake This is a form of calibration to make the transmitters identical with each other As a result it should be possible to exchange transmitters and transfer calibration data without the need for extensive calibration against pulp samples Where necessary it is also possible to adjust the feedback signal to show 100 at an adjustable torque of between 50 150 kpm gt This function is particularly useful if the difference in feedback within the predetermined measuring range is very small This can occur at low consistencies and in particular with pulp grades that have a low shear force e g recy
75. al Max 5 10 min If the mechanical seal is water flushed there is no time lim it g Motor cable see section 2 4 3 T6 T3 14 49 56 34 X U V W Connected for 11218 56 3en MEK 2300 Installation instructions BTG 2004 49 2 5 Installing the transmitter Fig 35 C5 Cc Suggested connection of the transmitter motor Transmitter From the pump control circuit Note Same phase as forthe circuitfor manual operation Contact for motor pro tection and control device for manual run in junction box AUTO MANUAL switch Safety switch 2 5 8 3 Connecting a single phase motor Instructions for the connection of the transmitter s electric motor are to be found in the cover of the junction box Note that the single phase motor has a smaller voltage tolerance than the 3 phase motor It is therefore very important that the actual voltage at the mill really is within the tolerance For 110 V AC motor max voltage 121 V AC and min 99 V AC For 220 V AC motor max voltage 242 V AC and min 198 V AC 2 5 9 Jumper on processor card The processor card located on the side of the transmitter can be config ured for RS 485 communication or for HART communication with the J4 jumper as follows d RS485 communication on J3 rd activated Optional 2 3 je je gt r HART communication on AnaOut1 4 20 mA Standard
76. al display and console for basic configuration of the transmitter and the collection of measuring values for calibration with the SPC 1000 Connection point between the transmitter power supply and the DCS Digital Control System Local connection for a hand held terminal SPC 1000 or for a lab top PC with BTG s SPCwin program 1 ment XXX Yo XX XX mA _ amp 9 9 Sample Enter 3 7 System cable to e transmitter 5 lo SE Terminal e D 6 LZ Li tf a e 7 S AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 157 BTG 2004 4 1 Product introduction 4 1 2 Technical data Type JCT 1100 for BTG transmitters Manufacturer BTG S ffle Sweden General Electronic Enclosure Protection rating Weight Made of poly carbonate thermoplastic with a transparent cover Nickel paint coated internally to protect against EMC interference IP65 NEMA 4x Electronics box 2 0 kg 4 4 lbs Signals Output signal analog Output signal digital Analog input Measuring ranges 4 20 mA Galvanically isolated Current limited to 21 mA Min load for communication with display terminal
77. ansmitter G mim settings on an external printer or down von loads them to a PC 61 7 amp 1008 3 35 De gees Displays the relevant Feedback signal Be ORE output signal and consistency and the DLL output signal s variation over time 0 55 minutes Displays the position in the process TAG No measuring range in opera tion according to external connection Output signal in 0 100945 Present consistency in according to calibration and the type of transmitter that is con nected 61 7 8 Cons 3 35 B General programming instructions These instructions apply only to software version and any future soft ware revisions within version 1 such as 1 1 1 1 1 1 2 ete gt See section 3 16 on page 152 for program modifications in relation to previous versions The following general instructions will apply to the rest of this manual Example Press the 3 button on the display that has this desig nation Example 20 s This should appear on the display The program is menu based with direct display of the current menu In other words the menu tree structure according to the traditional con cept is very limited c These instructions apply only to software version 1 X O1218 56 3en MEK 2300 Operating instructions 83 BTG 2004 3 4 Operating t
78. ansmitter removed from the pipe alternatively with the transmitter mounted in the pipe and no pulp in the pipe The torque brake is an accessory to the consistency transmitter fitted to the measuring part side of the transmitter By varying the current to the torque brake different torques corresponding to different pulp consistencies can be used See special instructions for the torque brake D M750 10 The transmitter signal in this case the feedback signal can then be adjusted to a certain level corresponding to the applied torque 100 kpmm torque shall correspond to 100 feedback MEK 2300 2 Against laboratory samples The transmitter is then mounted in the pipe and running Comparison to lab samples implies several sources of error Origi nally the transmitter is as a rule calibrated against a great number of lab samples and adjusted accordingly Thus comparison to one lab sample only implies a source of error The sample can be extracted from the pipe in a number of ways Different types of sampling valves respectively common ball valves result in a various number off more or less serious sources of error which cannot be discussed here The main points for a good sampling are generally that the samples shall be extracted from the pipe in a uniform repeatable way in accordance with the origi nal calibration The sample volume must not be too small At least 0 5 liter 0 13 US gallon is necessary The treatment of t
79. ants will now appear 106 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration 10 Evaluate the calibration as per section 3 6 6 5 on page 120 11 Transfer the calibration to the transmitter Press Se Check that all data that is displayed is correct If a code has been entered see section 3 9 on page 140 key this in correct Yes ly and press to transfer all the data to the transmitter If the message Transmission fail appear there is a commu nication problem Refer to the Service manual and section 4 item 5 12 Press 7 in the main menu Check the stability of the signal over time If necessary go back to the main menu and set a suitable time constant Press is see section 3 6 7 on page 125 Then transfer the new data to the transmitter again 13 Trim the controller See section 3 14 on page 150 14 Document the calibration either manually or by making a printout refer to section 3 6 6 2 on page 112 Refer also to gt Calibration is now complete but can generally be improved by entering additional calibration points i e multi point calibration 01218 56 3en MEK 2300 Operating instructions 107 BTG 2004 3 6 Calibration 3 6 3 3 Multi point calibration See section 3 6 1 1 on page 93 item C Multi point calibration is based on several measured values and is used to obtain exact
80. approved only the junc tion box and motor 52 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 8 Type sign explanation 5 Manufacturing number BTG internal manufacturing number 6 Warning sign The device is designed for industrial use Installation handling and ser vice must only be carried out by trained and authorized personnel and ac cording to valid standard Read the manual for detailed information and pay special attention to the warning signs 7 Sensing element Sensing element part number see Parts List SP218 56 8 Rubber quality in wetted parts FPM Standard Flour carbon rubber For general purpose up to pH 12 EPDM Ethylene Propylene rubber For high pH applications pH 8 14 See Service Manual SM218 56 chapter 2 2 9 Splined fastening of sensing element No marking Alt 2 Traditional fixed center screw fastening SP Alt 1 New splines standard screw fastening See Service manual SM218 56 chapter 2 1 1 10 Mechanical seal of Hastelloy No marking Original mechanical seal part no 27006121 mounted See Parts List SP218 56 position 215 S2 New model of mechanical seal part no 27010487 mounted See Parts List SP218 56 pos 215 11 Wetted parts made of SS 2343 SMO HC SS 2343 Standard material stainless steel SS2343 AISI 316 SS DIN 1 4436 SMO Stainless steel 254 SMO HC Nickel alloy Hastelloy C 276 See data sheets D218 56 and D750 01 12 Pressure PN 10 25 ba
81. asuring range Can be changed to access other ranges ranges 1 2 3 or 4 Measuring span low limit 4mA high limit 20mA Offset adjustment OFFSET 40 00 Process value offset if required Damping setting DAMPING 0s Damping on output signal if required Calibration setting Hep ora SEIN constants for the transmitter s calibration 172 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 7 Operating instructions Language selection JCT Communication Collecting samples LANGUAGE en Language setting in this case English JCT COMM ON Shutdown of communication between the junction box and the transmitter 4 7 3 Collecting samples and changing settings 4 71 12 53mA When the Result display is shown samples can be collected to calibrate the transmitter NO 5 X 20 Press the sample button 0 and collect a process sample for lab calibration No 5 on the display indicates which position in the calibration table the sample value will be stored The first empty position in the table is selected The X in X 20 will increment as each value is stored When all values have been stored an average sample value will be calculated and displayed c Always mark the lab sample with the table number for the sample value The lab sample value for the corresponding calibration cannot be entered f
82. at at least 10 mm 0 4 in of the pipe extends into the main pipe where the cover is at its nar rowest see Fig 17 Then weld the pipe into the hole taking care not to deform the inspection cover pipe in doing so Check that the inspection cover pipe fits properly in the groove of the cover Then tighten the inspection cover against the pulp line with the clamp and nut Fig 14 Material thickness in Le Mm main pipe to PN10 For low pressure weld in studs tmin mm Minimum mate rial thickness in main pipe for PN 10 D mm Outer diameter of main pipe A Stainless steel to SS2343 AISI 316 254 SMO B Hastelloy C 276 300 400 500 600 700 800 OD mm Example using Fig 14 What is the min material thickness required for a main pipe size 400 of ISO standard when dimensioned for PN 10 Material Stainless steel to SS2343 standard D 406 4 mm according to standard Select line A SS2343 According to the diagram tmin 3 75 mm Select standard pipe 406 4 x 4 5 mm Due to the standard thickness tol erance of 10 it will not be sufficient with t 4 0 mm gt Use valid standard for exact calculation 26 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Use a valid calculation standard for an exact calculation The devia tion from Swedish Standard is as a rule of minor importance However when tmin in the diagram approaches the thickne
83. ately 3 hours c Switch off the terminal immediately after use to obtain the maximum operating time Rechargeable batteries or manganese batteries provide much shorter op erating times The display lighting does not come on in battery mode in order to maximize battery life and provide maximal operating time De spite this display readability is quite sufficient in normal room lighting 3 3 2 2 Communication As mentioned earlier the hand held terminal communicates with the transmitter via a special protocol some functions are identical to HART protocol For communication to take place the circuit resis tance must be at least 250 Q at 4 20 mA For more information see the Installation instruction section of the JCT 1100 manual included in this manual Normally the terminal s telephone jack is connected to the junction box socket This connection provides power and is also the communications link between the terminal and the transmitter Communication with the transmitter can also be achieved at a greater dis tance In theory the maximum distance from the transmitter is approxi mately 600 m which also applies for the output signal but this distance is often limited in practice to a couple of hundred meters because of volt age drop over the cable Compare section 3 5 I1218 56 An adapter set fitted with snap on test pins and mini grippers Fig 44 is supplied with the terminal and plugs in to the terminal s telepho
84. ates the direction of rotation for the motor 0 5 1 min The sign is fastened 0 13 gal min to the transmitter at delivery 13 130 psi 77 5432702 Take care of instruction manual test protocol fastening screws and wate overflow 1 in package 2 5 7 3 High pressure flushing Model MEK 2320 Code type designation SSW ESW voilier are BE If the flushing water pressure is lost even momentarily particles from than media pressure the media may enter the area around the seal and this will result in wear Any particles sticking between the hub of the water guide bushing and the hub of the sensing element will disturb measurement The rate of flow for MEK 2300 is 0 95 l min 0 25 US gal min The flow 1s controlled by a built in flow controller For this model the water penetrates into the pulp protecting strings or other objects spinning around the sensor sensor hub It is very important that there is no pressure loss We recommend the installation ofa check valve at the water supply There must not be any loss of water pressure which must always be min 0 5 bar above media pressure Avoid taps at the water supply To check the flow we recommend a flow indicator Install a filter that must be kept clean if clogging particles are present Arrange the filter cleaning to pre vent pressure loss during the cleaning period 11218 56 3en MEK 2300 Installation instructions 47 BTG 2004 2 5 Installing the transmitter
85. brated against the consistency trans mitter 3 Connect the temperature transmitter to the AUX in terminals in the JCT 1100 junction box See the wiring diagram in the Installation instructions section of the JCT 1100 manual included in this manu al The flow rate value is obtained at Trema The function can be disabled by using the button E Continue pressing the button until the arrow points to Off Send Remember to data OI218 56 3en MEK 2300 Operating instructions 139 BTG 2004 3 9 Code protection 3 9 Code protection A security code can be entered to prevent unauthorized adjustment of the transmitter settings All the functions in the hand held terminal can still be accessed By using the simulation function see section 3 7 7 on page 137 you can also see how the transmitter reacts to changes The code protection prevents the settings on the hand held terminal reaching the transmitter if the security code is not entered A personal code can be en tered and if this is lost a general code is available from BTG gt A general code is available from BTG if your personal code becomes lost General code 42 600 A Initial activation of the security code input of a personal code 1 This should be done at the first opportunity during installation Send Turn Go to data in the main menu Press 99 followed by Se Load old code will be disp
86. c motor briefly and check the rotational di rection c The motor should not be allowed to run for more than 5 10 minutes without a supply of flushing water Proceed to the MEK 2300 Operation instructions 11218 56 3en MEK 2300 Installation instructions 51 BTG 2004 2 8 Type sign explanation 2 8 Type sign explanation 2 8 4 Transmitter type sign eem 3 Ver Pulp A Paper Sensors AB m Industrigatan 1 2 i NC 661 29 S ffle N E SWEDEN A NS N1619 SS Di lbnr aens 2 PN10 FPM SP S2 OROKO gt The third letter at section designation below refers to the no s in the figure l e 7 1 3 Where 3 describes the mechanical seal code 1 Manufacturer 2 Transmitter version MEK 2300 2308 2310 2311 2312 2314 2315 and 2320 See Always refer to the type data sheets sign when ordering spare parts 3 Mechanical seal code SSW SSO HSW ESW ESO FSW First letter Mechanical type S Crane Sealol 680 or 670 H HF4 668 E Eagle F Flexibox Second letter Material in seal faces S silicon carbide Third letter Water flushing of seal W with water flushing O open version without water flushing See section 2 5 7 and Service manual SM218 56 section 2 3 4 CE marking CSA The device complies with the amendments and requirements of the CE directives 89 392 EEC 73 23 EEC 89 336 EEC and 97 23 EEC Note The transmitter itself needs not to be CSA
87. ced by a larger one 4 Press Be 108 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration Take N Ye x 5 Select sapie then calib Press for a new calibration ration or for an UPDATED CALIBRATION UPDATED CALIBRATION is used if you want to preserve the val ue of sample 1 from single point calibration 6 Select Z and take laboratory samples normally three at each level immediately while at the same time storing the feedback signal in the memory Mark the laboratory sample with the sample number shown on the display 7 Decrease the consistency and repeat the procedure For next sample press amie You should take at least three samples at high me dium and low level within the measuring span The wider the spread within the measuring span the better results will be Menu Exit by pressing the key after collecting suitable amount of samples at various levels 8 Load the laboratory consistency mean value of samples under Sample Feed Lab Active No back cons Load gites m lab for all numbered samples EBD i The FEEDBACK IN WATER signal should normally be included SE i e activated If any sample is faulty it should not be activated i e SPC 1000 M not included in the calibration Menu Calc 9 Press the key then new Let the m
88. chanical seal and the sensing element Fig 31 Warning sign installation CAUTION Don t lift or twist sensor or sensing shaft when mounting 1408533 44 MEK 2300 Installation instructions BTG 2004 11218 56 3en 2 5 Installing the transmitter 2 5 7 Connection of flushing water to mechanical seal All MEK 2300 transmitters except the MEK 2340 are equipped with a mechanical seal for the drive shaft The seal can be flushed with water to produce a cleaning lubricating and cooling effect gt In most cases the water flushing can be avoided provided certain precaution are taken see section 2 5 7 1 Water flushing can be avoided for most units to be installed Flushing operation can be achieved in one of two ways e In low pressure flushing the flushing water goes to a drain e nhigh pressure flushing the flushing water is pressed into the media Models No MEK 2320 have high pressure flushing All other models except the MEK 2340 are designed for low pressure flushing The flushing water must be of standard quality with no impurities larger than 200 um 2 5 7 1 No water flushing Code in type designation SSO ESO As mentioned above the flushing water provides a cleaning lubricating and cooling effect and normally gives the seal a longer life However the cost of installation and operation of the water flushing in relation to a somewhat shorter life for the sealing are factors that sh
89. cled fibres Note however that when the size of the sensing element determines the basic sensitivity this is always changed first As the feedback resolution increases the sensitivity is increased as well as the signal noise A Standard adjustment of Feedback resolution 100 feedback NC 100 and MC 150 kpmm torque respectively Criteria The transmitter must be started up and rotating in air 1 Press gaze inthe main menu followed by Feedba adjust 2 The adjustment is protected by a code 2300 Enter this code Press Sensor sens calib OI218 56 3en MEK 2300 Operating instructions 133 BTG 2004 3 7 Special calibration functions 3 Fit the torque brake as shown in data sheet D M750 10 appendix to the Service Manual SM218 56 Adjust the dynamometer torque to 100 and 150 kpmm respectively according to the transmitter model see above FB 100 Press Ze Enter 100 or 150 kpmm as required 4 Press d to transfer the calibration to the transmitter The raw signal for SETPOINT ANGLE FEEDBACK and AUX in will then be displayed The feedback signal 1s now calibrated against the torque adjusted 5 Exitby pressing 5 B Increased sensitivity of feedback resolution 100 feedback 50 100 kpmm torque max 150 gt The transmitters are not interchangeable The standard Feedback in water setting is not valid Procedure Refer to Item A
90. d and calibrated as described above the temperature can be read in main menu at output signal 4 Returnto 8 according to item 1 A C 5 Enter the typical temperature measured during the multi point cali Worl s S s Point bration according to point 4 above at Temp There is no compen sation at this point 6 Calibrate the compensation factor 96 consistency C Be sure to make the calibration at a temperature e g 45 C which differs sub stantially from the one used in the multi point calibration e g 35 C Consistency should be normal 130 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 7 Special calibration functions Start by storing the consistency from the transmitter at Sample Then enter the lab consistency at IA xx Note that because the calibration is made at one point only the value must be as accu Calc rate as possible Calculate by pressing The compensation factor is shown in the display button A and can also be input directly here 7 Check the compensation factor at Saie XE You can re move the compensation by pressing 23 0 zero The compen sation factor will normally be negative in temperature compensation because the feedback signal decreases with increas ing temperature The factor varies because it depends on pulp qual ity sensor etc It increases directly in relat
91. d held terminal Press carp 2900 SENSOR ver1 0 c Do not Read data If so the values obtained from the backup card will be erased 5 Press 5 in the main menu 6 Press SEIT and then range for the relevant measuring range to transfer the data from the backup memory to the editing memory in the terminal 7 Press The data for the respective measuring range is now available in the terminal for further processing 118 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 6 Calibration SPC 1 000 Documentation program for Windows Version 1 0 BIG GS Co right 1995 All ri rights r 3 6 6 4 Documenting calibration using a personal computer PC Installation Document PC The SPC 1000 terminal program comes with an automated installation program called setup Installing the terminal communication program a Start Windows Insert the installation diskette marked SPC 1000 Documentation program for Windows into drive A b Choose File from the Program Manager main menu c Choose Run d In the Command Line text box type a setup then choose OK e Follow the instructions and the program will be installed on your hard drive Connection and starting your program gt Arrange a suitable library in the File manager to help you to keep track of downloaded fi
92. d tested prior to shipment However even the best products can sustain transport damage that will only be seen if the product is inspected Before proceeding check the transmitter the hand held terminal and the junction box for transport damage Look for loose screws wires or electronic components 11218 56 3en MEK 2300 Installation instructions 7 BTG 2004 2 3 Basic system description 2 3 Basic system description 2 3 1 The system The system consists of a transmitter connected by a system cable to a junction box type JCT 1100 To set up the transmitter a hand held termi nal type SPC 1000 must first be connected see Fig 1 As an alternative a PC with BTG s SPCwin program installed can be connected to JCT 1100 with BTG s modem cable and be used to set up the transmitter Fig 1 MEK 2300 1 Transmitter 2 Junction box type JCT 1100 3 hand held terminal type SPC 1000 The transmitter contains measurement devices and electronic circuitry for signal conversion It is mounted in a measuring vessel or weld in stud depending on pipe dimensions that is welded or flange fitted to the pipe system The hand held terminal allows the operator to set up and monitor the sys tem and includes a liquid crystal display LCD with a touch screen key pad 8 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 3 Basic system description 2 3 1 1 Conformity to CE directives and CSA approval The entire s
93. drain valve for emptying the measuring chamber will also be required These are not in cluded in the delivery Installation in pipe a Turn the valve so that its hand wheel is uppermost b The stud should be profiled and welded in the manner described in section 2 5 2 2 above The length of the measuring chamber should be kept as short as possible approximately 180 mm 7 in c Brace the valve if the pipe is subject to vibration and or is of small diameter 11218 56 3en MEK 2300 Installation instructions 29 BTG 2004 2 5 Installing the transmitter Warning Assure yourself that the pipe is empty before opening it up 2 5 3 High pressure pipe installations 25bar 226 C Where pressure is gt 10 bar at 20 C 150 psi at 68 F and pipe diameter is lt 250 mm 10 in the transmitter should be connected to the pulp line via a measuring vessel See Fig 19 and Fig 20 See section 2 9 2 Where pressure is gt 10 bar at 20 C 150 psi at 68 F and pipe diameter is gt 300 mm 12 in the transmitter should be connected to the pulp line via a weld in stud See Fig 22 See section 2 9 2 2 5 3 4 Installation with measuring vessel Standard measuring vessels for high pressure applications are designed for weld connection See Fig 19 Measuring vessels equipped for flange connection in conformity with DIN 2655 ANSI 300 Ibs or other stan dards are available t
94. e SPCwin version i SPCwin PC version of SPC 1000 Mas d rune Simulation of SPC 10 Leg g N BIG All rights reserver d SPCwin 76 MEK 2300 Operating instructions BTG 2004 01218 56 3en 3 4 Operating the transmitter 3 4 Operating the transmitter The transmitter can be programmed from the hand held terminal SPC 1000 from the SPCwin PC program or from the JCT 1100 junction box limited functions Programming of the transmitter from SPCwin is the same as from the SPC 1000 hand held terminal This section describes programming of the transmitter from either For further information about SPCwin see section 3 3 8 on page 76 For instructions regarding how the transmitter is programmed from the JCT 1100 see the Operation instruction section of the JCT 1100 manual included in this manual OI218 56 3en MEK 2300 Operating instructions 77 BTG 2004 3 4 Operating the transmitter Fig 48 Using the touch screen 3 4 4 Programming the transmitter with hand held terminal SPC 1000 general instructions The software is designed for simple user friendly programming com bined with a high degree of flexibility A certain amount of training us ing simulation in a comfortable workplace accelerates the learning process and reduces the risk of mistakes in actual process operation T
95. e buttons are always in English not translated to other languages The buttons are within the framed area where the menu choice text is located Pressing the display area actuates the button displayed there Touch the MEK 2300 ver 1 2 button as in Fig 50 Fig 50 Selection of MEK 2300 program 4 20mA MODEM PRINTER PWR ON OFF EJECT MEMORY CARD SPC 1000 Communication Terminal OI218 56 3en MEK 2300 Operating instructions 79 BTG 2004 3 4 Operating the transmitter MEK 2300 Ver 1 2 A A A A 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD SPC 1000 Communication Terminal d Selection of type of sensor MEK 2300 this manu al Program ver sion 1 2 Sensor type MBT 2300 not in this manual Sensor type OCT 2300 not in this manual X X Future trans mitter programs c See section 3 16 on page 152 for details regarding software revisions The MEK 2300 main menu is displayed see Fig 51 What follows is an explanation of the selections you have available on the buttons in the main menu This menu is identical for all BTG Smart transmitters Fig 51 Selection buttons in the main menu of 4 20mA MODEMPRINTER MEK 2300 program PWR ON OFF EJECT MEMORY CARD SPC 1000 Communication Terminal 80 MEK 2300 Operating instructions BTG 2004 01218 56 3en 3 4
96. e changed for each Range However the changes will not take affect until the transmitter s range is changed via the Range select switch Press enter e to change the Span When the first number starts to blink press 4 or v to change the number Press enter to accept The next number will blink Repeat the procedure until done After the last value has been entered the new span is set Press the sample button in this position and collect a process sample for lab calibration SAMPLE is displayed while sample values are collected and an average is calculated Save the sample value by pressing enter e or discard the sample value by pressing 4 or v 174 BTG 2004 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e 4 7 Operating instructions Damping setting Calibration setting NOT SAVED OFFSET 0 00 1 77 0 08 DAMPING 0s 00 s CALIBRATION K0z0 2 NOT SAVED is displayed if the sample value is discarded When the results from the lab sample are ready calculate the offset the value for the lab sample minus the sample value If the lab value is 1 69 the offset will then be 1 69 1 77 0 0896 Press enter e to change the offset When the plus sign starts to blink press 4 or v to change Press
97. e main menu signal reading display refers to the externally connected measuring range 2 Setthe consistency level for the lower limit of the measuring span Press 1 90 for the lower limit 4 mA seess 0 61 7 100 coo E 3 Press 08 and set the upper limit 20 mA SREI 4 Check that the settings are correct first Send the new settings to the Send transmitter Press da 126 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 7 Special calibration functions 3 7 Special calibration functions 3 7 1 Offset adjustment See section 3 6 1 2 on page 96 item C gt Offset adjustment can be done in two ways A Based on a laboratory sample B Based on a deviation detected from laboratory samples gt The entire calibration curve is shifted bodily on the basis of a single point so it is most important that the laboratory sample value for that point is correct The offset adjustment which is a zero point displacement can be made to all types of calibrations but should normally be used only when a multi point calibration has been made A Offset adjustment based on a laboratory sample Procedure 1 Goto MAIN MENU option fxs 2 Press sample and save the consistency value in the memory in the normal manner taking correct laboratory samples at the same time Loa
98. easuring vessel is of standard dimensions but is always flanged The main pipe should be equipped with flanges to match those of the ves sel The material available and selection of it is described as above gt Do not turn the vessel upside down Air may accumulate in its upper part and disturb measurement 2 5 4 3 Installation in pipes gt 300 mm 12 in diameter using an intermediate flange according to Fig 26 and Fig 27 Where pressure is lt 10 bar at 20 C 150psi at 68 F defined as PN10 and pipe diameter is 2 300 mm 12 inch the transmitter should be connected to the pulp line using an intermediate flange connected to an FRP stud located on the main pipe The FRP stud is made to obtain the correct M measurement Contact BTG for correct M measurement MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Warning Assure yourself that the pipe is empty before opening it up Fig 26 Flanged FRP stud connection 300 mm Installation in pipe a e For a solution according to Fig 6 use an FRP stud Fig 26 and fix it to the main pipe flange size 300 mm PN 10 to DIN 2642 Remember that the total length M of the stud can be either 80 mm 3 1 in or 150 mm 5 9 in depending on the consistency of the pulp e When M is 150 mm 5 9 in Fig 27 Alt 1 lower consistencies the stud length must be 126 mm 4 96 in Fasten with plastics six 6 symmetrically p
99. ed to the measuring shaft The rotation of the sensor in the pulp sample results in torque This torque retards the measuring shaft in relation to the drive shaft The de gree of retardation is detected by the transmitter which in its turn pro duces a feedback force to counterbalance the torque The torque angle between the shafts 1s fed back and balanced to give a constant value via an electromagnetic feedback system The signal is then converted into a 4 20 mA output signal with a superimposed digital signal according to the Hart protocol 2 5 1 1 Positioning the transmitter The transmitter is usually installed in a vertical pipe and located down stream ofa pump that mixes dilution water into the pulp It should always be installed as close as possible to the point where the dilution water is injected to ensure minimum time lag See Fig 5 c To ensure minimum time lag locate the transmitter close to the dilution point 2 5 2 Low pressure pipe installations PN10 Where pressure is lt 10 bar at 20 C 150 psi at 68 F defined as PN10 and pipe diameter is lt 250 mm 10 in the transmitter should be connect ed to the pulp line via a measuring vessel See Fig 9 and see section 2 9 2 c The measuring vessel is delivered as standard with weld ends for weld connection to the main pipe On request it can be delivered with flanges Where pressure is 10 bar at 20 C 150 psi at 68 F and pipe diameter is 2 300 mm
100. elding it to its stud Join ing the flanges If welding a full penetration weld should be used c Fit the 10 mm stud bolt supplied into the upper hole in the trans mitter flange and lock it in position with sealant d Fit a 1 inch ball valve in accordance with the recommendation above e If the transmitter and sampling valve where fitted are not to be installed immediately screw a blank flange onto the transmitter Blank flanges are available as accessories from BTG Pipe diameter OD according to Inner Diameter ID metric standard or ISO standard See section 2 9 3 for detailed measures 11218 56 3en MEK 2300 Installation instructions 31 BTG 2004 2 5 Installing the transmitter Fig 20 Measuring vessel for Fig 21 high pressures and temperatures 25 bar 226 C or 375 psi 439 F Design with flanges according to DIN 2655 or ANSI 300 Ibs available to order Always mount bolt in the upper position For 1 in flushing valve Measuring vessel flanged on two sides for consistency transmitter and sampling valve type HDS Joined by weld standard or flange available to order Dimensions os po pos Le 150 6 165 6 5 285 112 410 16 1 165 6 5 285 112 410 16 1 310 122 460 18 1 32 MEK 2300 Installation instructions BTG 2004 11218 56 3en 2 5 Installing the transmitter
101. em Measure all TP s between TP GND and the TP at hand using a high impedance digital voltmeter 184 MEK 2300 JCT 1100 Junction box appendix BTG 2004 AX218 56 3e 4 9 Parts list 4 9 Parts list 4 10 JCT 1100 with power supply unit Item Rec we No Spare Qty Part No Spare Part Description parts A0012070 Junction box complete 100 240 V AC version 1 1 A0012146 Main circuit board with power supply unit 2 1 27014281 Shield gasket 3 1 A0006635 Terminal connection SPC 4 1 A0068726 HART filter included A0014274 Isolation amplifier optional 5 1 A0012229 System cable Transmitter 6 4 46022638 Fuse TR5 2AT 250V 7 2 46028221 Cable gland M12 8 1 46028130 Cable gland M20 9 1 46027330 Power supply unit Pulse 10 1 A0012203 Front panel complete without sticker 11 1 A0012401 Front panel sticker 12 1 A0015958 Sticker inside terminal box Connection MEK 2300 13 1 A0012112 Junction box AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 185 BTG 2004
102. emove the jumper before the output signal cable is connected I u Out 1 4 6 1 1 Range select input Transmitter calibration ranges for different production circumstances can be changed with binary inputs to the transmitter Range Input A Input B 1 0 0 2 1 0 3 0 1 4 1 1 AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 169 BTG 2004 4 7 Operating instructions 4 7 Operating instructions 4 7 1 Starting the junction box The junction box is started by switching on the power supply with the switch in the terminal box See fig 78 below See the start up instructions in the transmitter section of this manual for detailed start up instructions Fig 78 Power supply switch eee no E amp FST2AT oc L PE 3 1 Power supply switch rovi 8 nouzman 4 7 2 Transmitter configuration from the junction box 4 7 2 1 General information The JCT 1100 junction box is equipped with a display and four push but tons The display has one row of sixteen characters The operator can make some basic adjustments using the push buttons and the display without using the hand held terminal SPC 1000 To make a complete calibration or to configure some major settings the SPC 1000 must be used The transmitter settings made from the junction box can be loaded into the SPC 1000 There t
103. enter e to accept The next number will blink Repeat the procedure until done Press enter e to change the damping value The first number starts to blink Press 4 or v to change the number Press enter e to accept The next number will blink Repeat the procedure until done Press enter e to access the calibration constants Press 4 or v to step between calibration constants c Some transmitters have two calibration constants while others have three Repeat the steps below for each calibration constant K0 K1 or K2 that is to be changed Press enter e if the value is to be changed When the first number starts to blink press 4 or v to change the number Press enter e to accept The next number will blink Repeat the procedure until done AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 175 BTG 2004 4 7 Operating instructions Language selection LANGUAGE en The selected language is indicated in small letters Bagisla Press enter e to change language Scroll with the 4 or v keys to the desired language Seene Press enter e to accept Espa ol Italiano Deutsch Portugu s Suomi Fran ais 176 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 8 Service instructions 4 8 Service instructions 4 8 1 Maintenance routines No
104. g instructions 65 BTG 2004 3 2 Routine servicing general remarks 3 2 Routine servicing general remarks Check the following items see Service Manual for detailed instructions Once a week Is the mechanical seal tight Is the flushing water system working Every six months Is the gear belt in good condition Once a year Total torque wheel clearance For information regarding routine service for JCT 1100 see the Service instruction section of the JCT 1100 manual included in this manual Also check as necessary e Rubber seals in contact with media containing high concentrations of chemicals black liquor chlorine etc Calibration of transmitter against laboratory samples Tuning ofcontroller control loop should respond quickly but should not oscillate spontaneously Check total free play of torque wheels see above Stop the transmitter Turn it until one of the end position stops is visible Turn the brake ring to each end stop and check that the torque wheel springs back to a central position c This check may be difficult to make if pulp is flowing past the sensor Measure the total play between end position stops with a feeler gauge nominal value is 0 30 mm 0 012 If the play is more than 0 50 mm 0 020 it should be adjusted See service manual section Checking torque wheel positions MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 3 Hand held Terminal SPC
105. hat simplifies evaluation and doc umentation of transmitter settings The printer must be EPSON compatible with an RS 232 serial input The recommended models are EPSON P 40S SEIKO DPU 411 or SEIKO DPU 414 which can be ordered locally or from BTG A special con necting cable supplied by BTG is needed Set the printer to a baud rate of 2400 Documentation can also be done manually Make a written record of all the data listed on the printout shown in fig 58 and draw a calibration graph z Send Cali Load gt Actual data are also available at data and Bate ab 3 6 6 2 Documenting calibrations see Fig 58 with printer or manually 1 Plug the printer into the hand held terminal Switch on the printer 2 Select printout from the measuring range you want to print press Print inge Press MAIN MENU option Then select ma 61 7 1005 cons 3 35 Printer RTE and a printout is made If the display reads No comm with printer check that the printer is correctly plugged in that the battery is charged or the printer is connected to a AC adapter and that the baud rate 2400 is correctly set Fig 58 shows a specimen printout If you do not have a printer access the relevant parts of the menu and make a manual note of the readings corresponding to those shown in Fig 58 Items 1 7 10 12 and 16 19 s
106. he software is designed for self instruction but calls for a basic under standing of how the transmitter works HELP functions and other important guidelines are displayed at critical points in the programming process Warning notices are included at points where faulty programming might affect the output signal A code query has been inserted at highly critical points in the program where the basic setting of the transmitter could be affected Optionally a personal code can also be inserted to prevent any unau thorized access to the program An overriding default code is available from BTG The first touch screen is shown in Fig 48 select by touching the area button with the text Sensor card The buttons function is ex plained in section Button functions for opening and main menus 78 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 4 Operating the transmitter A Button functions for opening and main menu Fig 49 Selection of prog ram 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD for the normal operation of the transmitter SPC 1000 Communication Terminal Used when the standard program card is installed for the normal sensor setting BACKUP CARD Used when the back up card is installed for storing sensor settings The first two button functions are common for all BTG smart transmit ters and independent of the type of sensor Thes
107. he sample after being extracted from the pipe must be made in a uniform repeatable way The lab analysis shall be in accordance with the established standards e g SCAN C 17 64 or valid TAPPI standard A rapid analysis with drying on a heating plate is not a reliable method A combination of verification against torque brake and lab samples might in practise be suitable By this calibration can first be checked 01218 56 3en MEK 2300 Operating instructions 153 BTG 2004 3 17 Maintenance Planning and Quality Assurance against lab samples during the normal follow up Should a deviation be discovered check and adjust the transmitter against the torque brake If comparison to torque brake corresponds to the previous result but the lab value differs when compared with the transmitter value you can sus pect a change of some component in the pulp suspension which has af fected the measurement If so investigate the reason A re calibration or possibly a zero point offset of the transmitter might then be necessary On the MEK 2300 it is possible to compensate for certain influencing factors temperature or use several measuring ranges in case of changed pulp composition A printout or other automatic documentation is an excellent comple ment to the ordinary protocol for documentary purposes 3 17 2 Recommendation concerning transmitters used for simpler measurements e g for indicating purposes Comparison t
108. he transmitter The program is structured in the following manner t Confi gure Pris Tag no t 257234 0 61 7 100 Cons 3 35 Posen Fig 52 Numerical keyboard of SPC 1000 The common basic functions for the opening menu Fig 50 for all types of transmitters are programmed into the terminals internal memory and is shown when using the sensor card or when the back up card is inserted Refer to item A Button functions for the open ing and main menus Buttons SENSOR BACKUP MBT MEK CARD CARD 2300 2300 and other future transmitter models These basic functions are specified only in English since they are stored in the terminals memory The main menu Fig 51 is exactly the same for all types of trans mitters that are programmed into the relevant sensor card It com prises 14 buttons with direct selection of the relevant sub menu refer to item A Button functions for the opening and main menus buttons There is also a signal display The sub menus are also much the same for all types of transmitters except for the Configure Misc and Note functions These are adapt ed to the individual type of transmitter A keyboard for entering the numerical values is displayed when required See Fig 52 When numerical values are entered the New values are displayed while the previously entered values a
109. hey may be used for docu mentation print out or backup The SPCwin PC program with a cable and a modem for connection to the JCT 1100 can be used as an alternative to the SPC 1000 hand held ter minal See the transmitter section of this manual for more information about SPCwin and the SPC 1000 c Do not configure the transmitter from the hand held terminal and the junction box at the same time Valuable configuration data can be lost Always close a configuration session by updating the transmitter 170 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 7 Operating instructions Fig 79 OO SS Gab A Front panel with push buttons and display Display Sample button Arrow up button Arrow down button Enter button e Pn 1 BIG SS XX XX mA 3 espe l Terminal The push buttons have the following functions depending upon position in menu structure Push button Function Reads a measurement value from the transmitter that corresponds to a calibration sample value Sample Scrolls up in the menu structure Change a value upwards Discard a sample value Arrow up Scroll down in the menu structure Change a value downwards Discard a sample value Arrow down Select menu options Verify entered values Moves the cursor
110. hould always be recorded In addi tion you should draw a consistency feedback calibration curve MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration Comments on specimen printout Fig 58 Corresponding data can be accessed in the program under the options shown in parentheses 1 CONSISTENCY TRANSMITTER model press G amp D and read buttons for MEK 2300 2 PROGRAM VERSION software release and data and language version in use Switch on the hand held terminal press GRD and read buttons for MEK 2300 3 Particulars to be filled in by hand 4 Pre programmed transmitter data eem 5 Trouble shooting data During operation ANGLE should match SETPOINT tolerance 20 units Nominal reading should be 1600 adjustable range 1440 1680 units Note These values has been changed In the first version the nominal set point was ca 360 and the adjustable range 320 380 units See section 3 16 Software revisions FEEDBACK IN AIR most recent setting Normal values 4 8 If the reading is high e g 35 this indicates that the feedback was set with the transmitter rotating in pulp sre Adjust code 2300 SS SE Torque value is the basic sensitivity set 100 kpmm for standard models NC and 150 kpmm for MC models See section 3 7 4 max FB Feedback is the feedback raw signal at set Torq
111. hree analog output signals depending upon the transmitter type in the junction box The front panel has to be removed before the circuit boards can be re placed or removed See section 4 8 3 2 Replacing the front panel on DANGER page 4 180 High voltage within the junction box Fig 81 Mounting of circuit boards for HART filter circuit boards for isolation amplifiers or No circuit No circuit board strapping of outputs Circuit board board connected connected connected strapped pins Position of isolation amplifiers under Output signal No output Output signal the front panel signal i i Li Li or LI or o Li Li 0000A Sample Enter n DEEN Ka j OUT MA1 ourz MA2 ours mA3 CONN15 CONN16 CONN 17 E H g e H 0 24V 7 Terminal X o eo EE o e 178 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 8 Service instructions DANGER High voltage within the junction box Connections may only be carried out by qualified personnel applies to version with 100 240 V AC power supply 4 8 3 4 Replacing the power supply unit If the power supply is faulty it needs to be replaced Tools required Star screwdriver medium size c Break and secure the AC power supply voltage to the junction box before the front panel is removed it is not sufficient to turn it off with the power supply s
112. i e sa Co e 2 y SS 373 115 EN S 14 7 mas Y uU L AS J Remember to provide access room for an operator as well as the full depth of the transmitter and junction box The transmitter including sensor and propeller is approximately 490 mm 19 5 in long In addition to the installed length of the transmitter which will be 375 mm 15 in you will need a minimum of an additional 115 mm 4 5 in for extracting the transmitter from the pulp line Leave sufficient room around the transmitter to perform this task The transmitter weighs approximately 36 kg 80 Ibs 2 3 2 2 Junction box type JCT 1100 For information regarding the System description for JCT 1100 see the Product introduction section of the JCT 1100 manual included in this manual For information regarding the dimensions installation clearances etc for JCT 1100 see the Installation instructions section of the JCT 1100 manual included in this manual 10 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 3 Basic system description Fig 3 Hand held terminal type SPC 1000 dimensions mm in 1 Telephone jack to junction box 2 Touchstone 3 Rubber casing Fig 4 Adapter for terminal connection included with SPC 1000 delivery 1 Mini grippers 2 Connection for SPC 1000 telephone jack 2 3 2 3 Hand held terminal type BTG SPC 1000 The dimensions of the hand held terminal are given in Fig 3 min ca 0 3m 1ft
113. ical conditions scale scale scale scale scale Related OK 273 15 C OR 459 67 F Absolute zero Temperature 255 372 K 17 778 C 459 67 R DE Melting point values 273 15 K 0 C 491 67 R 32 F for ice Related 273 16 K 0 01 C 491 688 R 32 018 F Water triple point Temperature 373 15K 100 C 671 67 R 212 F Water boiling point difference 1K 1 C 1 8 R 1 8 F 0 55556 K 0 55556 C TR TF Mass Kg Ib Slug Oz Hundred Ton Short Short ton weight UK hundred sh ton weight pound ounce cwt sh cwt sh ton 1 2 2046 68 552 10 35 274 19 684 10 0 98421 10 22 046 10 1 1023 10 0 45359 1 310813107 16 8 928610 0 44643 10 10 107 0 510 14 594 32 174 1 514 79 0 28727 14 363 10 0 32174 16 087 10 28 350 10 62 5 10 1 9426 10 1 0 55804 10 27 902 107 0 625 10 31 25 10 50 802 112 3 4811 1 792 10 1 50 107 1 12 56 10 1 0161 10 22410 69 621 35 84 10 20 1 22 4 1 12 45 359 100 3 1081 1 6 10 0 89286 44 643 10 1 50 10 907 19 2 10 62 162 32 10 17 857 0 89286 20 1 ton UK is in the USA called long ton slug lbfs ft lbf pound force ft fot oz ounce also called ounce avoirdupois 1 ounce troy 31 1035 103 kg cwt hundredweight UK in USA long hundredweight Energy J KWh kpm kcal hpm ft Ibf BTU British Kilopond Horse power Foot pond Thermal joule Kilowatthour meter Kilo calory hour force unit 1 0 27778 10 0 10197 0 23885 10 0 37767 10 0 73756 0 94782 10 3 6 106 1 0 37610 10 859 85 1 3596 2 655210 3 4121 10 9 8066 272411
114. icroprocessor com pute the calibration The transmitter is then in operation 10 Evaluate the results from the displayed calibrating curve If the a curve shows that any sample deviates widely from the calibration D T e e line thereby skewing the line as a whole in relation to the other sam tants 500 19 57 B5 uu pee b ples go back to LOAD LAB CONS step to the offending sample eui number and deactivate that number A faulty calibration constant K2 0 can likewise be corrected i e the signal can be linearized if bad samples are not activated see section 3 6 6 on page 112 Note o that you must always press few in order to recalculate the cali bration O1218 56 3en MEK 2300 Operating instructions 109 BTG 2004 3 6 Calibration 11 Transfer the calibration to the transmitter Press ta Check that all data that is displayed is correct If a code has been entered see section 3 9 on page 140 key this in correctly and press Yes to transfer all the data to the transmitter If the message Transmission fail appear there is a communication problem Refer to the Service Manual and section 3 5 on page 86 item 5 12 Press inthe main menu Check the stability of the signal over time If necessary go back to the main menu and set a suitable time constant Press x see section 3 6 7 on page 125 E
115. ime constant because the feedback signal is unsteady the transmitter is probably working in an unstable poorly mixed pulp flow see section 3 6 6 5 on page 120 Symptom 5 In such a case you should consider relocating the Transmitter farther from the pump improving the remixing system or the supply of dilution water etc If the time constant is too long you loose the advantage of the transmit ter s high precision Contact BTG for further advice Procedure 1 Study the stability of the signal under MAIN MENU option pm 2 GotoMAINMENU option 3 Enter a suitable time constant 4m 20 190 Za Misc pee 61 7 amp 100 eeh Cons 3 35 Ee Send SPC 1000 me e g 5 seconds Press data 3 Returnto 77 and study the result 4 Ifnecessary adjust the time constant 01218 56 3en MEK 2300 Operating instructions 125 BTG 2004 3 6 Calibration 3 6 8 Setting measuring span and alarm limits See section 3 6 1 2 on page 96 item B Normal measuring span settings are e Normal consistency range 1 8 Nominal span 1 e High consistency range 8 16 Nominal span 2 Try to keep the measuring span as narrow as possible remembering that it must never extend below the sensing element s minimum consistency limit Procedure 1 Press the key Range for the measurement range you want c Range indication in th
116. imensioned for a rate of flow of 0 5 5 m s 1 6 16 5 fps where consistency is 0 1 to 10 and for a rate of flow of 0 3 3 m s 1 9 fps where consistency is 8 to 16 c See Fig 37 and Fig 39 for a nomogram how to estimate the flow velocity Note the recommended flow velocity In specific cases where consistency is 8 to 16 rates of flow of 0 2 5 m s 0 65 16 5 fps are acceptable somewhat increased flow depen dence Typically the main line is dimensioned for a normal rate of flow of 2 3 m s 6 5 9 8 fps for normal consistency installations and 0 5 1 m s 1 6 3 3 fps for medium consistency installations see accepted values above c Do not mount the transmitter in the fluidized zone after an MC pump It is recommended to mount it in the increased pipe section following Sampling valve The sampling valve should be installed as close to the transmitter as pos sible and it is recommended that it be installed on the same side of the pipe This will help ensure that the laboratory sample is identical to the sample measured by the transmitter Installing a BTG sampling valve will ensure reliable results Measuring vessels for low pressure installations can be supplied with the sampling valve mounted directly in the vessel Main power supply Main power supply voltage and frequency must be within acceptable limits and must be protected against transients such as electrical storms or other equipment installed
117. in Ibf ft Energy heat quantity J joule Nm Ws 1 0 10197 8 8508 0 73756 Effect energy current Ww Watt J s Nm s 9 8066 1 86 796 7 2330 Electric voltage V Volt Nm As 0 11299 11 521 1 83 333 10 3 Electric resistance Ohm Nm A s 1 3558 0 13826 12 1 Electric quantity charge 1C Coulomb As Decimals and multiples of units Sign Abbreviation Parts Sign Abbrev ea E DC ded peta P D centi gga G DC miko Multiples Ee E femto 1 852 10 Fo Yard Mie 3 2808 1 0936 0 62137 10 0 53996 10 Natic mile 83 333 10 27 7778 15 783 10 a 0 33333 0 18939 10 E31 0 56818 10 0 1 1 Angstr m 107 m Area m in ft yd acre mile 1 1 550040 10 764 1 1960 0 24710 10 0 38610 10 06451610 1 6 9444 10 07716110 0 1594210 024910 10 92 903 10 144 1 0 11111 22 957 10 35 870 10 0 83613 1 296 10 9 1 0 20661 10 0 32283 10 4 0469 10 6 2726 10 43 56 10 48 4 10 1 1 5625 10 2 5900 10 _ 4 0145 10 27 878 10 3 0976 10 640 1 1 ha 1 hektar 10 000 m Volume m in fe yd UK gallon US gallon 1 61 024 35 315 1 3080 219 97 264 17 1638710 1 0 57870 10 21434 10 3 6046 10 4 3290 10 28 31710 1 72810 1 37 037 10 6 2288 7 4805 0 76456 46 656300 27 1 168 18 201 97 4 5461 10 27742 0 160
118. ing valve Otherwise the valve should be installed in such a way as to avoid interference from pipe bends pumps etc Recom mendations regarding turbulence damping zones are the same as for the transmitter itself If the transmitter and sampling valve are far from each other we recommend installation of a separate junction box where the hand held terminal could be connected to be able to perform the cal ibration procedure in a convenient and safe way c To ensure acceptable precision in taking laboratory samples we recommend use of the BTG sampling valves 2 Take at least two and preferably three laboratory samples at each consistency level Calculate the mean value reject samples that de viate widely from the mean Take an adequate volume for sampling at least 500 ml 1 2 US quart for a reliable sample 3 Make sure that samples for calibration and subsequent checking are always taken in the same manner regardless of who does the sam pling Similarly the laboratory procedure must always be exactly the same 01218 56 3en MEK 2300 Operating instructions 99 BTG 2004 3 6 Calibration c The design of and compliance with sampling routines are of crucial importance in assuring uniform treatment of samples and thus the calibration and future precision of measurement of the transmitter c During calibration the pulp flow past the Transmitter must be representative for the position in which it is installed
119. ion to the size of the sensor used and inversely with the length of the fibers in the pulp The factor i e the absolute error is normally 0 010 0 015 consistency C The compensation factor can be directly entered at sample SE if known unit Off function gt T Off The function can be turned off by pressing the button see item 1 C Press the button and observe the arrows move it should point to Off 8 Don t forget to ata OI218 56 3en MEK 2300 Operating instructions 131 BTG 2004 3 7 Special calibration functions 3 7 3 Manual loading of feedback settings See section 3 6 1 2 on page 96 item E This function will be found in Sie E It is a special function which can be of assistance in some cases Procedure Cali Ti 1 Goto MAIN MENU option Ee Ee 2 Step with the arrow at ow and load the desired feedback set T I Sess 99999 R S 2 i H H EL ting by pressing Sample 0 should normally have the new value FEEDBACK IN WATER value for the sensor fitted Exit by press M Ons E CG D eoooooneu 833388500 RECEN Menu ing the key 3 Do you also want to load the corresponding laboratory sample val ad ues If so go to Tab cons Calc 4 Press new to m
120. iscellaneous Fig 40 Max operating pressure at different operating temperatures 2 9 2 Pressure and temperature limits for piping pipe flanges and fittings of stainless steel according to Swedish Standard SMS 1233 For conversion to SI units 1 at 9 8 N cm Max operating pressure Max operating pressures under normal conditions are given in the table below The values stated must not be exceeded by more than 5 How ever the operating pressure must never exceed the nominal pressure PN The diagram in fig 40 shows max operating pressure for different pres sure classes at different operating temperatures Stainless steel 2343 according to SS 142343 SS 316 Example What is max operating pressure at 100 C operating tempera ture and pressure class PN 10 Answer 8 ato 8 bar Max operating pressure ato PN Operating temperature C ato atmosphere atm overpressure 11218 56 3en MEK 2300 Installation instructions 61 BTG 2004 2 9 Miscellaneous 2 9 3 Measuring vessel with weld ends Dimensions of the vessel s weld ends 2 9 3 4 Pipes according to ISO standard dimensions Pipe connection Pipe dimension Pipe dimension Low pressure High pressure PN 10 150 psi 25 bar 360 psi mm inch mm inch mm inch 100 4 114 3x3 4 50x0 12 125 5 139 7x3 5 50x0 12 150 6 168 3x3 6 63x0 12 168 3x6 3 6
121. ithout flushing water to the mechanical seal SEC 1000 The transmitter data must always first be transferred to the terminal for the setting to work 3 5 Starting the transmitter Familiarize yourself with the operation of the hand held terminal and transmitter see section 3 3 on page 67 and section 3 4 on page 77 Before being started the transmitter must be installed in the pulp line and wired electrically according to the Installation instructions 11218 56 Before admitting water or pulp to the line check the following points where applicable to the model installed 1 Is the inspection cover properly tightened 2 Has flushing water been supplied to the mechanical seal and is the water running off to drain as it should where applicable 3 Switch on the motor briefly Is it rotating in the direction shown by the arrow Reverse rotation can cause the sensor to unscrew from the shaft Cer tain types only 4 Switch on the power supply to the transmitter s electronics Connect the hand held terminal to the junction box Switch on The display should now light up If not check in the Trouble shooting section of the JCT 1100 manual that is included in this manual SENSOR MEK Press ARD 2300 Then transfer the relevant transmitter s Yes Wait data to the hand held terminal by pressing E should now be displayed The transmitter data wil
122. jor pressure variations To ensure good control dilute no more than approximately 20 in each dilution stage though a higher percentage may be acceptable early in the process If considerable dilution is required it should be carried out in two stages 70 to 80 of the water being added in the bottom part of the pulp chest and the remainder in the form of a fine dilution upstream of the pump Thorough mixing at the bottom of the pulp chest upstream of the trans mitter is vital to avoid consistency variations The dilution water pipe should be inserted in such a way that it extends a minimum of 15 50 mm 0 6 2 in depending upon pipe size into the main pipe on the suction side ofthe pump See Fig 5 The pipe must be inserted perpendicular to the suction stud The pipe should be located at 1 3 of the distance between the pump and the chest counted from the pump to avoid back flow into the chest At the point of injection the dilution water pipe should be dimensioned to produce a rate of flow 3 4 times larger than the flow in the main pipe Typically this means a dilution water flow 3 5 m s 10 16 5 fps at max flow in the suction pipe The dilution water pipe should have the same or larger dimension as the valve bore to prevent the valve from being plugged by pulp at water pressure loss Choose a dilution water valve with linear characteristics The pressure drop over the valve should be at least 0 5 bar 7 psi and should exceed 25 of
123. kpmm 100 max F B 1694 F B in air 6 4 6 RANGE No 1 7 1 Damping sec 1 4mA cons 1 00 gH RES 20mA cons 4 00 H ben Cons offset 0 00 Calibration constants 10 kO 19 57 kl 1 38 k2 1 83 u Samp Active Cons Feedback 0 on 0 00 20 00 1 on 1 05 22 40 2 on 1 52 25 50 3 on 1 86 28 70 4 on 2 41 33 60 5 on 2 82 37 50 6 on 3 06 42 40 7 on 3 37 45 50 100 00 8 off 3 68 46 80 E 9 on 3 92 52 40 90 00 hub ERR eege d 80 00 12 70 00 60 00 50 00 52 40 x 45 50 i 42 40 O 46 80 F 40 00 E 37 50 30 00 33 60 28 70 25 50 20 00 22 40 Note These FB values in diagram are not printed at a normal printout 10 00 0 00 1 00 1 50 2 00 2 50 3 00 3 50 4 00 4 50 5 00 5 50 Cons 01218 56 3en BTG 2004 MEK 2300 Operating instructions 115 3 6 Calibration Fig 59 Calibration diagram for MEK 9o Feedback 100 90 80 70 60 50 40 30 20 10 7 8 Consistency 116 MEK 2300 Operating instructions BTG 2004 OI218 56 3en 3 6 Calibration Always switch off the hand held terminal when changing a memory card The terminal could be damaged in some cases if this is not done Protect memory cards against moisture and dirt handle them with care do not bend them Fig 60 Store data menu 3 6 6 3 Documenting calibration using the back up card
124. l Fig 69 Dimensions To N0 34 28 RS dap 9 Jee 5 6 AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 163 BTG 2004 4 5 Installation instructions Fig 70 Attachment lugs Fig 71 Protecting roof The junction box has three attachment lugs which are bolted to a flat sur face 95 3 BTG recommends that a roof or overhang is mounted above the junction box to protect it against spray and pulp If the junction box is located out doors a roof should be mounted that protects from direct sunlight which can cause excessive operating temperatures If possible the SPC 1000 should also be protected when placed in it s holder 200 75 Self OIN oD L Y em Fig 72 Holder for SPC 1000 160 6 3 S D eo NIO 2x955 II XC of T g Aan Y i 7 Lm 1 2 2 164 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 5 Installation instructions 4 5 2 Junction box with external 24 V DC power supply This section describes the requirements on an external 24 V DC power supply when the junction box is delivered without BTG s built in 24 V DC power supply unit gt It is the mill s responsibility to arrange the transmitter power supply correctly BTG will disclaim any liability for problems and damage caused by incorrect power supply Dimensioning the power supply unit is the mill s responsibi
125. l circuit for consistency control Consistency transmitter MEK 2300 Junction box type JCT 1100 Hand held terminal SPC 1000 3 System cable to transmitter Controller and recorder DCS Dilution water valve Pulp chest with sufficient mixing Stock pump BTG Sampling valve type MPS 1000 3 3 2 Connecting the SPC 1000 3 3 2 1 Power supply The hand held terminal can be powered in three different ways A 24 V DC supply from a junction box B 12 V DC supply from an AC adapter C 9 V DC from an internal battery A 24 V DC supply from a junction box This is the normal way of providing power for transmitter calibrating and process monitoring The terminal s telephone jack is connected to the junction box socket as shown in Fig 42 This also provides a communications link with the transmitter When this supply option is chosen the display lighting comes on for best visibility 68 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 3 Hand held Terminal SPC 1000 Fig 43 Hand held terminal SPC 1000 Connections Check that the AC adapter is suited to power supply voltage 110 or 220 V AC SL 1 J Sensor card A A 4 20mAMODEM PRINTER PWR ON OFF EJECT MEMORY CARD SPC 1000 BIG B 12 V DC supply from an AC adapter This method of supplying power is suitable during
126. l not have been transferred if Transmission failed is displayed Check to ensure that the terminal s telephone jack is fully inserted and makes good contact The transmission could also fail if the signal circuit resis tance is less than 250 O To continue press the display anywhere 5 Is the relevant transmitter s position number in the process Tag No entered This can be seen from the main menu s signal display win Confi dow If not press Sue followed by 79 7 12 1234 and enter the rele vant number A maximum of six characters can be entered e g 25 NT 1237 is entered as 25 Mena 1237 Mena gt Enter the TAG number to identify the relevant transmitter 86 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 5 Starting the transmitter 6 Start the motor after switching on the electronics unit Confi 7 Press gare Feedba Aut adjust Enter code 2 3 0 0 Press N until the arrow points to check Press d amp ta Check that the display Set point value corresponds to the original adjusted value stated in the attached test protocol If not enter the Set point value at setpoint End with 8 amp 2 To enter the Max Feedback value see section 3 7 4 on page 133 point C Direct input for required feed back resolution 8 Check the feedback signal for rotation in air if necessary Go
127. lange 3 Clamping flange size 300 mm to PN 10 according to DIN 2642 dj 324 mm 12 75 in stainless steel to SS 2343 AISI 316 Other flange standards available to order 4 Rubber gasket diameter 350 300 x t where t 2 3 mm 0 08 0 12 in Shore A hardness 40 70 viton Flanged FRP stud size 300 mm PN 10 FRP reinforcement Six 6 4 mm 0 16 in thick guide rails of plastic only for M 150 mm 5 9 in 60 apart 8 12 screws to M6S 20 x 90 stainless steel 9 12 nuts to M6M 20 stainless steel 10 12 flat washers SR BRB AY 21x36 x3 Three 3 10 mm 0 4 in thick FRP deflectors only for M 80 mm 3 1 in positioned to have a 30 mm 1 18 in c c distance oa NO 1 ncluded in delivery from FRP pipe in accordance to existing pipe dimension Wetted parts are made of Hastelloy C 254 SMO or SS 2343 AISI 316 according to order c M dimension M 150 or M 80 mm according to recommendations from BTG TENNE 3 AYI dum Z jaa M cH js f 4 7 HI a WL N i8 M 80 3 1 7 Y A SES PIPE MADE OF REIN FORCED PLASTICS Alt 2 M 280 3 1 91 IN ACCORDANCE WITH ACTUAL PIPE DIMENSION 40 MEK 2300 Installation instructions BTG 2004 11218 56 3en 2 5 Installing the transmitter 2 5 5 Pulp chest overflow box stuff box installations A Pulp chest installation The s
128. layed Enter 42 600 applies only on this occasion Press Mem 2 Enter your personal code Load new code will appear Enter your personal code e g 123 max 8 digits and press Mena 3 Press GFF to get G and enter your code e g 123 follow with Mema Your new code is now activated finish by pressing Menu Data can now be transferred to the transmitter If you wish to check that the code has been entered press 388 and VT The signal transfer will not take place without the input instruction for the code being displayed B Changing your personal code Send Go to data A SS Press Sede Load old code will be dis played Enter your old personal code or the general BTG code Load new code will then be displayed Enter your new code Press Enter 140 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 9 Code protection C Deactivating the code you have entered Press SS H Turn RIDE Press the See code off Enter your personal code D Activating the code you have entered Press code on Enter your personal code Send data H Turn E Press the jore button so that it displays button so that it displays 01218 56 3en MEK 2300 Operating instructions BTG 2004
129. layed as Old value A higher set point value means higher feedback value and vice versa Typical values may differ somewhat between individual transmitters Then press a Ifyou do reset the Set point Angle and Feedback raw signal values will be displayed after a while Repeat the procedures if the feedback in air is not 4 896 3 Checking the Set point Angle Feedback Check This function is used to check the predetermined Set point Angle Feed back values This is an important fault tracing function No adjustment can be carried out at this stage Step the arrow to om and commu nicate with the transmitter press Sa 01218 56 3en MEK 2300 Operating instructions 91 BTG 2004 3 6 Calibration 3 6 Calibration 3 6 1 General remarks on calibration and sampling The transmitter can be calibrated for the specific application after it has been installed in the line and all connections have been made This section assumes you have completed section 3 5 on page 86 and studied the operation of the hand held terminal as described in section 3 3 on page 67 The calibration system is flexibly designed to ensure maximum precision under a wide range of operating conditions Fig 55 Typical calibration curve consistency F feedback Feedback output signal 76 Output 100 2 3 4 Consistency Linear output signal Example shows a sulfate kraft 10 p
130. le front panel has to be replaced However the transmitter will still work properly without the display or the buttons functioning in the junc tion box This allows the replacement to be made at a convenient time Tools required Star screwdriver medium size gt Break and secure the AC power supply voltage to the junction box before the front panel is removed it is not sufficient to turn it off with the power supply switch in the terminal box All numbers within below refer to fig 80 on page 4 177 1 Check that the 24 V DC LED 7 and the display are off 2 Unscrew the front panel 2 and carefully lift the front panel plate aside 3 Detach the display connector 8 by pushing the two levers aside and pulling the connector straight out from the main circuit board 4 Detach the SPC connector 9 by pulling it straight out from the main circuit board It might be necessary to loosen the locking flap using a flat screw driver 5 Unscrew the front panel grounding strap 12 from the main circuit board 6 Move the display wiring 8 from the faulty display panel to the new display panel To mount the new front panel perform the steps above in reverse order If the front panel sticker is not mounted it is easier to mount it after the front panel has been replaced in the junction box 180 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 8 Service instructions DANGE
131. les Tag no s 1 Plug the serial cable into a free comm port on your computer and into the hand held terminal marked Printer Double click on the BTG icon Double click on the SPC 1000 icon Click on CommpPort Settings and select the connected comm port Click on CommPort Port open to open your selected comm port If you click once more on port open you will close the comm port For more help click on the menu choice Help Switch on the hand held terminal Print Send data to PC Main menu option Press option 7 and the values as well as the calibration curve are copied to the PC 10 Save and print if necessary 01218 56 3en MEK 2300 Operating instructions 119 BTG 2004 3 6 Calibration 3 6 6 5 Evaluating calibrations By studying the calibration curve calibration constants and correlation factor you can pinpoint and correct most calibration errors Typical errors in single point calibration Symptom 1 Calibration lacks precision The further away from the calibration point the greater the error Sample 0 FEEDBACK in water is not activated The curve is drawn between 0 FB value and the loaded point Action Go to nb and activate sample 0 Calculate the new con Calc stants in calibration press new const Alternatively you can pro ceed to a multi point calibration to get better p
132. lity See sec tion 4 1 2 Technical data on page 4 158 Supply voltage for require ments For safe operation the external 24 V DC supply must comply with SELV PELV Separated Extra Low voltage To avoid power outs BTG recommends a UPS Uninterruptible Power Supply power supply unit Cable connections must be made according to section 4 5 3 Cabling on page 4 166 The junction box is tested as a complete system to conform with the relevant CE directives and their standards The junction box and transmitter may conform with EMC and associat ed safety requirements when properly installed in combination with cus tomer installed external devices and using an adequate power supply The mill operator is responsible for CE directive conformity Conformity has to be checked by inspection AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 165 BTG 2004 4 5 Installation instructions 4 5 3 Cabling 4 5 3 1 Cable types BTG recommends properly dimensioned cables as described below for connections between the junction box and external equipment The power cable should be in accordance with the IEC 227 245 standard Power supply cable Shielded 280 96 3 x 0 75 mm 3 x AWGI8 with PE c BTG recommends that the power supply cable has a 2 A slow blow fuse Signal cables for Output Range Select Alarm AUX in etc Shielded 100 twisted pair Min 2 x 0 3 mm 2 x AWG24 Typical
133. llers M Type S82343 254 SMO Hastelloy Cons range deua Large 73198772 A0004978 73198798 1 5 5 150mm Small 74359886 A0004986 74359902 lt 1 5 150mm Hub 74360587 A0004994 74360603 gt 5 70mm c Avesta 254 SMO replaces AISI 317L stainless steel 148 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 13 Training 3 13 Training The SPC 1000 hand held terminal can be used for training without any other equipment being connected It is preferable in this case if the hand held terminal is powered by the AC adapter When no transmitter is con nected it is not possible to send or read data from the transmitter and thus the program sometimes locks If this occurs switch the terminal off and start it again Typical functions that can be simulated are single point multi point and updated calibration calibration using given calibration constants mea suring span adjustment and offset adjustment The result is seen on the calibration curve or printout The temperature compensation or produc tion calculation can also be simulated but a transmitter needs to be con nected in this case Refer to the relevant section in the instructions with respect to each item To enter the feedback values for calibration or the calibration constants gpecial Cali brate go to H OI218 56 3en MEK 2300 Operating instructions 149 BTG 2004 3 14 Trimming the controller 3 1
134. manual or you have any questions about installation please get in touch with your BTG sales engineer When you are satisfied that your MEK 2300 has been correctly installed and you are ready to power up the system for calibration please turn to section 2 7 Quick start checklist Double check items in the list before powering up This list can help en sure a trouble free initialization of your system MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 2 Before you start Following this introductory section Section 1 are the following 1 Basic system description This section introduces the essential components of the system It also includes important information about the dimensions of the components including working space and installation clearance requirements 2 Planning an installation This section is vital to the correct layout of the system components for the end user engineer and or consultant It contains advice on locating the transmitter in your process and positioning the junc tion box relative to the transmitter 3 Installing the transmitter This section contains detailed instructions for installing the trans mitter and measuring vessel 4 Installing the junction box This section describes how to connect main power supply inputs and outputs 5 Quick start checklist 6 Type sign explanation 7 Miscellaneous 2 2 2 Visual inspection This product was inspected an
135. mitter during operation A clear warning such as a sign should let other people know that work is in progress and that switch must not be touched SR218 56 3en MEK 2300 Safety recommendations 3 BTG 2004 06 09 1 6 Installing the junction box DANGER High voltage within the junction box Connections may only be carried out by qualified personnel applies to version with built in power supply To prevent electrical shock connect the protective earth e PE properly AN There is risk of injury by crushing or cutting if the covers have been removed 1 6 1 7 Installing the junction box A hazardous voltage is used to drive the junction box AC version The junction box may only be connected by a qualified electrician in accor dance with instructions The earth should be connected correctly and checked It should be possible to switch off the voltage in the distribution centre for example A clear warning such as a sign should let other people know that work is in progress and the switch must not be touched e Use only metallic cable fittings with shield connection for the junction box For the motor a plastic cable fitting should be used Starting up and servicing the transmitter Read through the following points before starting up and servicing the transmitter Bear also in mind that the points mentioned above contain important information for these operations If the motor is switched on s
136. n the more accurate the calibration will be provided ti b coristants k0 19 5 oe S that the laboratory consistency is accurate see section 3 6 1 3 on page 99 and section 3 6 6 5 on page 120 Each type of sensing element produces a characteristic signal level FEEDBACK when it rotates in water but when the mains power fre quency affects the motor the speed of the sensing element will vary and the signal will change somewhat a 60 Hz power supply gives a higher signal than a 50 Hz supply The FEEDBACK IN WATER value is pre programmed it is used in calibration to improve the accuracy when one point is defined subject to the condition that FEEDBACK IN AIR is between 4 and 8 and that FEEDBACK IN WATER has been programmed for the correct type of sensing element and mains frequency see sensor table in Fig 64 gt Multi point calibration results can be improved by plotting in additional points under updated calibration The consistency feedback curve is normally parabolic see Fig 55 the signal increases with increasing consistency If something goes wrong for example if laboratory testing gives erroneous results for a high con sistency sample the calibration curve may be inverted i e the signal lev el falls with increasing consistency This makes calibration constant K2 negative which is not admissible If this happens the calibration curve for the output signal is automatically
137. n will be a suitable dimen sion 11218 56 3en MEK 2300 Installation instructions 57 BTG 2004 2 9 Miscellaneous Fig 37 Nomogram for estimation of flow velocities of liquids 0 5 1 2 3 45678 V m s 1000 10000 Q mh 20 25 32 405060 80100 150200 300400 800 Pipe diam GG A correction factor must be applied when the valve is smaller than the supply pipe When dimensioning the valve a correction factor must be included to cor rect when a reduction from a larger supply pipe to the smaller valve is made See Fig 38 The calculated capacity factor K C is multiplied by the correction factor The correction factor is determined by the amount of reduction made Fig 38 Correction factor for Correction factor reduced bores V RALITIILLLLLLLLLLLIT iv ten NEM x ANS Di a 70 EN a 75 071 Jooga a 80 0 6 0 5 a 85 0 4 0 3 1 2 3 4 5 D d valve bore d D pipe line diameter a opening 58 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 9 Miscellaneous c Use the curve for 85 valve opening when calculating the correction factor Example Calculated K value 75 4 Pipe line dimension 60 mm D Selected valve e g BTG VBG 40 size 50 d which has a K value of 155 at 85 opening Check that selected valve K is sufficient See Fig 40 D 1 2 which gives a correction factor of 0 78 The valve K will be 0 78 x 155 116
138. n MEK 2300 Table of contents BTG 2004 2 5 3 2 Installation with weld in stud Eo 2t eee eee 33 2 5 4 ERP pipeinstalations 4 54230 or Eege REUS bebe TT y 38 2 5 4 1 Transmitter material selection 0 000000 eee 38 2 5 4 2 Installation in pipes lt 250 mm 10 in diameter using a measuring vessel 38 2 5 4 3 Installation in pipes gt 300 mm 12 in diameter using an intermediate flange according to Fig 26 and Fig 27 38 2 5 5 Pulp chest overflow box stuff box installations 41 2 5 6 Installation of the transmitter llllllllllllllllllnn 43 2 5 6 1 Installing the transmitter 2 2 2 6 6b eR 43 2 5 7 Connection of flushing water to mechanical seal 45 2 5 7 1 No water flushing NN we EIER eee nen mm ER a nn Tn den 45 2 5 7 2 Low pressure flushing Fig 32 255000 cece eee eee ees 46 2 5 7 3 High pressure flushing Model MEK 2320 05 47 2 5 8 Connection of electric EE 48 2 5 8 1 General 46 Ma stet e ere NEE ne eh Be DOLO C 48 2 5 8 2 Connecting a 3 phase molor 2 ec odes he ood a pase ewe ee 48 2 5 8 3 Connecting a single phase motor 000000 eee eeee 50 2 5 9 Jumper on processor card WEE 50 2 6 Installing the junction box type JCTOm00 aaan 51 2 7 Quick Start checklist 12 50 ened ree EE 51 2 8 Type sign explanation 20a sex exe be e mE RR RR ete wes ee 52 2 8 1 Transmitter type sIQria x voe Zeg eg d EE ah C
139. n page 133 If the transmitter strength is adjusted differently to the above the pre determined feedback water value is not relevant In that case do not use sample 0 feedback in water value or let the transmitter run in water measure the actual feedback in water value and enter it at fine as sample 0 Then determine which actual sensing element is used see type la bel on the transmitter order Fig 64 whichever is relevant Finally determine and set the sensing element s feedback in water value according to Fig 64 Procedure Cali 1 Press brate in the main menu 2 Then press aac Press Load new value and enter the correct feed back in water value at sample 0 Exit by pressing 102 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration 3 6 3 Calibration 3 6 3 4 Predefined calibration curves See section 3 6 1 1 on page 93 item A In the table below calibration constants KO K1 amp K2 are listed for dif ferent pulps These constants are only valid for the sensing element type B and it s consistency range 1 595 for long fibers and 1 6 5 for short fibers The constant KO is dependent upon network frequency 50 or 60 Hz for the motor rpm Predefined calibration constants K0 60 K0 50 nm Hardwood bleached HWB 24 20 0 7 2 3 Short fiber chemical pulp bleached Hardw
140. nce to the pipe wall at the narrowest point min 6mm 0 24 max 6mm for ID 300 mm 28 MEK 2300 Installation instructions BTG 2004 11218 56 3en 2 5 Installing the transmitter Warning Assure yourself that the pipe is empty before opening it up Incorrect use of shut off valves is a potential hazard Fig 18 AUN oa Installation with shut off valve Weld in stud or measuring vessel Measuring chamber Slide gate valve Water valve size R in for clean flushing of the joining thread in the nipple coned according to ISO 7 1 BSP male Drain valve size R 1 in 1 in BSP for emptying of the measuring chamber Nipple joining thread coned according to ISO 7 1 1in BSP male Tube to outlet Note Items 4 and 5 are not part of the delivery 2 5 2 3 Installation with shut off valve c Shut off valves should only be used with the standard model of the MEK 2300 and where consistency does not exceed approximately 4 Weld in studs can be ordered ready fitted with slide gate shut off valves This makes it possible to remove the transmitter while the pipe is filled with pulp see Fig 18 Note that shut off valves should only be used in low pressure installa tions and with non hazardous media as a reliable seal over the valve can not be guaranteed Each shut off valve is supplied welded to the weld in stud A water valve for flushing the measuring chamber and a
141. nd with data 13 Trim the controller See section 3 14 on page 150 14 Document the calibration either manually or by making a printout refer to section 3 6 6 2 on page 112 Refer also to section 3 6 6 3 on page 117 or section 3 6 6 4 on page 119 Calibration is now complete but can generally be improved by entering additional calibration points i e an updated calibration according to section 3 6 4 on page 110 3 6 4 Updated calibration See section 3 6 1 1 on page 93 item D Updated calibration can be used at any time to improve an existing single or multi point calibration A total of ten sample points includ ing FEEDBACK IN WATER can be entered in each measuring range This calibration option works in exactly the same way as the multi point calibration described above The only difference is that you select option at Galib the ration 3 mode which means that the existing calibration is not erased Any sample taken can be updated with a new sample at any time 110 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration 3 6 5 Calibration with given constants See section 3 6 1 1 on page 93 item E The three calibration constants KO K1 and K2 define the calibration curve 1 e Cali It is a simple matter to enter new constants under brate 56 Step down to accurate constant with Ze and give ac tual inpu
142. ne jack The test pins can then be connected to a terminal block e g in the rack room The connection is made in parallel across the 4 20 mA con nection which can be kept intact The connection is not polarity depen dent When used in this manner the terminal is usually powered from the in 70 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 3 Hand held Terminal SPC 1000 ternal battery Fig 44 Adapter for terminal connection included with SPC 1000 delivery 3 3 3 Connecting a printer A standard printer can be connected to the hand held terminal socket marked PRINTER The printer must be EPSON compatible recom Do not use the hand held mended models EPSON P 40S SEIKO DPU 411 or SEIKO DPU terminal s 12 V DC AC 414 It must have a serial input and be set for 2400 baud The connection adapter for the EPSON cable between the hand held terminal and the printer is supplied by BTG printer 6 V DC refer to the parts list Accessories for hand held terminal The printer may be damaged if connected The printers have a rechargeable battery and are provided with a 6 V DC incorrectly AC adapter The printer is used to document all important calibration and adjustment data and is a very useful tool when trouble shooting Fig 58 01218 56 3en MEK 2300 Operating instructions 71 BTG 2004 3 3 Hand held Terminal SPC 1000 Fig 45 PC contact alt disk SPC 10
143. ng measuring ranges as well gt All settings in the editing memory are now deleted and replaced by the data in the back up memory 142 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 11 Trouble shooting functions 3 11 Trouble shooting functions A number of functions are important in connection with trouble shooting the transmitter These functions will be found under MAIN MENU option Configure and on the printout 3 11 1 Checking measured set values Go to MAIN MENU option S with sub menu 38juse Enter Che E code 2300 Here you can check some very important values at Press the button until the arrow points to iun and then push deba and the SETPOINT ANGLE and FEEDBACK values ap pear In this function the values can only be checked not adjusted FEEDBACK When the transmitter is connected to the hand held terminal feedback should vary from FEEDBACK IN AIR i e approximately 4 896 to 100 when the transmitter is braked by hand at the brake ring in the mea suring part Both the Feedback raw value and the Feedback values are shown The raw value varies between 0 4095 If the Sensor sens calib see section 3 7 4 on page 133 is not adjusted the Feedback value is not relevant SETPOINT Nominal value is 1600 When FEEDBACK IN AIR is set at 4 896 you get a SETPOINT reading that can vary from approximately 1440 to 1680 units Note See remarks
144. nual calculation of calibration constants 3 6 6 6 Manual calculation of calibration constants KO K1 and K2 see Fig 61 In special cases it may be useful to calculate the calibration points by hand Fig 61 shows how to calculate points KO and K1 This is done in the same way as for the Older models MEK 2000 MBT 100 Opticon etc In this case points 5 and 6 would have made K2 negative if the program had not manipulated the calibration KO may be positive or can assume a negative value as shown in the fig ure KO is the feedback value where the calibration line intersects the Y axis See Fig 61 for calculation of K1 First press Range to access the appropriate measuring range Then load the calibration constants under MAIN MENU option Siate ecial Edit fone Press fow W to appropriate constant No and enter the value Always end with gt FEEDBACK 100 K1 2 X K2 0 Calibration 3 line 9 K0 1 2 3 4 5 CONSISTENCY 124 MEK 2300 Operating instructions BTG 2004 01218 56 3en 3 6 Calibration 3 6 7 Setting time constant damping See section 3 6 1 2 on page 96 item A The time constant is set after calibration has been completed Set it so Do not set too long a time that the signal is stable normally at 2 5 to 10 seconds constant You loose the advantage of the control system accuracy If you find you have to set a very long t
145. o another type or changing sensing element or propeller Altering sensor transmitter data See fig 58 fig 64 section 3 6 2 1 on page 100 and section 3 6 2 2 on page 101 for detailed instructions The transmitter is delivered from the factory with ready loaded program data according to the manufacturing order The data can be seen on the print out fig 58 or at p Esc Example SENSOR 73198814 Type of sensing element fitted PROP 73198772 Type of propeller fitted Serial no 123456 01 03 Serial number See Parts list for part nos of sensors and propellers or fig 64 and fig 65 If the transmitter is modified to another type or if the sensing element and or propeller is replaced the new type designation should be entered in the program See Confi gure When the sensor is replaced it is most important for purposes of calibra tion that the correct type designation and FEEDBACK IN WATER value are entered in the program 01218 56 3en MEK 2300 Operating instructions 145 BTG 2004 3 12 Altering sensor transmitter data 19 WAA YIVQPI9 J oO Fig 64 Choice of OIN 949 ON 949 ON 2010 9 9A0qv SY OIN 7 VoL ON Dall p 9A0qv SV OW o T ON D 9 9A0qv SV OIN 400 ON LE ZH09 MEK sensing ments OW 969 ON S ON 6 E oqe sy OW 9 ON 6 p Age sy OIN ZT x ON 0Z 49 OAoge SV OIN LT x
146. o lab samples and previous calibration to be made twice a year 3 17 3 Recommendation concerning transmitters used for measuring control function of vital importance to the process Comparison to lab samples and previous calibration to be made every month 3 17 4 Recommendation concerning transmitters used for measuring control function of vital importance to the process or used for debiting purposes Comparison to lab samples and previous calibration to be made once a week or after a considerable change of the process variables c Gained experiences concerning necessary extent of comparison affect the above recommendations which should be considered general 3 17 5 Maintenance of the transmitter The maintenance need will vary heavily as the transmitter position and thereby the influence from the media and ambient conditions vary from case to case 154 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 17 Maintenance Planning and Quality Assurance Regular maintenance includes Inspection of flushing water and possible leakage once a week Inspection of transmission belt condition twice a year Inspection of wetted rubber details and metal parts for damages twice a year if exposed to aggressive chemicals Inspection of play between moment wheels twice a year in case of heavy pipe vibrations Long time maintenance includes Replacement in transmission of pulley and belt recommended after 1
147. o order see Fig 20 c The dimensions for the weld connected measuring vessels weld ends are given in section 2 9 3 gt The highest operating pressure temperature to which the measuring vessel is to be exposed determines the choice of flange despite the fact that some flanges will themselves accept higher pressures than these All measuring vessels are supplied with deflector rails as previously de scribed Because of the high pressure there is no inspection cover Measuring vessels can also be supplied flanged on two sides to enable the transmitter to be fitted on one side and a BTG HDS sampling valve on the other for use with a BTG KNA kappa number analyzer See Fig 21 Cleaning and emptying of the measuring vessel can be simplified by in stalling a 1 inch ball valve either welded or threaded for water flushing Where a threaded valve is used tap the welded length of pipe on the ves sel to the desired thread standard 30 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 19 Measuring vessel for high pressures and temperatures 25 bar 226 C or 375 psi 439 F Standard design with weld ends according to ID ISO standard 1 Always mount bolt in the upper position 2 For 1 in flushing valve Installation in pipe a Turn the vessel so that the flow direction arrow points in the actual direction of flow b Align the vessel and any gaskets before w
148. o that the transmitter rotates there is risk of injury by crushing or cutting if the covers have been removed This ap plies to the cover over the motor s drive belt wheel the cover over the measuring part and the inspection cover Also take care when working close to the propeller and the sensor if these are exposed Take all professional precautions before servicing Do not wear gloves or rings which may get caught e Before removing the transmitter from the measuring chamber or opening the inspection cover check carefully that the line is empty Hot or corrosive liquid flowing out under pressure may cause serious chemical burn injuries Take care when opening the cover of the junction box with built in power supply unit There are live parts here which may cause electric shocks Live parts are protected against normal contact provided that the connections are made correctly e When the transmitter is exposed to dangerous basic or acidic corrosive media it should be removed from the pipeline regularly for inspection Replace any damaged seals If the transmitter s or measuring chamber s pressurized parts have corroded check that the material is correct for the application Leakages may cause personal injury or damage to equipment due to corrosion or burning MEK 2300 Safety recommendations SR218 56 3en BTG 2004 06 09 2 1 Important information 2 Installation instructions For Safety precautions please refer to SR218
149. of the calibration line it must always be positive Action KO Check the type of sensor fitted and whether its FEEDBACK IN WATER value matches sample 0 see Fig 62 The value of KO should not deviate by more than a percentage point or so K1 IfK1 is negative the FEEDBACK IN WATER value may be too high for the sensor fitted or the signal level may be too low for the sensor because the FEEDBACK IN AIR adjust ment is wrong If the symptom is caused by an erroneous value of sample 0 it can be deactivated as a temporary measure K2 The calibration constants are calculated according to a sec ond order equation which can have both positive and negative solutions If K2 is negative this means that the calibration curve first rises normally but then turns and falls again be cause one or more points are located too low As this is not permissible the program automatically performs a linear re gression K2 is now zero Study the calibration graph and deactivate those points usual ly at high consistencies that are pulling the curve down see the example in Fig 61 where points 5 and 6 are doing this point 5 ought to be higher than point 4 and point 6 higher still This figure also shows how to calculate the calibration con stants manually i e the same operation as in the linear regres sion OI218 56 3en MEK 2300 Operating instructions 123 BTG 2004 3 6 Calibration Fig 61 Specimen of ma
150. ogram running in the SPC 5 2 Not enough resistance minimum 250 Q in the 4 20 mA output loop 5 3 The analog output signal is not between 4 20 mA 5 4 Faulty or incorrectly connected SPC cable 5 5 Faulty Hart communica tion with the SPC Faulty HART filter or isolation amplifier 6 2 Incorrect transmitter analog out configuration 7 1 Old software version in transmitter Action See point 1 above Check the display for output signal Check if the HART filter or isolation amplifier is correct ly mounted See section 4 8 3 Check the complete 4 20 mA loop for breaks See the transmitter part of this manual for calibration instructions Replace or remove the iso lation amplifier circuit board See section 4 8 3 Switch to correct sensor card and program in the SPC If the output signal is con nected to a DCS check that the total loop resistance is between 250Q and 7500 with HART filter or between 250 and 10000 without HART filter See point 4 above Check the connectors and cabling from the SPC to the main circuit board 9 Check that the SPC func tions correctly If it does it is necessary to replace the main circuit board See section 4 8 3 3 Replace or remove the cir cuit board See section 4 8 3 See the transmitter part of this manual for calibration instructions Check with your BTG office if transmitter software can be updated MEK 2300 JCT
151. on of the memory cards The hand held terminal is fitted with a PCMCIA slot for a memory card This card is the size ofa credit card 85 x 54 x 3 mm Two types of mem ory card are available A Sensor card and B Back up card The type of memory card to be used is task dependent A Sensor card This memory card has a flash memory and is available with different memory capacities The memory card contains the operating programs for different BTG transmitters in the smart transmitter series and is available only from BTG The first version contains an operating pro gram for consistency transmitters MBT 2300 and MEK 2300 A maxi mum of eight different sensor module programs can be stored on the card 512 kB card Each language version English German French etc has its own version of the sensor card The card is marked with the language software version and part number For future updates of the operating program BTG is able to supply the latest version and updates can easily be used on the different transmit ters e Some of the basic functions are however stored on the transmitter s processor card in its EPROM and can be changed only by replacing the EPROM carried out by BTG Since the memory card has good ESD protection the old card can be re turned to BTG for reprogramming and can be used again as long as it is not damaged gt The life time of the memory card is given as 10 years There is a risk after this time
152. ood unbleached HWE Short fiber chemical pulp E 20 Sb aer unbleached Soft wood bleached SWB 24 20 1 1 34 Long fiber chemical pulp bleached Software unbleached SWU Long fiber chemical pulp 24 20 1 0 3 0 unbleached TMP Thermo mechanical pulp 24 20 2 1 2 9 GW Ground wood 24 20 2 6 2 8 ONP Old newspaper recycled 24 20 0 8 2 0 Old corrugated container OCC recycled 24 20 1 0 1 6 For a mixed pulp or a pulp not included in the table calibration constants can be approximated according to the pulp type with the closest shear force aspects The transmitter has to be adjusted for 100 feedback at 100 kpmm be fore this calibration can be made To enter the calibration constants follow the instructions in section 3 6 5 on page 111 01218 56 3en MEK 2300 Operating instructions 103 BTG 2004 3 6 Calibration Fig 57 Predefined calibration curves MEK 2300 Predefined calibration curves Typical results from actual installations e SWU m SWB x TMP HWU e GW Feedback t HWB ONP OCC Consistency 104 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 6 Calibration 3 6 3 2 Single point calibration See section 3 6 1 1 on page 93 item B Single point calibration is often used for quick start ups and refined lat er by a multi point calibration see section 3 6
153. or very small changes in feedback In practice the lower limit usually lies at around 596 feedback units Transmitter set to 0 100 feedback for a torque of 0 100 kpmm To improve the display resolution the feedback resolution can be in creased in steps The changed setting only affects the calibration curve display 3 7 6 Trend See section 3 6 1 2 on page 96 item G Ys d e Trend This function is in the main menu under The time scale of the display is changed by pressing Minutes Registra tion does not occur until the function in the menu is accessed and starts from beginning again when Minutes is pressed The 4 20 mA output signal is displayed as 0 100956 This means that the resolution is relatively low approximately 1 0 16 mA but the dis play is still a useful tool when setting the time constant 1s for ex ample 136 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 7 Special calibration functions SN ation mode On can be used to view the result without the actual output signal being af fected Refer also to section 3 7 7 on page 137 When simulating different output signal settings the function 3 7 7 Simulation mode See section 3 6 1 2 on page 96 Item H A Simul This function is in the main menu under and in the sede
154. ositioned anti rotation rails 7 inside the stud 5 The anti rotation rails should have a length of 110 mm 4 33 in a height of 15 mm 0 6 in and a thickness of 4 mm 0 16 in When M is 80 mm 3 1 in Fig 27 Alt 2 fasten three 3 deflector rails upstream from the stud Position them symmetrically and 30 mm 1 18 in apart see also 11 fig 26 and fig 27 There is no need to install the deflector rails if there are no solid particles in the pulp that can damage the transmitter BTG can also deliver an intermediate flange 2 manufactured of either Hastelloy C 254 SMO or SS2343 AISI 316 including a clamping flange 3 size 300 mm PN 10 according to DIN 2642 made of stainless material to SS 2343 AISI 316 Prepare a gasket 4 Tighten the intermediate flange and the gas ket with the clamping flange use screws nuts and washers 8 10 Make sure to direct one of the transmitter s fastening holes up wards d Insert the stud screw which was included with the delivery in the upper screw hole 12x O 23 PN 10 DIN 2642 1 To be profiled and fixed S to the main pipe S E e Sa i z Min 34 1 3 L 300 H 11 8 11218 56 3en MEK 2300 Installation instructions 39 BTG 2004 2 5 Installing the transmitter Fig 27 Installation of Consistency Transmitter in FRP piping gt 300 mm 12 in low pressure 1 BTG Consistency Transmitter MEK 2300 Intermediate f
155. other type the corresponding feedback in water value must be entered see section 3 6 2 2 on page 101 If not the calibration might be wrong 100 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration Procedure Confi gure 1 Press in the main menu Tx Spec 2 Then press to obtain the relevant Serial no Sensing ele ment part no and propeller part no 3 Press sensor and enter the correct part no see order or Fig 64 4 Press Bropelle and enter the correct part no see order or Fig 64 5 Press Send to transfer to the transmitter 3 6 2 2 Adjusting feedback in water When the transmitter rotates in water the feedback signal is dependent primarily on the type of sensing element selected it s size the transmit ter s speed of rotation determined by the mains power frequency and the transmitter s pre set strength the torque in relation to the feedback sig nal These values can be determined in advance and as a consequence the transmitter need not be run in water The water value of the feedback sig nal is important for calibration accuracy since one calibration point that is usually quite different from the normal operating range can be prede termined Applies only for Multi point calibration gt If the transmitter is to operate at very low consistencies lo
156. ould be consid ered In general a satisfactory operational life of the seal can be obtained without water flushing provided the restrictions as outlined are borne in mind Where the water quality is extremely poor it is advantageous not to use water flushing However see the following restrictions General restrictions when not using water flushing of the mechanical seal e The transmitter motor must be interlocked with the pump motor so that transmitter and pump stop at the same time to prevent dry run e The consistency must not exceed 10 Fillers type China clay or similar that contain small abrasive particles may not be present in large quantities larger than 5 filler content e The media must not be crystallizing e g unwashed pulp containing large quantities of black liquor gt approximately 4 TS e The pulp temperature must not exceed approximately 90 C 195 F 11218 56 3en MEK 2300 Installation instructions 45 BTG 2004 2 5 Installing the transmitter Running the mechanical seal without water flushing is only applicable to models MEK 2300 and MEK 2314 All other models must have water flushing except model MEK 2340 which doesn t have any mechanical seal 2 5 7 2 Low pressure flushing Fig 32 Code in type designation SSW ESW HSW or FSW c Only model No MEK 2320 requires high pressure water The other models use low pressure water or no flushing water at all The rate of fl
157. overs the measuring span and make a note of the signal strength at the minimum and maximum readings These readings can be entered as step F below 01218 56 3en MEK 2300 Operating instructions 129 BTG 2004 3 7 Special calibration functions E Enter the minimum limit of the temperature span at Tem Enter the maximum limit ofthe temperature span at Temp e g 20 C F Calibrate the temperature transmitter against the consistency transmitter Connect a simulator capable of supplying the ap propriate mA signal to the AUX in terminals in the JCT 1100 junction box Seethe wiring diagram in the Installation instructions section of the JCT 1100 manual included in this manual G First set the minimum signal for the measuring span e g 4 mA at 20 C and press S H The raw signal AUX input should now be displayed When the signal is stable press Rawsign I Setthe maximum signal for the measuring span e g 20 mA at 60 C and when the raw signal is stable press fawaign 2 Connect the temperature transmitter to the AUX in terminals in the JCT 1100 junction box See the wiring diagram in the Installation instructions section of the JCT 1100 manual included in this manu al 3 Perform a normal multi point calibration according to section 3 6 3 3 on page 108 Measure and record the typical temperature during calibration If the temperature transmitter is connecte
158. ow is controlled by a built in flow controller External purge meters should therefore not be installed as they have a definite tendency to clog Rate of flow is 0 5 l min 0 13 US gal min to 0 95 l min 0 25 US gal min depending on transmitter model Pressure can vary from nearly zero to approximately 10 bar 150 psi If pressure is higher than this the flow rate will increase but this is not a critical factor A flow indicator need not necessarily be installed but arrangements should be made for observing the water leaving the floor outlet Connect the supply of incoming flushing water directly to the water inlet pipe s G 1 4 in 1 4 in BSP male connection at the built in flow control ler Pipes should preferably be at least 8 mm 0 31 in in external diame ter with a wall thickness of 1 mm 0 04 in Install a shut off valve close to the transmitter Install the water overflow supplied on the outgoing water pipe Overflow and outlet pipe are in a separate plastic bag in the packing case Connect a 3 8 in reinforced plastic tube to the outlet draw it to the floor outlet and fasten it just above the floor outlet so that the flow can be observed The tube should not be bent to the extent that flow through is restricted 46 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 32 Warning sign for the flushing water gt connection j onsistency ai ransmitter It also indic
159. pening its covers The overall length of the transmitter is 490 mm 19 5 in Remember to leave suf ficient room for insertion and removal Install the transmitter so that it is protected from direct mechanical damage Install under a roof if there is any risk of frequent water or pulp spray Protect the transmitter from heavy vibration such as cavitation or un balanced pumps One method is to install a rubber bellows in the line 16 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 4 Planning the installation Fig 7 Recommended minimum calming length distance between pump pipe elbow shut off valve and consistency transmitter The minimum distance the transmitter should be located downstream of a pump bend or elbow is the greater of two numbers Upstream the transmitter L 1 m 3 ft or the diameter of the pipe multiplied by 3 where consistency is lt 8 and 0 5 m 1 5 ft or the diameter of the pipe multiplied by 1 5 where consistency is gt 8 Downstream the transmitter L For all consistencies the minimum distance between the transmitter and a pump bend or elbow located downstream is similarly the greater of two numbers 0 5 m 1 5 ft or the diameter of the pipe multiplied by 1 5 gt Always choose the largest of the values calculated above c n order to obtain the best measu
160. possible to weld the rails from inside the pipe grind three slots in the pipe fit the rails in the slots and weld them from the outside d Profile the weld in stud to the pipe dimensions by reference to the length of the measuring chamber so that no part of the stud ex tends into the pulp line Do this by inserting the stud into the hole in the pipe and marking it with a marking pen Note No part of the weld in stud may extend into the pulp line Align it to the vertical line See Fig 22 e Observe that the holes for the transmitter retaining screw should be aligned to the vertical line Fig 22 f After profiling weld the stud into the hole A full penetration weld must be used 11218 56 3en MEK 2300 Installation instructions 33 BTG 2004 2 5 Installing the transmitter Fig 22 Installation of high pressure weld in stud 300 mm 12 in pipe or larger 25bar 225 C or 375 psi 439 F 1 Weld in stud Must be profiled to suit the pipe dimension Material SS2343 28 254 SMO or Hastelloy C 276 according to order 2 Main pipe 300 mm 12 in Not included in delivery from BTG Calculate min t4 according to current standard Selected pipe thickness depends on present calculation pressure temperature Maintain t4 over a pipe length of minimum 505mm 19 9 in according to the figure 3 Align the transmitter fastening screws to the vertical line sloping pipes as well Always mo
161. r making it sluggish If later checks on transmitter readings compared to laboratory sam ple values reveal a confirmed deviation the lead value ofthe control ler can be temporarily reset With a MEK 2300 transmitter where the zero point is independent of the measuring span setting we rec ommend that you make an offset adjustment in the transmitter program at a suitable opportunity 150 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 15 Using the HART communication 3 15 Using the HART communication Refer to II218 56 for the functions available on the digital communica tion superimposed on the 4 20 mA signal loop Since this communication takes place using the HART standard proto col refer to the relevant user instructions from the HART association BTG is also able to provide advice on the relevant code instructions gt For reliable HART communication to the DCS the polling mode should be used When connecting the SPC 1000 the HART communication to the DCS may be inhibited during this occasion 3 15 1 Digital communication according to the HARTO protocol The transmitter complies to the HART protocol standard requirements To set and calibrate the transmitter the BTG hand held terminal is re quired Since additional functions are not covered by the HART protocol a standard HART competitive terminal can only be used for certain func tions Certain functions are available as a digital signal
162. r 226 C PN 10 Pressure class rating 25 bar 226 C Pressure temperature rating See data sheets D218 56 and D750 01 13 C Tick mark for Australia 11218 56 3en MEK 2300 Installation instructions 53 BTG 2004 2 8 Type sign explanation The device complies with the amendments and requirements of EN 61010 1 2 8 2 Junction box type sign For information regarding the type sign for the JCT 1100 junction box see the System description section of the JCT 1100 manual included in this manual 2 8 3 Measuring vessel weld in stud low pressure models type sign BTG Kalle Inventing AB SAFFLE SWEDEN Design Max media temp _ PN10 120 C 150 psig 68 F 248 F 116 psig Material vo DN Connection NOTE WHEN USING WELD IN STUD CHECK THICKNESS OF MAIN PIPE AGAINST OPERATING CONDI See explanation for transmitter type sign and data sheet D750 01 The parts are designed and manufactured according to the Swedish pres sure vessel codes AFS 1988 11 RN 78 TKN 97 The parts are calculated according to American National Standard ASME section VIII Div 1 and comply with PED regulations 1 Design PN 10 Max 10 bar pressure at 20 C equal to 150 psig at 68 F 2 Max medium temperature 120 C 248 F Max medium temperature for stated material specifi cations and valid standards In case of the medium temperatures are higher than stipulated please contact BTG before manufacture Note that the max
163. r a protective cover should be installed For more information see the Installation instruction section of the JCT 1100 manual included in this manual Fig 46 Handling the SPC 1000 terminal When the terminal is not in the wall terminal holder place it on your left forearm for right handed users and hold it securely using the hole in the handle This is the best and safest way of using it you can work properly without damaging the terminal The telephone jack on the spiral cable can be parked in the hole in the rubber casing for transport 3 3 7 2 Cleaning The terminal can be cleaned using a cloth dipped in water Use only mild cleaners not strong solvents Avoid getting water in the edges of the covers Use only washing up liquid Clean and dry with care 01218 56 3en MEK 2300 Operating instructions 75 BTG 2004 3 3 Hand held Terminal SPC 1000 Fig 47 SPCwin 1 DB 9 serial connector 2 Modem 3 SPC connection cable 4 CD with SPCwin program 3 3 8 SPCwin program for PC As an alternative to the hand held terminal SPC 1000 the SPCwin PC program with a cable and a modem for connection to the JCT 1100 junc tion box is available See fig 47 below It is necessary to order the SPCwin PC program separately Contact BTG for ordering information The program runs under Windows95 or later versions and simulates an SPC 1000 in the PC windows environment All functions in the SPC 1000 are available in th
164. r firmly to the transmitter use a tool If not tightened firmly the shield will not be properly ground ed Fig 75 Transmitter cable E JCT 1100 connection HP Ka Conn2 NS AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 167 BTG 2004 4 6 Wiring diagram Fig 76 Wiring diagram CONNG RS 485 Reserved for serial communication FB CONN5 Reserved for Field Bus o mo Oo 4 6 Wiring diagram c Unshielded long looped wires may cause interference to the signal The terminal markings become visi ble when the screw clamp connec tors are removed CONN4 OUTPUT Production output signal 4 20 mA Optional E Output signals i Concentration output signal 4 20 mA See section 4 6 1 E CONN21 O ee Signal output cable shield should be connected here See section 4 5 3 2 26 oo z AUX in 0 4 20 mA CONN3 Z o USER 2 ao Range select input B See section 4 6 1 1 Q o Range select input A See section 4 6 1 1 20 mo AO Q Cable shield not connected in junction box See section 4 5 3 2 m Cable shield connected to junction box PE via cable gland See section 4 5 3 2 OO Z Grey CONN2 oo Black no Yellow SENSOR ze Ve Red Transmitter cable 2 Brown transmitter supply Blug eat Pink GO Whi
165. re dis played as Old values When the Enter Menu button is pressed the Old values are replaced by the New values and the program goes to the menu CE Clear Entry can be used to clear the input if incorrect data is entered 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD Communication Terminal SPC 1000 1G Alarm indication is actuated by decreasing the output signal to 4 0 mA the value goes below the measuring span set or to 21 mA the span is exceeded analogue output signal 4 20 mA Indication is also transmitted via the digital communication 84 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 4 Operating the transmitter 6 Code protection can be activated to prevent unauthorized persons sending incorrect terminal programming to the transmitter The code can be selected individually but can be overridden by using a general code 7 Other code protections are applied to configure and factory set tings and to certain optional functions that can be ordered from BTG 8 Switch off the terminal for a few seconds if the program locks up can be caused by incorrect programming or communication prob lems You have to restart again after this but it is not normally nec essary to enter the transmitter s setting d a Note If pressing data any previous setting in SPC 1000 not sent to the transmitter is erased Edit 1 9 Adjusting the mea
166. recision see section 3 6 4 on page 110 Symptom 2 The measurement correlates badly against lab samples At a one point calibration the consistency should not deviate too much from the nominal value as the accuracy becomes lower The calibration is however always correct at the consistency point where the calibration was made If the consistency can be varied for example at other changes of the operating conditions we recommend you to make a multi point calibration Special conditions apply in single point calibration KO may be ei ther positive or negative K1 is normally positive K2 and the cor relation factor are always zero in single point calibration 120 MEK 2300 Operating instructions O1218 56 3en BTG 2004 3 6 Calibration e e Blconstant s a 50 k0 19 57 elkl 1 38 k k2 1 83 Typical errors in multi point and updated calibration Symptom 3 Poor match between calibration points and calibration line low correlation factor The reason may be that the feedback value for rotation in air is wrongly adjusted should be between 4 and 8 The set value can normally be read from the FEEDBACK IN AIR line of the printout If the value is normal according to the printout the setting ofthe transmitter may have been disturbed Another rea son may be that the sensor has been replaced or moved to another location without the FEEDBACK IN WATER value being repro grammed
167. ret rbi ru gue eh eds 73 3 3 5 1 Function of the memory Cards Er ieoeReRRLRLERLIELIddu e 73 3 3 5 2 Inserting the memory Gard deg yere y eEHERESEEH a p RW 74 3 3 6 ele RE EE EE EE 74 3 3 7 Operating and cleaning the hand held terminal 74 3 3 7 1 Operating erias tte paler dort dista st e cb cp died ed bei eti a cc Ro 75 3 3 7 2 RE ee EE 75 3 3 8 SPCwin program for PG 226 0 26 eer 76 3 4 Operating the transmitter eee 77 3 4 1 Programming the transmitter with hand held terminal SPC 1000 general instructions 222 225 22224 e544 ss ee tere ad ebee ei ese de 78 3 5 Starting the transmitter iecore rt ede em 86 3 5 1 Feedback adjustment in air 88 3 5 1 1 PUNCHON e dido c d Rite tenprcsd ibd R24 nee E Epid idt bets 88 3 6 EE See bereet E Et e e 92 3 6 1 General remarks on calibration and sampling 92 3 6 1 1 Calibration methods 26 oss mex EREMESHpBa R4 tex E EREZASUOME PRA 93 3 6 1 2 Other functions that affect calibration 96 3 6 1 3 General remarks on sampling 99 3 6 2 Criteria for calibration 2 154022 rte Are ct Aer cette test 54d 100 3 6 2 1 Adjusting Tag no Serial no Sensing element no Propeller no 100 3 6 2 2 Adjusting feedback in water liliis 101 3 6 3 Calibration 54 504 eit EEN 103 3 6 3 1 Predefined calibration curves 2 006000 bebe eee eee ee eee 103 3 6 3 2 Single point calibration veces an ese oe ERPeR a rtv aes 105 3 6 3 3 Multi point calibration
168. ring results it is strongly recommended that the transmitter is mounted in relation to the piping and other equipment as shown in the figures above 11218 56 3en MEK 2300 Installation instructions BTG 2004 2 4 Planning the installation Fig 8 Installation of the transmitter in relation to a pipe elbow gt Alt Ais the most possible avoid 2 4 3 Motor Cable Motor supply cable Min 4 x 1 5 mm 4 x AWGIA Shield is not required For further information See section 2 5 8 2 4 4 Choosing a site for the JCT 1100 junction box For information regarding choosing a site for the JCT 1100 junction box see the Installation instruction section of the JCT 1100 manual included in this manual 18 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter 2 5 Warning To avoid personal injuries burning injuries aggressive chemical injuries etc it is of outmost importance that the pipe is depressurized and empty before opening itfor installation or removal of the equipment Installing the transmitter 2 5 1 Operating principle The MEK 2300 is based on a shaft system belt driven from an electric motor The shaft system consists of an inner shaft the measuring shaft that can move within a few degrees of arc independently of the outer shaft and an outer shaft the drive shaft with a propeller that draws a continuous pulp sample past a sensor connect
169. rom the JCT 1100 The hand held terminal SPC 1000 must be used NO 5 20 21 OK NOT SAVED SAMPLE TAB FULL Save the sample value by pressing enter e or discard the sample value by pressing 4 or v NOT SAVED is displayed if the sample value is discarded If all nine sample values in the calibration table are already in use select which sample value in the table to replace with a new sample value Press enter e and select which sample value to replace with the 4 or v buttons verify with enter e Press 4 or v to return to the Result display without replacing any sample value AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 173 BTG 2004 4 7 Operating instructions Range setting RANGE 1 Span setting SPAN 0 50 2 00 0 50 2 00 SPAN 1 00 2 50 Offset adjustment OFFSET 0 00 SAMPLE 1 77 OK Press enter e to select another range Press 4 or v to choose a Range Verify by pressing enter e Note The transmitter will continue operating with the range set by the Range select switch and the output signal will not change All Range specific parameters Span Offset Damping amp Calibration can b
170. s ent a Gal Cora Ee d 185 4 10 JCT 1100 with power supply unit llesless 185 M218 56 3en MEK 2300 Table of contents V OBTG 2004 VI MEK 2300 Table of contents BTG 2004 M218 56 3en 1 Safety recommendations Installation handling and service must only be carried out by trained and authorized personnel and according to valid standard Read the manual for detailed information The product is designed for industrial use Installation category III Pollution degree 2 IP Code IP65 NEMA 4X The product complies with the following EEC directives and relevant standards Machinery directive 93 44 EEC Generic standard Low voltage directive 73 23 WWC EN61010 1 EMC directive 89 336 EEC EN 50081 2 89 336 EEC EN 50082 2 To meet the EMC directive the following precautions have to be taken 1 All wiring has to be shielded Power supply electronics shielded coverage X 80 Interface cable coverage 100 aluminium 2 All units are tested as a complete system to conform with rele vant CE directives and their standards When using the units in other combinations BTG cannot guaran tee the CE directive conformity The units in combination with customer installed external devices may conform with EMC and safety requirements when properly installed and using an adequate CE marked equipment The system operator is responsible for the CE directive con formity The conformity ha
171. s function is also a useful tool when trimming the control loop The direct output signal in mA 4 20 the calibrated momentary consis tency in and the momentary feedback value in 0 100 are shown in SPC 1000 addition to the output signal over time in 0 100 98 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration H Simulation mode see section 3 7 7 on page 137 S The mae function is found in the main menu under It can Off be enabled ON or disabled OFF normal status gt This function is used to simulate different settings on the terminal without affecting the actual output signal All functions with the exception of Feedback adjust and Damp can be reset in different ways to achieve optimum adjustment The result is then viewed in the Trend display This can be sent to the transmitter once you are satisfied with the adjustment The simulation function is then auto matically disabled 3 6 1 3 General remarks on sampling The only way to calibrate the transmitter correctly is to take correct laboratory samples of various consistencies and adjust the transmitter accordingly Sampling procedure 1 Install the sampling valve close to the transmitter Where a measuring vessel is used it is best to install the valve in the vessel itself The measuring vessel can be ordered complete with weld in stud for sampl
172. s to be checked by inspection Take precautions when handling equipment in pressurized hot lines in vessels SR218 56 3en MEK 2300 Safety recommendations 1 BTG 2004 06 09 1 1 Safety recommendations for consistency transmitters in the MEK 2300 Family 1 1 1 2 1 3 1 4 Safety recommendations for consistency transmitters in the MEK 2300 Family These safety recommendations are based on a risk analysis carried out in accordance with the requirements of the machinery and low voltage di rective in order to comply with European standards for CE marking General In practice a consistency transmitter in operation means a risk only when covers have been removed during installation and servicing due to rotat ing machine parts or a hazardous electrical voltage Read these safety recommendations before installing the transmitter Follow the recommendations when installing the transmitter starting up and when carrying out service Use warning signs for safety information These safety recommendations apply to the transmitter fitted with an AC powered junction box Mounting parts such as measuring vessels and weld in studs are dealt with in accordance with the pressure vessel stan dards of the respective countries c For good personal and functional safety Use only parts which have been manufactured or approved by BTG Mounting parts such as measuring vessels and weld in studs have been manufactured by BTG in
173. special maintenance routines are required However it is recom mended that the following preventive maintenance is carried out e Check that the junction box is not damaged and complies with the protection rating IP65 e Check that the cables to and from the junction box are not damaged e Keep the junction box clean and free from pulp etc 4 8 2 Service hardware The different hardware components are identified in fig 80 below Fig 80 Hardware components Screws for terminal cover 2x 2 Screws for front panel 4x 24 V DC connector AC power connector AC power supply or 24 V DC power supply board Mounting plate for power supply unit 24 V DC LED Display connector SPC 1000 connector Screws for main circuit board 15x 11 Isolation amplifiers 12 Screw for front panel grounding strap Oo oR 0 OO d ON AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 177 BTG 2004 4 8 Service instructions 4 8 3 Handling of circuit boards for output signals Upon delivery a HART filter on a separate circuit board is mounted see fig 81 below No isolation amplifiers are mounted The HART filter circuit board can be replaced with an isolation amplifi er or removed as required If the circuit board is removed and not re placed then the connector pins have to be strapped in order to get an output signal See fig 81 below It is possible to mount isolation amplifiers for up to t
174. ss of the selected pipe we recommend an exact calculation Please also note that the manufactur ing tolerance of the selected pipe must be included in your calculation If the calculation the diagram shows that the existing main pipe is of insufficient thickness and therefore needs to be strengthened i e have a thicker wall you must observe that the strengthened pipe must extend to a minimum of 300 mm 12 in on each side of the weld in stud mea sured from its center Calculation values Weld in stud Outer diameter OD 308 mm Material thickness t 4 mm Sizing temperature 20 C 68 F Omax Max permitted stress value Nimm SS2343 o 147 N mm 254 SMO o 185 N mm Hastelloy C 276 Gan 155 N mm Fig 15 Weld in stud to PN 10 M 150 100 mm 6 4 in Measuring chamber Main pipe Inspection cover Position of sensing element M 150 mm 6 in Position of sensing element M 100 mm 4 in P GO c1 11218 56 3en MEK 2300 Installation instructions 27 BTG 2004 2 5 Installing the transmitter Fig 16 Weld in stud with deflectors PN 10 M 70 mm 2 75 in 1 Deflectors x 3 2 Position of sensing element M 70 mm 2 75 in 3 Aligned to the vertical line Fig 17 Installation of inspection cover Yoke Nut vibration proofed Inspection cover chained to the measuring vessel CN A gt Min 10 mm 0 4 in dista
175. stream the three deflector rails supplied should be welded upstream of the stud with their sharp ends facing upstream see Fig 16 This will have the effect of protecting the sensing element which will be in the main stream Should the guide rails become lost new ones can easily be made See Fig 16 If it is impossible to weld the rails from inside the pipe grind three slots in the pipe fit the rails in the slots and weld them from the outside c Profile the weld in stud to the pipe dimensions by reference to the length of the measuring chamber dimension M Fig 15 Fig 16 so that no part of the stud extends into the pulp line Note The attached label fitted on the stud shows the M di mension Be sure that the proper stud is taken to be used at the Tag no in question d Profile the stud by inserting it into the hole in the pipe and marking it with a marking pen Observe that the holes for the transmitter re taining screw should be aligned to the vertical line See Fig 16 pos 3 e After profiling it weld the stud into the hole A full penetration weld must be used 11218 56 3en MEK 2300 Installation instructions 25 BTG 2004 2 5 Installing the transmitter f The use of an inspection cover is recommended Cut a hole with a diameter of 156 mm 6 14 in in the pipe opposite the transmitter and grind and bevel the edge to receive a weld Insert the inspec tion cover pipe into the hole ensuring th
176. suring range Refer to section A There are four discrete measuring ranges that can be individually calibrated This option is used to improve the accuracy of the trans mitter for example when different pulp qualities are present gt The different measuring ranges can be selected and programmed via the hand held terminal but the relevant measuring range for the actual output signal can be set only via the external connection This is accessible on the junction box terminal block The terminal s pre set measuring range e g Range 3 agrees only with the terminal s output signal and consistency display when this measuring range 3 is also connected via the terminal block In the case of the other three measuring ranges 1 2 and 4 all settings in the terminal agree for the respective measuring range except for the output signal and the consistency display By pressing Edit Range 1 Edit Range 2 etc you can step to the relevant measuring range for setting The measuring range is also set for copying the relevant measuring Misc range s back up data to the editing memory See A The following provides detailed step by step instructions with explanations for beginners The terminal s display is usually quite sufficient for experienced users 01218 56 3en MEK 2300 Operating instructions 85 BTG 2004 3 5 Starting the transmitter The motor must not be allowed to run for more than 4 5 minutes w
177. t Transfer the calibration to the transmitter Press S Check that all data that is displayed is correct If a code has been entered see section 3 9 on page 140 key this in correctly and press Yes to transfer all the data to the transmitter Ifthe message Transmission fail appear there is a communication problem Refer to the Service Manual and section 3 5 on page 86 item 5 Press 7 9 in the main menu Check the stability of the signal over time If necessary go back to the main menu and set a suitable time constant Press ZS see section 3 6 7 on page 125 End with data Trim the controller See section 3 14 on page 150 Document the calibration either manually or by making a printout refer to section 3 6 6 2 on page 112 Refer also to section 3 6 6 3 on page 117 or section 3 6 6 4 on page 119 gt Calibration is now complete but can generally be improved by entering additional calibration points i e by making a multi point calibration according to section 3 6 4 on page 110 OI218 56 3en MEK 2300 Operating instructions 111 BTG 2004 3 6 Calibration 3 6 6 Evaluation and documentation of calibration When you have made a calibration it should be evaluated and documented Programmed data essential to subsequent fault tracing or replacement of a card are then available on file 3 6 6 1 Print out documentation A standard printer is an invaluable aid t
178. tandard model of the MEK 2300 can also be installed in a pulp chest using a weld in stud provided that maximum consistency is 3 to 4 and the pulp is well mixed in the chest Formation of layers will result in incorrect consistency measurement To prevent this cut the weld in stud to a length of 150 mm 6 in of which 50 mm 2 in should protrude from the inside wall of the chest see Fig 28 Position the transmitter on the periphery of the pulp chest at 30 to 90 angle relative to the mixer and preferably at the same level as the mixer B Overflow box installation The MEK 2340 has an elongated shaft making it suitable for installation in an open overflow box or level box Shaft lengths for distances of 500 700 or 1 000 mm 19 7 27 5 or 39 5 in between the end of the fastening flange and the sensing element are available See Fig 29 for a typical in stallation in an overflow box where the distance is 700 mm 27 5 in gt Note that this transmitter has no mechanical seal and an open space between the transmitter flange and the liquid surface must exist Fig 28 Installation in pulp chest 11218 56 3en MEK 2300 Installation instructions 41 BTG 2004 2 5 Installing the transmitter Fig 29 Example of level box for MEK 2340 shaft length 700 mm 27 5 in 1 Mounting plate for 42 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmit
179. te transmitter supply 1 CONN1 w rt Protective earth SUPPLY 20 Line 100 240 V AC ZC Neutral Power Supply 168 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 6 Wiring diagram Fig 77 Removal of jumper CONN 21 Er TE m 4 6 1 HART communication The junction box is delivered with a HART filter that removes the super imposed HART signal on the analog output signal from the junction box to the DCS and so on If the HART protocol is used after the junction box the HART filter must be removed See section 4 8 3 Handling of circuit boards for output signals on page 4 178 BTG s hand held terminal SPC 1000 and the display in the junction box use the HART protocol for communication between the transmitter and the junction box The HART communication requires a 250 ohm minimum loop resistance which is normally provided by the HART fil ter If the HART filter is removed it must be verified that the output cir cuit DCS etc has at least 250 ohms resistance If this is not the case then an extra resistor must be connected in series with the output signal cable Always connect the resistor to the plus mA terminal To ensure that there is a closed 4 20 mA loop between the transmitter and the junction box the output signal from the junction box is jumpered on delivery This jumper must always be removed when a signal cable is connected See figure below CONN4 S es sapt R
180. tem Before starting the motor make sure that the flushing water supply to the mechanical seal is working applies to this model Familiarize yourself with the operation of the transmitter program before starting the transmitter Make sure the direction of the motor is checked before admitting pulp to the line Check that the actual Set point and Max feedback values agrees with corresponding values stated in the attached test protocol Is a suitable sampling valve for pulp located close to the transmitter This is very important for calibration and check up of the transmitter We recommend BTG sampling valves When calibrating the transmitter make sure that representative samples are taken from the line They should always be taken in the same way which also applies for the laboratory routines When operating the hand held terminal make sure that all data are correct before sending them to the transmitter Check transmitter performance regularly See section 3 17 on page 153 Check the flushing water supply once a week Take remedial action immediately if necessary Check the condition of the drive belt every six months Check that the transmitter junction box hand held terminal are not exposed to abnormal vibration or splashing which can lead to poorer performance and make repairs and servicing more difficult Type sign information see installation instructions in manual 01218 56 3en MEK 2300 Operatin
181. ter Warning Assure yourself that the pipe is empty before opening it up 2 5 6 Installation of the transmitter 2 5 6 1 Installing the transmitter a Leave the protective cover on the transmitter until it is to be in stalled b Check that the stud bolt supplied is fitted in the upper hole on the flange of the measuring vessel weld in stud c Check that the O ring on the flange is in position d Carefully lift the transmitter to a point from which it can be slipped onto the stud bolt gt Do not allow the sensing element to abut or become damaged by the edge of the flange see Fig 30 c Do not rest the mechanical seal on the edge of the flange Slip the transmitter directly onto the stud bolt see Fig 30 gt Do not lift or turn the transmitter round using the sensing element see Fig 31 e Fasten the transmitter in position with the 15 nuts bolts and wash ers supplied oiling and tightening the bolts alternately preferably with the help of a torque wrench gt Use recommended torque settings for transmitter fastening screw Tightening torque for 8 mm bolts 24 Nm 2 4 kpm 17 7 ft Ibs Tightening torque for 10 mm bolts 47 Nm 4 7 kpm 34 7 ft Ibs 11218 56 3en MEK 2300 Installation instructions 43 BTG 2004 2 5 Installing the transmitter Fig 30 Warning sign installation gt Slip the transmitter onto the stud screw The edge of the measuring vessel must not touch the me
182. ter D Temperature compensation see section 3 7 2 on page 129 c This function is an option which can only be reached by entering an access code obtained from BTG If the code is not entered the function does not appear in the display The transmitter sensor processor card must be equipped with components for this function Certain external factors affect the transmitter s shear force and thus the signal This effect is normally negligible The function can be used in cases where for example the temperature regularly undergoes wide fluctuations 10 C 50 F It will be found in the main menu under Confi gre To access this function an external temperature transmitter must be connected Here again it is necessary to perform a fine calibration first The func tion operates by applying a correction factor to the calculated cons value and with it the output signal is compensated for variations in tempera ture To get the exact amount of compensation first make a fine calibration at a known temperature the working point the compensation is cal ibrated later at a different temperature at which the fine calibration is compared with a new measured value This gives the absolute consisten cy error i e the compensation factor 01218 56 3en MEK 2300 Operating instructions BTG 2004 3 6 Calibration E Load feedback see section 3 7 3 on page 132 Calc new D WE
183. tes before the feedback system comes into operation and attains equilibrium This delay is the result of the very small torques obtained when rotation takes place in air To speed up the sequence the cover over the transducer part can be re moved and the transmitter retarded by hand by pressing on the brake ring If the transmitter is delivered from factory before november 1995 wait min 1 hour leaving the power to the electronics switched on before making any adjustment If the transmitter s mechanical seal is not water flushed the transmitter must not be run for more than a few minutes maximum 5 since there is a risk that the mechanical seal could overheat and become damaged We recommend that the transmitter be retarded by hand immediately after the motor is started to prevent overheating For Feedback adjustment se lect S f The following menu appears see Fig 53 Feedback Then press adjust E 88 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 5 Starting the transmitter Fig 53 Feedback adjust menu Fig 54 Load code menu Your code is 2300 Fig 54 Feedback adjust sub menu With Auto Preset and Check choice A 4 20mA MODEMPRINTER PWR ON OFF EJECT MEMORY CARD See no Tx Spec Comp 12 1234 Feedback adj in air basic EE setting A KE n Ico i Re toad SPC 1000 Communication Terminal You will be asked to enter your code as in Fig
184. that the software may deteriorate or disappear partly or completely Make sure a new sensor card is ordered in good time 01218 56 3en MEK 2300 Operating instructions 73 BTG 2004 3 3 Hand held Terminal SPC 1000 Backup card SPC 1000 74414152 The terminal must be switched off when changing cards It can otherwise be damaged B Back up card The storage card is a SRAM card and is used to store the transmitters different settings 1 e calibration data and other settings also shown by the printer output see section 3 3 3 on page 71 A maximum of 125 different transmitter settings Tag no can be stored on one card using a 64 kB card configuration Since each transmitter has the option of four different measuring span settings a total of 500 different settings can be stored on one card c Change the back up card battery regularly The battery life of the back up card is given as four years There is a risk that the data could disappear after this time The battery should therefore be replaced in good time If battery voltage level is low it is shown on the display when the card is inserted gt To protect from overwriting the card can be set in write protect mode with a switch 3 3 5 2 Inserting the memory card The protective cover must be opened first to remove the memory card Then make sure that the terminal is switched off Press the button marked EJECT and remove the card
185. the box 9 The main circuit board can now be removed Space is tight so be careful Lift out the upper part first where the display connector 8 is located To mount the new main circuit board perform the steps above in reverse order AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 181 BTG 2004 4 8 Service instructions 4 8 4 Service software Software can only be serviced by BTG s technicians Contact BTG re garding any suspected software problems 4 8 5 Trouble shooting This section only covers troubleshooting with regards to possible faults that can occur in the junction box Please consult the transmitter part of this manual for transmitter related problems In the trouble shooting table below the probable causes are listed in a log ical order They should be checked in that order The fuses and the test points indicated in the troubleshooting table be low are shown in fig 82 on page 4 184 All numbers within in the troubleshooting table below refer to fig 80 on page 4 177 Symptom Probable cause Action 1 The junction box 1 1 No power to the junction Check the external power does not power up box supply voltage 1 2 Fuse on main circuit Check fuses board blown FS1 and FS2 for AC power supply FS3 for 24 V DC to transmitter and FS4 for DC DC converters 1 3 Faulty or incorrectly Check the AC power 4 connected cabling to the and 24 V DC 3 wiring power supply unit
186. to the right Stores a measurement value that corresponds to a calibration sample value that is used for calibration curve adjustment or for offset adjustment Enter AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 171 BTG 2004 4 7 Operating instructions Start up display Result display Range setting Span setting 4 7 2 2 Menu structure c The display on the junction box always returns to the Result display after 15 seconds of inactivity or after 3 minutes if a message has been shown If data was changed it is automatically saved to the transmitter XXX 2300 5 55 12 53mA The transmitter type is displayed when the JCT 1100 has established contact with the transmitter While reading or writing data Wait is displayed Result display shows the process value and the output signal To access the main menu items press the up or down on the arrow buttons 4 v c Data can be saved to the transmitter by returning to the Result display Wait followed by DATA SAVED is shown on the display The reason for this is that the whole transmitter configuration file must always be saved to the transmitter and it is more efficient to do this after all configuration changes have been made RANGE 1 SPAN 0 50 2 00 The present me
187. tor temperature exceed 80 C 176 F It can be measured between two cooling flanges on the outside of the motor e Position the START and STOP switches centrally and the safety switch overload protection and contacts close to the motor This will facilitate calibration and maintenance when the motor must be started and stopped several times fig 35 shows a typical ar rangement Where the transmitter s mechanical seal is not water flushed the motor must be interlocked with the pump motor to ensure that the transmitter stops when the pump stops However it must also be possible to jog the motor manually and to lock it in manual con trol 48 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Dry running of the mechanical seal will rapidly cause irreparable damage to the seal Fig 33 Motor wiring diagram Y Connection for e g 380 V AC 50 Hz or 440 V AC 60 Hz Connection for e g 220V AC 50 Hz or 255V AC 60 Hz see manufacturer s label on the motor Fig 34 Motor junction box Information about connected voltage at deliv ery See this label in the motor junction box It shows how the motor is connected at delivery Example Connected for 220 V 50 Hz f Run the motor for sufficient time for basic adjustment of the trans mitter s signal in air This should be done as fast as possible to limit dry running and prevent breakdown of the se
188. ue value To obtain the actual Feedback value in Feedback in air sae adjuse code 2300 Seng Torque max FB 6 Externally set measuring RANGE choice of four 7 Set DAMPING TIME in seconds Z 01218 56 3en MEK 2300 Operating instructions 113 BTG 2004 3 6 Calibration 8 Set measuring SPAN dita 9 OFFSET Set zero point displacement in consistency a 10 Calibration constants K0 K1 K2 See section 3 6 6 3 on page 117 Sec 11 Present calibration values ACTIVE shows whether or not a sam ple is included in the calibration made Load Calib lab ration cons y curve 12 Calibration curve based on data in item 11 above The output sig nal is linearized from this curve as indicated by the horizontal scales i e the consistency can be read direct from the signal Calib ration A curve c The consistency scale of the calibration curve is limited to the set measuring span but activated points outside the span also influence the way the line is drawn 114 MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration Fig 58 Specimen of PROGRAM VER 1 2e calibration documen Rd Mn 5 Tag no 12 1234 tation printout PC seriar goi P4 RE A Sensor no 7319 8814 Prop no 7319 8772 Setpoint 1595 5 Angle 1593 Torque
189. uirements of the S ffle Jan 1999 CE Declaration of Conformity According to EN 45014 BTG Pulp amp Paper Technology AB P O Box 602 S 661 29 S FFLE Sweden Junction box JCT 1100 EN 61010 1 April93 EN 50081 2 Aug 93 EN 50082 2 Mar 95 Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Per Waernes MD AX218 56 3e MEK 2300 JCT 1100 Junction box appendix BTG 2004 161 4 4 Safety recommendations 4 4 Safety recommendations See the corresponding section in the transmitter User Manual for Safety recommendations 162 MEK 2300 JCT 1100 Junction box appendix AX218 56 3e BTG 2004 4 5 Installation instructions 4 5 Installation instructions 4 5 1 Mounting Locate the junction box close to the transmitter and sampling valve to achieve a convenient connection of the SPC 1000 hand held terminal for calibration and monitoring For convenient working height and a good operating position the bottom of the junction box should be approximately 1 4 m 4 6 ft above the floor The SPC 1000 can be placed in a holder if one has been mounted close to the junction box Install the box in a position where it is protected from mechanical dam age Fig 68 Recommended clearances gt The front cover swings open and is A hinged on the left P 300 side Es 12 eo SS T VT P u
190. ulp Sensing element type B is used 96 1 2 3 5 6 7 Consistency lt M Measuring span MEK 2300 Operating instructions 01218 56 3en BTG 2004 3 6 Calibration 3 6 1 1 Calibration methods The transmitter produces a raw signal feedback that is used to calculate the consistency signal via a second degree algorithm The accuracy of the calibration constants used in the algorithm are very important for the fi nal measuring result Different calibration methods can be used Which one to choose depends on how accurate the transmitter needs to be over a wide range of consis tency The following calibration methods are available Predefined calibration curves Single point calibration Multi point calibration Updated calibration SS SP Calibration constants A Predefined calibration curves see section 3 6 3 1 on page 103 Compared to a single point calibration Item B below this calibration method results in a more accurate measurement during initial start up The reason for this is that the predefined calibration constants have been calculated from BTG s wide experience from actual field installations We recommend that multi point calibration Item C below is used to fine tune the transmitter In this method predefined calibration constants in the transmitter are used and are adopted to process characteristics with an offset calibration This is a fast method with which only one laboratory sample is necessary
191. unt the guiding bolt for the transmitter in the upper hole c Always mount the guiding bolt for the transmitter in the upper position 34 MEK 2300 Installation instructions 11218 56 3en BTG 2004 2 5 Installing the transmitter Fig 23 Installation of high pressure weld in stud 200 250 mm 8 in 10 in pipe 0168 3 60 gt Additional information according to Fig 22 gt Be aware of the restrictions using this weld in stud See section 2 5 3 2 Calculating material thickness in main pipe Fig 24 and Fig 25 Example for PN 25 and PN16 c The data given in Fig 24 and Fig 25 are only valid for the weld in stud used in pipes 250 mm 10 in gt Use valid standard for exact calculation c The same weld in stud is used for 25 bar and 16 bar installations The main pipe dimension is different Use a valid calculation standard for an exact calculation The devia tion from Swedish Standard is as a rule of minor importance However when tmin in the diagram approaches the thickness of the selected pipe we recommend an exact calculation Do also note that the manufacturing tolerance of the selected pipe must be included in your calculation If the calculation the diagram shows that the existing main pipe is of insuffi cient thickness and therefore needs to be strengthened i e have a thicker wall ensure that the strengthened pipe extends to a
192. uter diameter of main pipe A Stainless steel to 300 400 500 600 700 800 OD mm 254 SMO x l l B Stainless steel to Calculation values for weld in stud SS2562 e Outer diameter D 240 mm Material thickness t 10 mm Omax Max permitted stress value Nimm Installation data SS2343 Omax 147 N mm Pressure 16 bar 232 psi P 254 SMO Oman 185 N mm Temperature 20 C 68 F 11218 56 3en MEK 2300 Installation instructions 37 BTG 2004 2 5 Installing the transmitter 2 5 4 FRP pipe installations Pipes made of fiber reinforced plastic FRP are now becoming quite com mon in chlorine bleach plants as they are less expensive than metal pipes and offer greater resistance to corrosion 2 5 4 4 Transmitter material selection c Select wetted material according to the actual process conditions Where the transmitter is to be installed in an FRP pipe its wetted parts are made of either Hastelloy C for highly corrosive applications or 254 SMO stainless steel for less corrosive applications Where exposure to corrosion is not significantly higher than usual however standard mate rials will be used 2 5 4 2 Installation in pipes lt 250 mm 10 in diameter using a measuring vessel Where pressure is lt 10 bar at 20 C 150 psi at 68 F defined as PN10 and pipe diameter is lt 250 mm 10 in the transmitter should be connect ed to the pulp line via a measuring vessel as described in section 2 5 2 1 The m
193. wer than approximately 1 1 5 it is recommended that where possible the transmitter should actually be run in water in the relevant installation In this case the true feedback value can be read manually at and entered at Sate finc as sample No 0 See procedure below Feedback in water and the relevant sensing element and propeller num bers are entered when supplied by the factory The new data must be set when the sensing element is replaced See section 3 6 2 1 on page 100 01218 56 3en MEK 2300 Operating instructions 101 BTG 2004 3 6 Calibration Tag no 282234 mum 0 61 7 1008 Cons 3 35 VEH PBFA Factors influencing feedback in water value The feedback in water value for the sensing element in question is giv en in Fig 63 A First determine the mains power frequency 50 or 60 Hz at loca B tion Then determine for which strength the transmitter is adjusted torque in relation to the feedback signal The standard settings are 100 Feedback signal corresponds to 100 kpmm torque NC Normal Consistency models Transmitter models MEK 2300 2314 2320 2340 100 Feedback signal corresponds to 150 kpmm torque MC Medium Consistency models Transmitter models MEK 2310 2311 2312 2315 gt Other settings can also be made for example to increase sensitivity see section 3 7 4 o
194. witch in the terminal box All numbers within below refer to fig 80 on page 4 177 1 Check that the 24 V DC LED 7 and the display are off 2 Unscrew the front panel 2 and carefully lift the front panel plate aside 3 Detach the display connector 8 by pushing the two levers aside and pulling the connector straight out from the main circuit board 4 Detach the SPC connector 9 by pulling it straight out from the main circuit board It might be necessary to loosen the locking flap using a flat screw driver 5 Unscrew the front panel grounding strap 12 from the main circuit board 6 Detach connectors for 24 V DC 3 and AC power 4 from the main circuit board 7 Detach the power supply unit from it s mounting plate by pushing the black lever located on the right upper corner to the left 8 Lift out the power supply unit 5 9 Move the wiring for 24 V DC 3 and AC power 4 from the faulty power supply unit to the new power supply unit To mount the new power supply unit perform the steps above in reverse order AX218 56 3e MEK 2300 JCT 1100 Junction box appendix 179 BTG 2004 4 8 Service instructions DANGER High voltage within the junction box Connections may only be carried out by qualified personnel applies to version with 100 240 V AC power supply 4 8 3 2 Replacing the front panel If there is something wrong with the display or the push buttons then the who
195. ystem consisting of the junction box including the BTG orig inal power supply the transmitter and the hand held terminal and the specified connecting cables see the Installation instructions section of the JCT 1100 manual included in this manual is designed to meet the following CE directives and their associated standards e Machine Directive 93 44EEC e PED Directive 97 23 EEC e EMC Directive 89 336 EEC Low voltage directive 73 23 EEC The junction box JCT 1100 is CSA approved and the transmitter motor can be order CSA approved 2 3 2 Working space and installation clearance requirements Always ensure that there is sufficient room for the full depth of the sys tem before installing the junction box transmitter and necessary compo nents Make allowance for the need to open the junction box and connecting the hand held terminal removing the transmitter from its mounting assembly as well as allowing sufficient working space to do this It is the responsibility of the end user to ensure that adequate working space is available gt For unit conversions please refer to section 2 9 4 on page 63 11218 56 3en MEK 2300 Installation instructions 9 BTG 2004 2 3 Basic system description Fig 2 Transmitter dimensions mm in 2 3 2 1 Transmitter The dimensions of the transmitter are given in Fig 2 A io e T LO Y

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