Appendix 1 - webadmin1.net
Contents
1. Figure 3 1 kajaaniTS FT installation principles 3 C Transmitter Central Unit TCU and shield The TCU is delivered attached to the shield The shield is attached to the wall with three mounting screws ina place that is easily accessed When selecting a place for the TCU remember that the sensor cable is 10m long Figure 3 2 shows shield mounting dimensions 3 D Electrical Connections NOTE When connecting the power supply cables check that the cables are de energized NOTE Perform and check all connections before you connect the power supply to the cables NOTE If the TCU has been switched off for a long time it may take a few minutes for text to appear on the display This is due to the charging of the device s internal back up battery i O Ola H o SS N are OO LI N 4 N O alin o 1 PN 70 s 2 76 Figure 3 2 TCU shield mounting dimensions kajaaniTS Installation Operating amp Service 3 2 3 D 1 Sensor2. Check process conditions Antenna leakage Contamination of antennas Sensor electronics failure Figure 6 1 Troubleshooting chart kajaaniTS Installation Operating amp Service 6 1 kajaaniTS Installation Operating amp Service Air can build up in bends in dilution or sludge pipes if the bends are at the highest spot in the production line In such cases an air pocket is formed and continues to grow in a bend in a pipe When the air pocket is large enough it begins moving with the flow in the pipe An air mass such as this may cause a momentary error in dry solids content measurements Air may be generated in the pulp through foaming caused by chemicals as well Chemicals Chemicals in the sludge weaken the measurement signal Therefore a maximum conductivity limit has been defined for each sensor type If conductivity exceeds this limit the measurement signal becomes too small and the measurement result contains noise and errors A large overshoot in conductivity can cause the measurement signal to disappear altogether Fluctuatations in the chemical concentration may also cause small errors within the conductivity specification limits You can eliminate these errors by using kajaaniTS chemical compensation See Chapter 5 F 1 Temperature Temperature affects dry solids content measurement which kajaaniTS compensates for with its own temperature m
3. kajaaniTS Installation operating amp service manual OUL00489 VA EN metso automation Table of Contents 1 Introduction 1 1 1 A kajaaniTS dry solids content transmitter 1 1 2 Structure 2 1 2 A kajaaniTS FT aaa 2 1 2 B Sensor Electronics ooousn nimineen 2 1 2 C Transmitter Central Unit TCU 2 2 3 Installation 3 1 3 A General Principles 17 7 7270002e0asasauuuan 3 1 3 B kajaaniTS FT aa aan 3 1 3 C Transmitter Central Unit TCU and shield 3 2 3 D Electrical Connections 1 1 sasaaanan 3 2 3 D Sensor Cable tumama lanasa nna 3 3 3 D 2 Power Supply cceeeeeeeeeeeeeeeeeeeeeeeenneees 3 3 3 D 3 Current Signal Cables eessen 3 3 4 Setting Up 4 1 4 A Mechanical Inspection ss cceeeeees 4 1 A B Installation cccsceceeeseseeeeeeseeeeeeeeeeeeneeeees 4 1 4 C Cabling Inspection ccccsceeeeeeeeeseeees 4 1 4 D Electrical Inspection cccssseeeeeees 4 1 4 E Configuration and Calibration 4 1 5 User Interface and Operation 5 1 5 A Transmitter Central Unit cseeee 5 1 5 B Operations Menu cccccccsseeeeeseteeeeeeees 5 1 5 C Calibration 2A 5 2 5 0 1 Sample Takingi aa naaa 5 2 5 C 2 Entering Laboratory Results 5 2 5 C 3 Offset Correction sersan hnus 5 3 5 C 4 Calibration and sample history 5 3 5 D C
4. SCTEWS kajaaniTS Installation Operating amp Service Figure 6 3 Removal diagram for FT 50 FT 100 antenna cables Figure 6 4 Removal diagram for antenna cables of other FT Sensor models 6 5 6 C 3 Antennas FT Sensor See Appendix 3 construction drawing NOTE Before removing the antennas check that the process pipe is empty and unpressurized and that removal is safe Removal 1 Remove the sensor electronics as described in Chapter 6 C 1 2 Remove the antenna cable as described in 6 C 2 3 Remove the antenna s six mounting screws with a 5mm Allen wrench Inthe FT 50 FT 100 model there are four mounting screws and the washers are self sealing 4 Pull the antenna out of the inlet hole and remove the O ring 5 Remove the antenna from the flange by unscrewing two M4x12 screws Installation 1 Attach the antenna to the flange with two M4x12 screws with washers 2 Clean the sealing surfaces of the antenna installation hole using e g isopropanol 3 Place a new O ring into the installation hole against the collar 4 Put locking medium Loctite 270 onto the flange s six mounting threads 5 Check that the antenna flange O ring is in place and then insert the antenna into place in the antenna coupling 6 Tighten the antenna s six M6x16 mounting screws and washers with a 5mm Allen wrench to 8 Nm torque In the FT 50 FT 100 model there are four screws and the wash
5. Tale the relative proportion of talc in the filler shown as a percentage TiO2 the relative proportion of TiO2 in the filler shown as a percentage Chemical chemical type required only for chemi cal compensation Lab cond laboratory conductivity mS m required only for chemical compensation Not used kajaaniTS NOTE If the conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 mS m 10 mS cm If the conductivity meter shows results in units mS m divide the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 uS cm 5 5 mS cm 7 C 3 Offset corr This function allows you to perform level correction on the measurement Move the cursor onto Level corr and press the right arrow The following display appears MCA MCA 1234 Set the offset correction 10 10 0 0 DEL ABORT ENTER Enter the desired value and press ENTER F4 The HART Communicator sends the value to kajaani TS 7 3 7 C 4 Lab cal History This menu shows ahistory of calibrations performed on the device Move the cursor onto Lab cal History and press the right arrow The following display appears MCA MCA 1234 23 04 05 10 32 09 Lab 3 00 MCA 3 10 Cum offset 0 00 Cs T 53 2 C Att 49 3 dB ABORT OK The display shows the date and time of the calibration as well as the sample s measured value and
6. Process Conditions Air Air in the pulp is seen in measurements as an excess in dry solids content Airexists as bubbles of different sizes Small bubbles dissolve in water at pressure of approximately 1 5 bar but large bubbles may disturb processes even at pressures higher than that At most the error caused by air may be in the range of several percentage points percentage of dry solids content Air causes disturbances to the process itself so the formation of air bubbles should be avoided Air formation mechanisms Airis mixed with pulp forexample when itis dropped into the stock tank If the level in the stock tank is low if the point of impact in near the pump or if the flow through time in the tank is low then air is not able to escape properly from the pulp before the pulp is forced into a departing flow The best way to put pulp in the tank is to run the input pipe under the level of pulp in the tank In addition a strong stirring at a low surface level can cause a whirl that causes air to be mixed into the pulp Air may also become mixed into the pulp through a leaking joint on the pump s intake side The dilution water may also contain air and cause air bubbles in the pulp Slow drift errorindication A sudden change in level when process conditions are stable Reference channel failure Check self diagnostic s Sensor electronics failure Sensor electronics failure error messages
7. MCA 1234 Calibrate 1 Sample taking Enter Lab Level corr Filler Lab cal History Sample history Special functions JA UR WD 7 C 1 Sample taking This function allows you to take a sample for single point calibration Move the cursor on to Sample taking and press the right arrow The following display appears Press OK to start sample taking ABORT OK Press F4 OK KajaaniTS begins to average the measurement result for the sample and the following display appears Press OK to stop sample taking ABORT OK Take the sample and then press OK F4 again kajaaniTS shows the results of its measurement MCA MCA 1234 Sampling ready Average Cs 3 02 Min 3 01 Max 3 03 T 42 3 c ABORT OK Select OK F4 to return to Calibrate display kajaaniTS Installation Operating amp Service 7 C 2 Enter Lab This function allows you to enter the laboratory value for the sample taken Move the cursor onto Enter Lab and press the right arrow The following display appears MCA MCA 1234 Enter lab Lab Cs Filler Kaolin CaCco3 Talc Ti02 Chemical Lab Cond Enter the necessary laboratory information Lab Cs laboratory consistency Filler the relative proportion of filler in the total consistency shown as a percentage Kaolin the relative proportion of Kaolin in the filler shown as a percentage CaCO3 the relative proportion of CaCO3 in the filler shown as a percentage
8. The device begins averaging the measurement result and a message Sampling appears on the Status line Go take a calibration sample and then press the Sample button again The device finishes averaging the measurement result and displays the result Sampling ready average TS 3 26 min 3 20 max 3 3 T 56 3 C 3 kajaaniTS Installation Operating amp Service In addition to showing the dry solids content average the device also shows the sampling period s minimum and maximum values as well as the process temperature The minimum and maximum values indicate dry solids content fluctuation during the sampling period This fluctuation should be small so that the dry solids content sample is reliable The sample you take goes to the Enter Lab menu to await the laboratory value Press the ESC button to move back in the menus NOTE If you press the Sample button when you are in a main menu the device begins averaging the measurement results A sample taken this way can not be used to calibrate the device Rather it is intended to be used to read the measurement result average over the desired period of time for monitoring purposes for example 5 C 2 Entering Laboratory Results When you have determined the sample s laboratory dry solids content press the ESC button to move from the main menu to the Operations menu Select Calibration Enter Lab after which the following menu appears dd mm yy hh mm TS 00 0
9. then small errors or drifting in the measurement might be caused by sensor electronics In such a case all the self diagnostics measurements might be within allowed limits due to which self diagnostics does not detect the error To locate the error it might help to analyze the device s internal trend and sample history table and compare these to the error results if such error data is available e g in laboratory monitoring This requires a deeper knowledge of the sensor and is typically performed by Metso maintenance personnel Reference Channel Failure Refer to Sensor Electronics Failure 6 B Self diagnostics error messages Self diagnostics monitors the signal of the measurement channel measuring the process and the signal of device s internal reference channel Self diagnostics is capable of detecting clear fault states in which case it generates an alarm by freezing the current signal or setting it to 3 75 or 22 5 mA according to user specifications If however the fault is not a clear device fault but rather measurement drifting then self diagnostics may not necessarily be able to detect it In such cases comparing self diagnostics measurements with device drifting and seeking correlations between these may help in locating the source of the error Self diagnostics measures the following values e Cab temp Shows sensor electronics temperature A continuously high temperature reduces the average fault interval e Ml
10. Keranen J metso automation
11. Profibus PA FieldCare HART Process Specifications jo a PaN BO ws AA 2 5 11 5 Process Temperature 2 0 0 0 ceeeeeeeeeeeeees 0 50 C Process Pressure Minimumrecommendation gt 1 5 bar no free air Maxam a 16 bar for FT sensor Vibration Max wo 20 m s 2 10 200 Hz Conductivity limits and sensor weights Conductivity Maximum mS cm 30 C 50 C 70 C weight kg kajaaniTS FT 50 2 25 25 25 8 5 kajaaniTS FT 100 4 18 16 13 10 0 kajaaniTS FT 150 6 13 12 10 13 5 kajaaniTS FT 200 8 13 11 9 17 0 kajaaniTS FT 250 10 13 11 9 24 5 kajaaniTS FT 300 12 10 9 7 29 0 A1 1 Appendix 2 Delivery Content kajaaniTS FT Metso delivers Order codes on the right side of the sensor unit size options Code Name Symbol Sensor Unit A OUL00471 kajaaniTS Transmitter Central Unit B with a 10m sensor cable OUL00489 Installation Operation and E Maintenance Guide Customer delivers Power supply cables 90 260 VAC C Network voltage cables D Sensor unit size options Order code of the whole delivery OUL00487 kajaaniTS FT 50 2 OUL00488 OUL00490 kajaaniTS FT 100 4 OUL00491 OUL00492 kajaaniTS FT 150 6 OUL00493 OUL00494 kajaaniTS FT 200 8 OUL00495
12. based on Pt 100 sensor measurement results If however temperature dependency still exists in the measurement result it can be eliminated by using the temperature compensation correction function The temperature dependency must first be determined via laboratory monitoring To ensure that the temperature dependency is accurately defined the temperature area must be sufficiently broad The results of the laboratory monitoring are shown on an kajaaniTS Laboratory vs Temperature graph kajaaniTS Lab graph points that are horizontal indicate that there is no temperature dependency in the measurement results Ifthe graph points are in ahorizontal position at a level other than zero you must perform offset correction on the calibration as explained in chapter 5 C 3 kajaaniTS Lab graph points that are in a position other than the horizontal indicate that there is temperature dependency in the measurement Temperature dependency is eliminated by entering into kajaaniTS the temperature compensation correction curve To go to the Temperature Compensation menu Select Special Functions Temperature Comp The following display appears S Lab 00 00 e OURWNH Q00000H O000005 O00000g7 T 0 0 0 0 0 0 DOGO OC000o Press the Edit button Then enter the correction curve as pairs of points kajaaniTS then performs the correction based on lines drawn through these points You can enter up to six pairs of points In the example i
13. is calculated as follows v c Ve where c speed of light in a vacuum e media s dielectric constant In water microwaves advance at amuch slower speed that in sludge Therefore dry solids content can be Figure 1 1 kajaaniTS FT calculated based on the time it takes the microwaves to move through the measured mass The advantages of this measurement procedure are substance independence insensitivity to flow speed and single point calibration The device is including the sensor unit figure 1 1 and Operating Unit functioning as the user interface figure 2 3 kajaaniTS Installation Operating amp Service 1 1 kajaaniTS comprises the sensor unit and a user interface called Transmitter Central Unit There are six different sized sensors between FT 50 FT 300 The appropriate model is selected according to the diamater of the process pipe 2 A kajaaniTS FT The body of the Flow Through sensor is a pipe which when installed replaces an identical length of process pipe Flush mounted antennas are installed on opposite sides of the sensor body so measurement takes place through the pipe The sensor electronics casings is installed on the sensor body by means of a connecting pipe The Pt 100 sensor which measures process temperature is installed inside the connecting pipe The antenna cables which are protected within casing run to the base plate of the electronics casing on the outside o
14. laboratory values Press OK F4 to browse through the calibra tions Press ABORT F3 to exit the menu 7 C 5 Sample History This menu shows the history of samples that have been taken Move the cursor onto Sample History and press the right arrow The following display appears MCA MCA 1234 23 04 05 10 32 09 MCA 3 04 Cs Att 49 3 dB T 53 2 C ABORT OK On the display you can read the date and time when the sample was taken as well as the sample s measure ment values Press OK F4 to browse backward through the samples Press ABORT F3 to exit the menu kajaaniTS Installation Operating amp Service 7 C 6 Special functions Special functions include chemical compensation tem perature compensation correction curve sensitivity compensation and recipes Chemical Compensation Large fluctuations in chemical content may cause errors in kajaaniTS dry solids content measurements These errors can be compensated for with chemical compen sation based on microwave damping measurement You must perform operations in two menus in order to use chemical compensation In Enter lab menu first select the chemical and then enter the laboratory con ductivity for the sample you take Note that the labora tory conductivity is given in unites mS cm If the conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 mS m 10 mS cm Ifthe conductivity meter shows results in units mS m divide
15. 0 Lab 00 00 dP dP The first row shows the sample s date and time in the following format dd mm yy hh mm The second row shows the dry solids content measured by kajaaniTS Press the Edit button to make the cursor appear in the Lab field In the Lab field enter the calibration sample s laboratory dry solids content Chem Na0H TS con 1 2 mS cm Lab con 0 0 mS cm Press the Save button to save your changes NOTE The lines Chem TS con and Lab con are needed only for the chemicals compensation chapter 5 F 1 The laboratory value for the sample can be entered only once in the Enter Lab menu If necessary you can perform offset correction for the dry solids content calibration as explained in the next chapters 5 2 5 C 3 Offset Correction If laboratory monitoring indicates that the kajaaniTS measurement results are dry solids content overly high or low you can correct this by performing offset correction on the calibration To do so press the ESC to move from the main display to the Operations menu Select Calibration Offset correction after which you see the following display Offset Cum offset 0 00 0 00 dP dP Press the Edit button to make the cursor appear in the Offset field Enter the desired offset correction value If forexample kajaaniTS shows a value that according to laboratory monitoring is 0 1 too high enter an offset correction value of 0 1 Press Save button to save your chan
16. 1 Choose recipe 2 Clear recipe Using Recipes You can select a recipe either manually using the keypad or with a binary control lines attached to the TCU In Recipes menu select 1 Select recipe The following display appears ne 000000 PA 000000 Jismasssen 000000 4 000 000000 kajaaniTS Installation Operating amp Service Press the Edit button to make the cursor appear in the Select field in the first row Use the up and down arrows to select the desired recipe number 1 4 or the Binary selection method If you select Binary then the recipe is determined by the TCU binary inputs Bin0 and Bin1 refer to section 5 F 4 subsection Selecting the Recipe with Binary Inputs You may name the recipe if you wish as follows Move the cursor to the desired recipe and write the name Successive pressing on the number keys scrolls through the letters marked on the key If you do not name the recipe then the program gives it a default name RESO1 etc Press Save to save the recipe selection and recipe name The date ddmmyy after the recipe name indicates the most recent calibration change The text ON after the date indicates that the recipe in question is in use Choose 1 1 RES01 150405 ON ren 000000 BE PA 000000 TEE 000000 When process conditions change such that you need a new recipe select the new recipe either manually or based on binary input according to the instructions above Choose 2
17. 1 RES01 150405 2 RES02 000000 ON 3na 000000 4 000000 The program saves the recipe calibration as for the previousrecipe The date 000000 indicates that the new recipe is not calibrated with its own sample Perform calibration with anew sample according to the instructions in section 5 C After calibration the date 000000 changes to the calibration date Ifnecessary scale the current output according to the instructions in section 5 D 1 and configure the special functions according to the instructions in chapter 5 F Configure recipes 3 and 4 in the same way 5 10 Clearing the Recipe If you wish to empty the recipe go to Recipe menu and press 2 Clear Recipe The following display appears Clear recipe 1 Press the Edit button and use the up and down arrow buttons to select the desired recipe Press the Save button after which the program asks you to confirm your selection This action clear recipe 1 ENTER OK ESC Cancel Press Enter to clear the recipe Note You cannot empty the recipe that is currently in use kajaaniTS Installation Operating amp Service Selecting the Recipe with Binary Inputs The recipe can be selected using two digital control lines connected to the TCU connector casing In this case you can use up to four recipes If only one binary input isin use you can use two recipes Select Binary as the recipe selection method according to the instructions in section U
18. 4 Ca 3 2 kajaaniTS wo 2 6 24 mr 2 2 2 2 2 2 2 4 2 6 2 8 3 3 2 3 4 3 6 3 8 Lab Figure 5 4 Calculating kajaaniTS measurement sensitivity kajaaniTS Installation Operating amp Service 5 9 5 F 4 Recipes The Recipe function may be necessary in special functions in which measurement conditions change so much that one calibration cannot cover it Such achange may be e g e Achange in dry solids content greater than the device measurement range 9 15 depending on the type of sensor e A change in the measured material since different materials have different dry solids content sensitivity e Alarge chemical fluctuation e g change of chemical type that cannot be compensated for with chemical compensation In these cases each process condition has its own calibration and configuration performed This calibration and configuration is saved as its own recipe In addition to dry solids content calibration for each recipe you can set chemical compensation temperature dry solids content correction sensitivity correction and current output scaling You can save a maximum of four recipes If a recipe is in use kajaaniTS indicates this by showing the name of the recipe on the main display status line instead of the OK text that is normally shown In Special Functions menu select 4 Recipes The following display appears
19. 7 3 CZ EME LAD persaaan iaasa ates Tun HAA NA 7 3 1 0 3 OUSEL COM iiciin 7 3 7 C 4 Lab cal History seese 7 4 7 0 5 Sample History saaan 7 4 7 C 6 Special functions assiro naniii 7 4 7 D Diagnostics oooummma nannaa 7 5 8 Recycling and disposing of a device removed from service 8 1 Appendix 1 Technical Specifications Appendix 2 Delivery Content kajaaniTS FT Appendix 3 kajaaniTS FT Construction Drawing Appendix 4 A Spare parts FT models Appendix 4 B Service Kit Appendix 5 kajaaniTS Installation Guide FT Sensors Caution Warning During installation maintenance and service operations remember that the sample line may contain hot sample or water be careful Always check that the incoming voltage amp freguency are correct before making any electric connections Wrong connection may damage the eguipment The applicable electrical safety regulations must be closely followed in all installation work Before any welding works in the vicinity of the devices make sure that operating voltage is not connected kajaaniTS Installation Operating amp Service WARNINGS 1 Introduction 1 A kajaaniTS dry solids content transmitter kajaaniTS in line dry solids content transmitter functions based on the measurement of microwave propagation time Microwaves are electromagnetic radiation the flying time depends on the media s dielectric constant Flying time
20. CU has the following connectors e Forthe sensor unit sensor electronics supply voltage and RS485 serial port connectors e For the current outputs passive From TCU Rev B 2 current outputs e For HART communicator HART only in the current output 1 e For RS232 connection to a PC for maintenance purposes e For network voltage The TCU is delivered attached to the shield as shown in Figure 2 3 Figure 2 3 Transmitter Central Unit TCU Power Cable Connector Fixing Screw N 5 F X LY gt D 0 O O O on 0 O O 9 O 2a O S n Guide hole Figure 2 2 Sensor Electronics kajaaniTS Installation Operating amp Service 2 2 3 Installation NOTE Before installing the process coupling or sensor check that the process pipe is empty and unpressurized and that installation is safe 3 A General Principles 3 B kajaaniTS FT The sensor model is selected according to the size of the pipe Flow through models are FT 50 2 FT 100 4 FT 150 6 FT 200 8 FT 250 10 and FT 300 12 Flow through models can be installed on the following pipe flanges e DIN PNIO e DIN PNI6 e ANSI Class 150 e JIS 10K Inchoosing an installation position note the following e Donotinstall the sensor on the pump s suction side or in the tank e After a change in pipe profile there should be a straight portion of pipe before the sen
21. Cable NOTE In a normal delivery the sensor cable is already connected to the TCU 1 Insert the end of the sensor cable that has no connector into the TCU connector casing through the inlet and connect it as shown in Figure 3 3 The protective shields are connected as follows e Twisted pair lines intertwined protective shields cable 3 are connected to adaptor GND together with cable 2 e The sensor cable s protective shield cable 6 is connected to adaptor SC SHIELD Sensor Cable Shield 2 Bring the sensor cable to the sensor unit and connect its adaptor to the adaptor in the base plate of the sensor electronics NOTE Do not place the sensor cable on cable shelves that contain cables of motors pumps or other electrical cables 3 D 2 Power Supply Insert the power supply cable 90 260 VAC into the TCU connector casing through the inlet on the left edge and connect it to the terminal block as shown in Figure 3 3 3 D 3 Current Signal Cables Another current output has been added to TCU Rev B Dry solids content is hardwired in the current output 1 CS CSIN Process temperature C F or process conductivity mS cm can be chosen to the current output 2 CS2 CSIN2 Insert the current signal cable into the TCU connectorcasing through the inlet and connect to the terminal block as shown in Figure 3 3 e Connect the voltage supply line to connector CS or CS2 e Connect the current output line to co
22. OUL00496 kajaaniTS FT 250 10 OUL00497 OUL00498 kajaaniTS FT 300 12 OUL00499 Options OUL00363 Sensor cable 30m OUL00515 kajaaniTS User Manual CD F kajaaniTS Installation Operating amp Service A2 1 Appendix 3 kajaaniTS FT Construction Drawing Sensor Cover Base Plate Assembly Pt 100 Thermoelement Sensor Body Antenna Sealing Microwave Antenna Antenna Flange Antenna Cable Antenna Cover kajaaniTS Installation Operating amp Service A3 1 Appendix 4 A Spare parts FT models Part no Order Code 1 OUL00480 2 OUL00469 3 OUL00271 4 OUL00178 5 OUL00294 7 OUL00198 8 OUL00046 9g OUL00189 g OUL00180 gi OUL00422 gi OUL00428 gr OUL00213 10 OUL00185 11 5060013 12 5160015 13 5060011 14 5160025 Description Sensor Cover Sensor Electronics Assembly Set FT Thermoelement Assembly FT Seal Ring O Ring 23 4x3 5 Viton Microwave Antenna AISI 316L Antenna Cover Antenna Cover Antenna Cover Attenuator 10 dB Gasket Screw DIN912 M6x16 A4 70 Washer DIN127 B6 A4 Screw DIN84 M4x12 A4 Washer DIN127 B4 A4 Screw DIN84 M4x8 A4 Models FT 150 FT 200 FT 250 FT 300 Models FT 50 FT 100 Model FT 50 antenna on the attenuator side kajaaniTS Installation Operating amp Service pag N N N N N N N N 12 12 4 12 8 Part no Order Code Description 6 OUL00420 Microwave Cable FT 50 2 6 OUL00114 Microwave Cab
23. aling between the kajaaniTS flanges and process flanges are properly installed and that the mounting nuts are tightened Pressure Ratings for Pipe Flanges DIN PN10 DIN PN16 ANSI CLASS 150 JIS 10K An BW Note the sensor s space requirements when choosing a mounting location kajaaniTS Mounting Locations oe ab Ha coon location The length of the cable between the sensor and Installation on a vertical pipe after a pump Installation on a vertical pipe after a horizontal pipe a NG N E a D D o E 5 Installing the NOVE sampler s Bae I oi o db I moi Gi L a mel Ag RES 5 KA z 2 z L Min4xD Min2xD O 2 2xD if Cs gt 8 1xD if 1 caren NOVEis usually mounted after kajaaniTS Check that the distance between NOVE and kajaaniTS is 22 x D and J 2 after NOVE 21 x D of straight pipe s g Mount NOVE on a vertical pipe such that it is at a 90 Si angle with the sensor s measuring line Min4xD If NOVE cannot be mounted after kajaaniTS then mount 3 if before kajaaniTS Check that before NOVE there is gt 4 Cs gt 8 ION x D and a
24. ature and dry solids content values for the desired points 1 6 Then press SEND F2 to send the values to kajaaniTS Sensitivity Correction kajaaniTS dry solids content sensitivity is set according to the sludge The measurement sensitivity can be changed if necessary e g if you are measuring some material other than sludge If you do not know the sensitivity correction of the material beforehand you can determine it according to the instructions in section 5 F 3 and enter it in the Sens Corr menu MCA MCA 1234 Sens Corr 1 00 1 00 DEL ESC ENTER Recipes The Recipe function may be necessary in special func tions in which measurement conditions change so much that one calibration cannot cover it Such a change may be e g Achange in dry solids content greater than the device measurement range 9 15 depending on the type of sensor A change in the measured material since different materials have different dry solids content sensitivity A large chemical fluctuation e g change of chemi cal type that cannot be compensated for with chemi cal compensation In these cases each process condition has its own calibration and configuration performed kajaaniTS Installation Operating amp Service This calibration and configuration is saved as its own recipe In addition to dry solids content calibration for each recipe you can set chemical compensation tempe rature dry solids content correction
25. atus Status nxt state of diagnostics variables alarm on off 7 5 8 Recycling and disposing of a device removed from service Most device parts are recyclable when sorted by material A materials list must accompany the device The device manufacturer can supply you with recycling and disposal instructions In addition you can return the device to the manufacturer which will recycle and dispose of the device for a fee kajaaniTS Installation Operating amp Service 7 1 Appendix 1 Technical Specifications Measuring range 0 16 TS If greater than 16 TS please consult Metso Automation Repeatability lt ooooonsnnnn manaamaan 0 01 TS Sens aa 0 001 TS FIItr tION AA 1to99s Ambient Temperature 2 000 20 70 C must be protected from direct heat sources kajaaniTS sensors Housing Class cssseseeerees IP 65 NEMA 4 Materials of wetted parts kajaaniTS FT sensors AISI 316 AISI 316L Ceramic Sealingrings Viton Simrit 483 kajaaniTS Installation Operating amp Service Operational Unit TCU Housing Class ccceessceseeeeereeeees IP 65 NEMA 4 Operating Voltage 90 260 VAC 0 1 A Outputs Current output to dry solids content 4 20mA HART 12 36 VDC Current output to process temperature process conductivity 4 20 mA Inputs 2 separate binary inputs 12 28 VDC 10 mA Communication PC interface RS 232
26. cripti HART user interface as on the device s TCU user on In order to function HART requires a HART interface Figure 7 1 shows the HART Communicator Communicator that contains the kajaaniMCA com operation menu mand base kajaaniMCA s Cs corresponds kajaaniTS s TS N PAN E PV Cs N Low Range N Measurement Process Temp High Range Meas Att Damping Conductivity Alarm Current AO mA of Range FT rend Int N is Recipe J ___ Position 7 lt Language I emp Unit j fo Poll addr Manufacturer N Model Range Values Final Asbly number Configuration User Settings m Tag Device Info Message Sensor Electronics Universal rev TCU Descriptor Set time Aa A We A N g Lab Cs EH Filler Take sample N Clay Enter Lab CaCO3 Offset correction Talc Calibration Fillers 1102 Ya Calibration history Chemical Sample History Lab cond Special Functions Ma y Filler Clay CaCO3 Talc Yo TI02 KO CN Chemicals Comp N he da Temperature Comp E lag values nsitivit Diagnostics Diag alarms SAAN i Digital inputs Na A Loop test Figure 7 1 HART Communicator operation menu kajaaniTS Installation Operating amp Service 7 1 When you connect HART Communicator to kajaa niTS the following menu appears MCA MCA 1234 Online 1 Measurement 2 Configure 3 Calibrate 4 Diagno
27. cs Options 3 75 mA 22 5 mA freeze User Settings Trend Int the sampling interval of the devices s internal trend table Pos device position information Lang TCU language version Temp unit process temperature unit C F Device info Poll Addr the device s HART address Manufacturer name of device manufacturer Met SO Model device name Final asmbly num field device identification num ber Universal rev the Universal Device Description version supported by the device Tag text entered by the user the tag is shown at the top of the display after the device name Message text entered by the user Descriptor text entered by the user Sensor Electronics Sensor type sensor model Sensor S N sensor electronics serial number Sensor HW rev sensor electronics revision Sensor SW rev sensor electronics software revision TCU S N A first part of TCU serial number S N B end part of TCU serial number HW rev TCU revision SW rev TCU software revision Cal date TCU s final testing date Cal ID tester s initials Set Clock 7 2 Date the date in mm dd yy Hours Minutes Second 7 C Calibrate kajaaniTS is calibrated with single point calibration Calibrate menu contains menu items for sample taking and entering the laboratory value In addition you can perform a level correction on the measurement perform various special functions and view calibration and sample history data MCA
28. e groove starting with the antenna end When the cable s casing is separated from the sensor body pull the cable connector on the base plate carefully out of its hole NOTE Lift the cable by its casing tube not by the cable itself NOTE Be careful not to dent the antenna cable connector on the base plate Installation 1 Check that the nylon sealing ring is in place in the base plate at the bottom of the antenna cable feed through thread Place the antenna cable connector gently into the hole in the base plate and press the antenna cable casing into its mounting groove Check that the antenna end feed through collar fits into place Take hold of the antenna cable connector on the base plate with an 8 mm set wrench From the other side of the base plate screw on the antenna cable lock bushing witha 10mm box key attached to the Beltzer Torque driver to 1 Nm torque Do not use force in tightening the lock bushing too much force will damage the connector Slide the antenna cable s through the inlet bushing down to the base plate and screw it into place Screw the antenna cable connector on the antenna into the antenna connector with an SMA wrench or or with the SMA Torque Wrench Adapter attached into a SMA wrench to the torque indicated by the wrench In sensor model FT 50 FT 100 you must also screw in two feed through mounting screws Attach the antenna s cover with its four mounting
29. easurement If the measurement is nonetheless noted to be temperature dependent it can be eliminated with the help of temperature compensation See Chapter 5 F 2 Antenna Leakage Antenna Leakage causes a measurement error which appears as a slow upward or downward drift In case of leakage you must change the antenna and the antenna cable as well because the cable may also have gotten wet In FT sensor models a clear case of leakage can be detected by removing the antenna cover and checking whether water drips from between the antenna and the connector that is connected to it 6 2 e Antenna Contamination Antenna Contamination causes an upward drift in the measurement If the antenna is cleaned periodically e g as a result of being washed then the error disappears The antenna is made of polished ceramic so contamination may be caused by some material that is adhering to this surface Checking for antenna contamination requires a break in the process and removal of the device Sensor Electronics Failure A typical electronics failure appears as a rapid level change in the measurement and as a rapid reduction in signal level after some component breaks A reference channel failure indicates that the fault is in the sensor electronics Self diagnostics includes an alarm limit for the reference channel signal level which detects obvious cases of broken components If all the a fore mentioned possibilities can be eliminated
30. en you are in the main display To perform calibration you must access Take calib sample menu Youcan also use the table as an aid if you wish to read kajaaniTS values for a certain sample To access the sample history table select Calibration Sample history in the Operations menu 10 12 03 12 10 48 TS 3 00 att 40 2 T 47 4C ENTER for next The first row shows the sample s date and time The second and third rows show dry solids content measured by kajaaniTS the attenuation of the measurement signal and process temperature 5 3 5 D Configuration The configuration menu has the following functions 1 Output signal 1 2 Output signal 2 3 User settings 4 Device info 5 Set clock 5 D 1 Choosing and Scaling the output signal Press ESC button in the main display to move to Operations menu Select 1 to configure dry solids content current output and you see the following display Low TS 4mA 0 0 High TS 20mA 10 0 Fi tering z1 8 Fault 3 75 mA Press the Edit button and enter values for the low and high dry solids content values If you wish you may also change the filtering time and behavior of the electricity source if self diagnostics notes a fault state Options for this include 3 75 mA 22 5 mA and freezing Process temperature or process conductivity can be configured in the current output 2 Select 2 and you see the following display Choose variable Process temperature Process conductivi
31. er into position Connect the sensor cable to its connector at the edge of the base plate If after the electricity is switched on kajaaniTS asks you to choose calibration choose as follows TCU if you did not replace the TCU Default calibration if you have replaced the TCU as well Figure 6 2 Removal diagram for sensor electronics kajaaniTS Installation Operating amp Service 6 4 6 C 2 Antenna Cables FT Sensor Removal See Figures 6 3 and 6 4 1 2 Remove sensor electronics according to the instructions in section 6 C 1 Open the inlet bushing of the antennacable connected to the base plate Slide it down until the connector body at the end of the cable becomes visible Hold the connector body in place with an 8 mm wrench e g SMA wrench while you use a 10 mm box wrench to open the lock bushing that is attached to the connector on the other side of the base plate Note Don t allow the connector body to rotate while you turn the lock bushing Loosen the four mounting screws of the sensor cover and lift the cover off Loosen the antenna cable s SMA connector from the antenna end with an SMA wrench or SMA wrench adapter In sensor model FT 50 FT 100 you must also loosen two cable feed through mounting screws Lift the antenna cable out of its mounting groove by forexample prying the casing tube with a screwdriver such that the cable begins to come out of th
32. error state began The second row shows the timestamp when the error state ended The third row shows the error type If the error state is still in effect the ending timestamp is shown as The message Shutdown in the place of the error state end time notifies that the error state was on when the power was shut down If the error state is still on when the power is swithced on next time the error is reported as a new error 10 12 03 15 32 45 RLEV ALARM ENTER for next The Error table shows the 10 most recent errors 5 E 2 Diagnostics Values In the Diagnostics menu select Diag Values 2 The following display appears Cab temp 40 6 C Mlev 121 mV Rlev 214 4 mV Mstab 9 8 Rstab 2 1 El drift 2 4 VCO drift 3 2 kajaaniTS Installation Operating amp Service The display shows values for the following diagnostics measurements Cab temp sensor electronics temperature Mlev measurement signal level Rlev reference channel signal level Mstab measurement channel signal stability Rstab reference channel signal stability El drift reference channel drift VCO drift signal generator drift Usage of this data for maintenance purposes is explained in more detail in Chapter 6 Troubleshooting and Maintenance 5 E 3 Diagnostics Limits In the Diagnostics menu select Diag Limits 3 The following display appears Ctmp max 90 OFF Ptmp max 50 0 ON Ptmp min 0 0 ON Mle
33. ers are self sealing 7 Attach the antenna cable as described in Chapter 6 C 2 8 Attach the sensor electronics as described in Chapter 6 C 1 kajaaniTS Installation Operating amp Service 6 C 4 TCU Removal 1 Disconnect the network voltage from the TCU and remove the network voltage lines from the TCU terminal block 2 Remove the sensor cable and the factory s system cable from the TCU terminal block 3 Remove TCU from its shield Installation 1 Attach the new TCU to the shield 2 Connect the sensor cable network voltage cable and the factory s system cable to the TCU terminal block 3 Switch on the network voltage NOTE it may take a few minutes for text to appear on the display This is due to the charging of the device s internal back up battery 4 If the program asks you to select calibration select e Sensor electronics calibration if you did not replace sensor electronics e Default calibration if you replaced sensor electronics as well 6 6 7 HART User Interface HART is a registered trademark of HART Commu HART Communicator is connected in parallel to the nication Foundation HART communication is amethod current output e g to the connector pins on the front of transferring information digitally between field devi panel of the TCU ces and host devices e g HART Communicator You can perform the same operations on kajaaniTS kajaaniTS is using the kajaaniMCA device des
34. ev Shows the measurement signal level in millivolts A decrease in measurement signal level below the alarm level may be caused by an electronics failure antenna leakage or high conductivity of the measured sludge If itis an electronics failure then the reference channel signal level Rlev is usually decreased to below alarm limits e Rlev Shows the device s internal reference channel s signal level in millivolts A decrease in the signal level to below alarm limits is always caused by a sensor electronics failure kajaaniTS Installation Operating amp Service e Mstab Mstab shows the stability of the measurement channel signal Stability reflects the effect of both electronics and the measured sludge Assuming that the electronics are in order see Rstab you can determine based on the Mstab value whether or not the process contains large air bubbles that are causing measurementerrors Large air bubbles cause both arise in the Mstab value as well as a temporary error in dry solids content measurement The level of the Mstab value is also affected by dry solids content and sensor model Also Mstab value is higher at a higher dry solids content than at a lower dry solids content e Rstab Rstab shows the stability of the device s reference channel signal The smaller the value the more stable the signal An Rstab alarm is caused by sensor electronic failure e El drift FI drift value shows the drift in electronic delay meas
35. f the connecting pipe Appendix 3 shows the sensor s construction drawing The material of the wetted sensor and antenna bodies is AISI 316 316L The antenna material is polished ceramic 2 B Sensor Electronics Sensor electronics for the FT model is described in figure 2 2 The sensor electronics card is installed between the round cover and base The electronics includes the microwave transmitter and receiver as well as control measurement and communication electronics On the bottom there are snap on connectors which connect with antenna cable connectors in the base plate when you press the electronics against the base plate The guide pinsin the base plate help guide the connectors into place The Pt 100 connector and the supply voltage serial communication connector are connected into the connectors located in the cover of the sensor electronics gt Sensor Electronics h Sensor Cable Connector Antenna Cable Pt 100 Microwave Antennas Figure 2 1 kajaaniTS FT kajaaniTS Installation Operating amp Service 2 1 2 C Transmitter Central Unit TCU TCU is kajaaniTS s user interface and calculator Perform operations using the number buttons and other buttons and the four line display In addition T
36. field options Up arrow Use the up arrow to scroll up if there are more than four lines An upwards pointing arrow in the upper right corner of the display indicates that you can scroll up You can also use the up arrow to scroll between edit field options 5 B Operations Menu The operations menu is divided into the functions Calibration Configuration Diagnostics and Special Functions and their respective submenus Use the ESC button to access the function menu from the main display In the menus you can use the number of the desired function to continue Use the ESC button to return to the previous level If the menu in view on the display has more than four lines i e more than fits on the display at one time an arrow appears in the upper or lower right corner of the display to indicate that you can scroll up or down with the up arrow or down arrow i i Sample takin TS FT200 POS 1234 sc Calibration a a ag Be Ki Offset Correction Status OK Calibration History Sample History ENTER a _ N Output signal 1 get o JA Conti Output signal 2 Cabin T 52 3 C onfiguration User Settings Meas Att 45 6 dB Device Info Set Clock E E Error Log Diagnostics m Diag values Diag limits o Special functions Chemical Compensation Temperature Compensatio Sensitivity Correction Recipes ee Figure 5 1 Operations Menu kajaaniTS Installation Opera
37. fter NOVE 21 x D of straight pipe FLOW Min4XD Min2xD 2xD if Cs gt 8 1xD if 2xD if Cs gt 8 FLOW Min4xD 2xD if Cs gt 8 5 e Vertical pipe If the section of horizontal pipe Horizontal pipe preceding the sensor is gt 10xD then the sensoris installed with its electronics m gt casing on top see the picture above Measuring line parallel to Measuring line at a 90 angle the previous horizontal pipe towards the pump axis Installation on a horizontal pipe after a vertical pipe kajaaniTS Installation Operating amp Service A5 1 Metso Automation Field Systems Division PL 237 Lentokentankatu 11 33101 Tampere FINLAND tel 02048 3170 fax 020 48 3171 This document discloses subject matter in which the manufacturer has proprietary rights Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document any part thereof any physical article or device except by written permission from the manufacturer Manufacturer reserves the right to alter the contents of this document without prior notice Modbus is the trademark of Modicon Inc Copyright April 2006 Metso Automation Inc Field Systems Division Documentation J T Tieto Oy P divi Piirainen Translation Matthew
38. ges 5 C 4 Calibration and sample history Calibration history Ten last calibration changes are stored in the calibration history table To see the calibration history table press the ESC button to move from the main display to Operations menu In the Operations menu select Calibration Calib history The following display appears 10 12 03 12 10 48 Lab 3 20 TS 3 00 Cum offset 00 00 Cs T 47 4C att 40 2 dB kajaaniTS Installation Operating amp Service The first row shows the calibration change s date and time in the following format dd mm yy hh mm If calibration was performed on a new sample the second row shows the entered laboratory value Lab and the kajaaniTS measurement result TS If offset correction was performed the second row shows the laboratory value Lab and the offset correction performed on it Offs The third row shows the cumulative change caused by offset correction This value shows whether the calibration has continuously moved in one direction or if the change has been back and forth The former case clearly indicates device drifting while the latter case may be a question of a device error or of erroneous laboratory interpretation of the calibration sample and calibration performed based on that Sample History The sample history table saves the 30 most recent calibration and monitoring samples You can take a monitoring sample without performing calibration Todo so press the Sample button wh
39. hanging the correction If after the correction there is still some amount of temperature dependency evident you can most easily perform the correction by editing the existing points In this case the size of the desired correction iss added to existing correction values If for example after the temperature compensation performed above and the new dry solids content calibration the results appeared as shown in Figure 5 3 The correction value for 42 C would be increased by 0 03 and the correction value for 48 1 C would be decreased by 0 02 after which the correction would appear as follows kajaaniTS Lab vs Temp 0 2 0 15 0 1 0 05 0 05 kajaaniTS Lab o 0 1 0 15 0 2 41 42 43 44 45 46 47 48 49 50 Temp C Figure 5 3 Results of new dry solids content calibration kajaaniTS Installation Operating amp Service 5 8 5 F 3 Sensitivity Correction The sensitivity of kajaaniTS dry solids content measurement is set according to the municipal waste If the device measures something else the sensitivity may have to be changed If the sensitivity of the measured material is previously unknown the sensitivity must be determined based on laboratory analysis The lab results must be from a sufficiently broad dry solids content area in order for the sensitivity to be accurately determined The results
40. le FT 100 4 6 OUL00118 Microwave Cable FT 150 6 6 OUL00194 Microwave Cable FT 200 8 6 OUL00197 Microwave Cable FT 250 10 6 OUL00216 Microwave Cable FT 300 12 N J Ng gd ON e N TTS A4 1 Appendix 4 B Service Kit kajaaniTS Service Kit OUL00512 Order Code Description Pcs OUL00513 Accessory Case 1 OUL00489 Manual 1 OUL00469 Sensor Electronics 1 OUL00471 Operating Unit TCU kajaaniTS 1 OUL00334 Simulation Cable 1 A4611042 SMA Torque Wrench Modified 1 OUL00407 SMA Torque Wrench Adapter 1 OUL00349 Torque Driver 1 4 1 OUL00409 Box key 10 mm 1 4 for Driver 1 OUL00352 Spare Part Set kajaaniTS FT 1 83200021 Thread Locking Compound Loctite 270 10 ml 8360019 Instant Glue Loctite 480 20g OUL00350 Thermoelement Simulator 1 OUL00352 Spare Part Set FT Service Kit Options Sensors FT Order Code Description Pcs Order Code Description 8060036 O Ring 14 3x2 4 Simrit 483 5 OUL00420 Microwave Cable FT 50 2 OUL00198 O Ring 23 4x3 5 Viton 5 OUL00114 Microwave Cable FT 100 4 OUL00182 O Ring 33x2 62 Viton 5 OUL00118 Microwave Cable FT 150 6 OUL00184 O Ring 56 2x3 0 Viton 5 OUL00194 Microwave Cable FT 200 8 OUL00294 Seal Ring 16x10x1 Polyamide 10 OUL00197 Microwave Cable FT 250 10 OUL00183 Seal Washer U6 7x11 0x1 5 OUL00216 Microwave Cable FT 300 12 5060011 Lock Washer DIN127 B4 A4 5 OUL00178 Thermoelement Assembly FT 5060013 Lock Washer DIN127 B6 A4 5 OUL00046 Microwave Anten
41. n Figure 5 2 two pairsof pointsare sufficient The pairs of points can be selected based on the results as in the following example Temp TS Lab 1 42 0 0 00 2 48 1 0 10 3 0 00 0 00 4 0 00 0 00 5 0 00 0 00 6 0 00 0 00 Compensation is also successful outside the defined interval such that the compensation curve is continued beyond the outermost points using the same slope kajaaniTS Lab vs Temp 0 2 0 15 o S 01 ae OS z X Cg s 0 05 ja n 0 ae al E 5 0 05 S g 0 1 0 15 0 2 T T 41 42 43 44 45 46 47 48 49 50 Temp C Figure 5 2 Determination of temperature dependence kajaaniTS Installation Operating amp Service 5 7 The effect of a new dry solids content calibration If a new dry solids content calibration is performed on kajaaniTS by taking anew sample after temperature dry solids content correction is determined the measurement program performs a level adjustment on the compensation curve In the level adjustment the program sets the value of the compensation curve to zero in the calibration temperature i e the effect of the compensation curve is zero at the calibration temperature If for example you performed a new dry solids content calibration with a sample that has a temperature of 45 C the program would perform a level adjustement of 0 05 on the compensation curve and the compensation curve would appear as follows C
42. na AISI 316L OUL00094 Rec Countersunk Screw DIN965 M3x12 5 5160025 Slothead Screw DIN84 M4x8 A4 5 5160015 Slothead Screw DIN84 M4x12 A4 5 OUL00185 Socket Head Screw DIN912 M6x16 A4 5 kajaaniTS Installation Operating amp Service A4 2 Appendix 5 kajaaniTS Installation Guide FT Sensors kajaaniTS Installation Checklist Mounting Dimensions NOTE Before beginning installation check that the process pipe is unpressurized and empty This allows you to perform installation safely MIN 500 mm 20 kajaaniTS L mm L inch Pipe size FT 50 100 3 94 DN50 ANSI 2 JIS50 FT 100 100 3 94 DN100 ANSI 4 JIS100 FT 150 100 3 94 DN150 ANSI 6 JIS150 FT 200 100 3 94 DN200 ANSI 8 JIS200 FT 250 120 4 72 DN250 ANSI 10 JIS250 FT 300 120 4 72 DN300 ANSI 12 JIS300 Note the following kajaaniTS requirements for the mounting location Process temperature max 50 C 106 F pH2 5 11 5 Pressure 1 5 16 bar The sensor cannot be installed on the pump s suction side Conductivity in accordance with sensor specifications See Appendix 1 2 Check that the mounting location and position are in accordance with the installation instructions Check that the flow arrow on the sensor casing is pointing in the direction of flow Protect the sensor and the TCU from direct heat sources and sunlight Before operating the sensor check that the se
43. nnector CSIN or CSIN2 NOTE kajaaniTS s current supply is passive and needs an external source of current The current output s load capacity as a function of voltage is shown in Figure 3 4 NOTE The current signal cable s protective shield must not be connected from TCU to the device in TCU Rev B The connection is made only from the system The cable s protective shield has been guided to be connected also to the connector SHIELD in TCU Rev O and TCU Rev A 90 260 VAC 47 63 Hz Sensor Cable 2x 2 1 x0 5 Shield Automation System L Ie CS VOLTAGE g SUPPLY INPUT 4 20 mA FIELDBUS FIELDBUS 4 20 mA HART Dry solids content 4 20 mA Process temperature Proce onductivit Figure 3 3 Electrical connections to the TCU kajaaniTS Installation Operating amp Service 3 3 Figure 3 4 shows resistance as a function of supply voltage Resistance here means the sum of measurement Q resistance cable resistance and power source resistance in the current loop 1000 500 250 Operating region 0 6 12 17 28 35 V HART communication requires the minimum resistance 250 ohm for the current loop Figure 3 4 TCU s Current output load capacity kajaaniTS Installation Operating amp Service 3 4 4 Setting Up 4 A Mechanical Inspection 4 D Electrical Inspection 1 Check that the delivery content cor
44. of the analysis are plotted on the graph kajaaniTS vs Laboratory dry solids content in which kajaaniTS is on the vertical axis and laboratory dry solids content is on the horizontal axis The slope of the points on the graph is calculated and it represents the kajaaniTS dry solids content measurement sensitivity In the sample kajaaniTS vs Lab graph in Figure 5 4 a linear regression curve is plotted for the points The slope of the curve equation indicates the measurement sensitivity which in Figure 5 4 is 0 89 To go to the Sensitivity Correction menu select Special Functions Sensitivity Corr The following display appears Input new sens coeff 1 00 Press the Edit button and enter the sensitivity value you determined for sensitivity correction Press the Save button to save the new value If you have to perform the sensitivity correction a second time for some reason you have to take into account the existing sensitivity correction This is done by multiplying the new defined sensitivity by the existing sensitivity coefficient and entering this result for the new sensitivity coefficient value For example if the sensitivity is defined again to be 0 9 after the correction of the previous example the new sensitivity coefficient is calculated 0 9 x 0 89 0 8 If you want to cancel the sensitivity correction write 1 forthe sensitivity coefficient value 3 8 kajaaniTS vs Lab y 0 8932x 0 291 3 6 3
45. on The operation unit of kajaaniTS is the Transmitter Central Unit TCU 5 A Transmitter Central Unit TCU s keypad controls are as follows Number buttons Use number keys to enter numerical data and choose menus On certain displays you can also enter letters To enter letters press a number button several times in rapid succession and the letters on the button appear on the display one after another Sample Use the Sample button to start and stop a calibration sample in the Calibration menu s Take calib sample function You can also use the Sample button in the main display to start and stop a monitoring sample Edit Save Use the Edit Save button to go into Edit mode When you are in Edit mode use this button to save data ESC Use the ESC button to exit Edit mode without saving data You can also use the button to move between the main display and the function menu Enter Use the Enter button to move between the main display and the Info display In Edit mode use the Enter key to jump to the next edit field Back arrow Use the back arrow in an edit field to return to the previous character Forward arrow Use the forward arrow in Edit mode to move to the next character Down arrow Use the down arrow to scroll down if there are more than four lines A downwards pointing arrow in the lower right corner of the display indicates that you can scroll down You can also use the down arrow to scroll between edit
46. onfiguration nananananannnaawanaaaannan 5 4 5 D 1 Choosing and scaling the output signal 5 4 5 D 2 User Settings ana nannat 5 4 5 D 3 Device information 11 11 100 m naaus aan 5 4 5 D 4 Setting the date and time 0 00 ee 5 5 5 E Diagnostics siusis diusa riigiga 5 5 5E 1 Error Table maa ANAN 5 5 5 E 2 Diagnostics Values eceeceeeeeeetteeeeeeeeees 5 5 5 E 3 Diagnostics Limits ce eeeeeeeeeee eee 5 5 5 F Special Functions s ccccssseeceeeseeeeseeees 5 6 5 F 1 Chemical compensation 00eee 5 6 5 F 2 Temperature compensation correction curve 5 7 5 F 3 Sensitivity Correction naaawa 5 9 5 F 4 Recipes u aaa 5 10 kajaaniTS Installation Operating amp Service 6 Troubleshooting and Maintenance 6 1 6 A Troubleshooting ccccssseseeeeeeeeeeeeteenrees 6 1 6 B Self diagnostics error messages 6 3 6 C Replacing Components ceee 6 4 6 C 1 Sensor Electronics ocoouuouummsm a 6 4 6 C 2 Antenna Cables FT Sensor 1 70 6 5 6 C 3 Antennas FT Sensor cceccceeeeseeeeeeeaeee 6 6 GCs TCU aaa BANA NAA KEANU T N ENS 6 6 7 HART User Interface 7 1 7 A Measurement oooonno nainen manaamaan 7 2 7 B Configure 11 annnanannanamanananananaanananamanana 7 2 7 C Calibrate oooooooiiinn onn mana naamaa aan aaaaan 7 3 FCA Sample taking Xa akan
47. ple The password is 3121 As a default password is not in use e Act siglev Active signal level adjustment ON OFF Use the up arrow and down arrow buttons to make your selection If you Select ON program make measurement signal level adjustment automatically when it goes too low 5 D 3 Device information In the Configuration menu select Device Info 3 The following menu appears 1 Sensor Electronics 2 TCU Select Sensor Electronics 1 to view sensor electronics information Type TS FT xxx S N 123456 HW Ver 0001 SW Ver 0001 e Type kajaaniTS Sensor type e S N Sensor electronics serial number e HW Ver Sensor electronics version number e SW Ver Sensor electronics software version number Select TCU 2 to view corresponding data for the TCU 54 5 D 4 Setting the date and time Inthe Configuration menu select Set clock The following menu appears Date Time 26 09 03 12 14 53 The date and time shown in this menu are used as a time stamp in the trend table and for calibration samples The main display status line shows Set clock until you have set the time Use the EDIT and SAVE buttons to edit and save date and time settings 5 E Diagnostics 5 E 1 Error Table In the Diagnostics menu select Error table 1 If self diagnostics has not detected any errors the display shows NO ERRORS If self diagnostics has detected errors the first line of the display shows the timestamp when the
48. responds to what was ordered 2 Check that the device was not damaged in transport 4 B Installation Install the sensor and TCU according to the instructions in Chapter 3 4 C Cabling Inspection 1 Check that the power supply is connected correctly 2 Check that the current output is connected correctly 3 Check that the sensor cable is connected correctly kajaaniTS Installation Operating amp Service 1 Connect the electronics to the power supply 2 Check that text appears on the TCU display Normally the main display appears but in connection with replacing a device you may be asked to select calibration In such a case select calibration of the unit Sensor Electronics TCU that was not changed 3 Allow the device to warm up one hour before starting it up NOTE If the TCU has been switched off for a long time it may take a few minutes for text to appear on the display This is due to the charging of the device s internal back up battery 4 E Configuration and Calibration 1 Select the language and temperature unit Celsius Fahrenheit according to Chapter 5 D 2 2 Set the device date and time according to Chapter 5 D 4 3 Scale the current output according to Chapter 5 D 1 4 Calibrate the dry solids content according to Chapters 5 C 1 and 5 C 2 After you have completed these procedures kajaaniTS is ready to measure dry solids content 4 1 5 User Interface and Operati
49. sensitivity correcti on and current output scaling You can save a maximum of four recipes The Recipes menu is as follows MCA MCA 1234 Recipes 1 Choose OFF In Choose set the desired recipe number The options are as follows OFF the recipe function is not in use default 1 2 3 4 select the recipe number BIN select the recipe according to binary input Select the recipe Then perform recipe calibration and current output scaling Begin using the recipes as follows When you use the recipe selection method BIN connect the automation system digital control lines to the TCU connector casing binary inputs BINO AND BIN1 Connect their grounded line to BINGND Select the recipe with the digital output lines accor ding to the following table BINO BINI Recipe 0 0 1 1 0 2 0 1 3 1 1 4 7 D Diagnostics MCA MCA 1234 Diagnostics Diag History Diag Values Diag Alarms Digital Inputs Loop test Clear Logs a ULB WNH Menu information and functions Diag History the 10 most recent self diagnostics alarms with beginning and ending times Diag values measured values of diagnostics variab les Diag Alarms diagnostics variables alarm limits switching alarms on and off Digital Inputs the state of TCU binary inputs BINO and BIN1 Loop test forcing the output signal to the desired value Master Reset Resets the TCU Similar to powering the TCU off calibration is not discarded St
50. sing Recipes Choose BIN 1 RES01 15 2 RES02 22 3 00 Connect e g the automation system s digital control lines to the connector casing binary inputs BINO and BIN1 Connect the grounded line to BINGND Select the recipe with the digital control lines according to the following table The text ON next to the recipe number indicates which recipe is selected BIN1 Recipe 5 11 6 Troubleshooting and Maintenance NOTE Before disconnecting the sensor or the flow through antenna check that the process pipe is empty and unpressurized and that disconnection is safe kajaaniTS does not require scheduled maintenance The instructions in this chapter refer to fault conditions 6 A Troubleshooting kajaaniTS s self diagnostics monitors certain internal measurements and generates error messages if the measurements exceed alarm limits Self diagnostics also detects definite faults which are often caused by sensor electronics An erroneous measurement result may also be due to antenna leakage contamination a fault in the antenna cable or a process variable that is skewing the measurement Self diagnostics may not detect such a fault The fault may also be in the current output sent by the TCU In this case the measurement is correct but the current output sent to the automation system is incorrect The following figure contains a troubleshooting chart for faults that appear in different ways
51. sor that is at least 4 times the pipe diameter In addition there should be a length of straight pipe 2 times the pipe diameter after the sensor e Reserve enough space for the sensor casing e The TCU must be installed within 10 meters of the sensor The sensor cable is 10m long You also have the option of purchasing a 30m sensor cable In addition you must note the following specifications e Process temperature under 50 C e Conductivity according to sensor specifications Refer to Appendix 1 Technical Specifications e Recommended process pressure of at least 1 5 bar to eliminate the effect of air bubbles e Sensor pressure tolerance e FT sensor PN16 In laboratory analysis of measurement results it is important to use a proper sampler e g NOVE Install it according to kajaaniTS installation instructions kajaaniTS Installation Operating amp Service When installed the flow through sensor replaces the corresponding length of process pipe figure 3 1 Appendix 5 contains the sensor installation dimensions The sticker on the electronics casing indicates the installation direction in relation to the direction of flow The sensors do not include flanges but rather they are tightened with stud bolts between flanges mounted on the process pipe eee Rc ae J II DN N pi I
52. stics The following sections explain the main menu fun ctions 7 A Measurement Measurement menu shows the kajaaniTS measure ment results MCA MCA 1234 Measurement 1 Sensor Type FT200 2 Cs 0 00 Cs 3 Prc Temp 57 3 C 4 Status OK 5 Conductivity 2 43 mS cm 6 of range 36 72 7 mA 9 88 mA 8 meas Att 32 4 dB Recipe OFF Menu information Sensor Type Cs measured consistency Pre Temp process temperature Status device status OK Alarm etc Cab Temp sensor electronics temperature of range consistency current output value as a percentage of the current output range mA value of in milliampers meas Att the measured microwave damping in the process Recipe the number of the recipe in use refer to section Recipes 7 B Configure In Configure menu you can configure kajaaniTS s current output and certain other parameters Configure menu also shows device information MCA MCA 1234 Configure Range Values User settings Device info SENSOR ELECTRONICS TCU Set Clock N H a UI PB W kajaaniTS Installation Operating amp Service Menu information and functions Range values LowRnge consistency that correlates to current output lower limit 4 mA UppRnge consistency that correlates to current output upper limit 20 mA Damping damping time of the current output Alarm cur how the output signal reacts to error situations detected by self diagnosti
53. the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 uS cm 5 5 mS cm After entering these values go to Special Functions conductivity and select Chemical Compensation to begin using chemical compensation The following display appears MCA MCA 1234 Chemicals Comp Chem comp OFF Comp value 0 00 Chemical NaOH Lab cond 2 45 mS cm ABORT OK To begin using chemical compensation set the Chem Comp value from OFF to ON Comp Value shows the chemical compensation value which chemical com pensation subtracts from the dry solids content results The lower two rows show the chemical and labora tory conductivity values entered in Enter lab menu TA Temperature Compensation Correction Curve You can define temperature compensation correction curve for kajaaniTS if you notice temperature depen dency in the measurement results Define the correction curve by entering 2 6 pairs of temperature dry solids content points Based on the curve drawn from these points kajaaniTS subtracts the curve dry solids content from the measurement results Determine the correction curve pairs of points as described in section 5 F 2 Then enter the pairs of points in the menu Temp Comp which appears as follows MCA MCA 1234 Temp Comp 1 1 C 0 00 2 15 0 00 3 2 C 0 00 4 2 5 0 00 9 5 C 0 00 5 5 0 00 6 5 0 00 6 5 0 00 Enter temper
54. ting amp Service 5 1 5 C Calibration The kajaaniTS is delivered with factory calibration which means that it will measure dry solids content as soon as you switch the power on Factory calibration is performed on the device in connection with final testing using clean water We recommend that you calibrate the device again when setting it up This allows the device settings to be optimized for the conditions in which it will be used Perform calibration by taking a dry solids content sample and entering its laboratory value into kajaaniTS When you have performed this according to the instructions in the next chapters the status line on the display will change from Factory Calibration to OK Calibration menu contains the following functions 1 Sample taking 2 Enter lab 3 0ffset correction 4 Calib history 5 Sample history 5 C 1 Sample Taking In the main display press the ESC button to move to the Operations menu Select Calibration Sample taking Whenever a factory calibrated device takes a sample it adjusts the measurement signal to the optimal level before taking the sample This may cause a small step like change in the device s dry solids content measurement For this reason the device may not be kept on dry solids content control in this phase The sample taking display is as follows Press sample key to start sampling TS 3 26 status Waiting Press the Sample button on the right side of the display
55. ty Low 4 mA 0 High 20 mA 50 Press EDIT SAVE Use the up arrow and down arrow buttons to make your selection and enter low and high values for the variable Press EDIT SAVE to save the selection 5 D 2 User Settings In the main display push the ESC button to move to Operations menu In the Operations menu select Configuration User settings The following menu appears trend int 10 min pos Eton tetra anguage english temp unit C password No Act siglev ON kajaaniTS Installation Operating amp Service The display fits four rows at a time Use the up arrow and down arrow buttons to scroll through all the lines Press the EDIT button to perform the following e trend int The trend table sampling interval Use the up arrow and down arrow buttons to change it e Position Sensor s mounting position In this field you can use letters of the alphabet To enter letters press anumber button several times in rapid succession and the letters on the button appear on the display one after another e Language Language selection Use the up arrow and down arrow buttons to select the language e Temperature unit Temperature unit C F Use the up arrow and down arrow buttons to select the temperature unit e Password Password Yes No Use the up arrow and down arrow buttons to make your selection If you select Yes the program asks for a password when you move into Edit mode or if you intend to take a calibration sam
56. up and down arrow buttons Enter the sample s conductivity in units mS cm Sample 12 08 04 TS 3 00 Lab TS 0 00 Chem NaOH TS cond 2 4 mS cm Lab cond 0 0 mS cm kajaaniTS Installation Operating amp Service If the conductivity meter shows results in units mS m divide the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 uS cm 5 5 mS cm Ifthe conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 mS m 10 mS cm Using Chemical Compensation After you enter the laboratory values go to Special Functions menu and select 1 Chemical Compensation The following display appears Chem comp OFF Comp value 0 00 Chem NaOH Lab cond 3 4 mS cm Press the Edit button to make the cursor appear in the Chemical Compensation field The OFF text indicates that chemical compensation is notin use Use the up and down arrows to change the text from OFF to ON Press Save after which kajaaniTS begins using chemical compensation The second line Comp Value shows the chemical compensation value or the value that chemical compensation subtracts from the measurement result The third and fourth lines show the chemical and laboratory conductivity values entered by the user 5 6 5 F 2 Temperature compensation correction curve kajaaniTS compensates for the effect of temperature on the measurement
57. ured by the reference channel This value is compensated out of the measurement channel result so electronic drift does not cause an error in the measurement result An El drift alarm is caused by sensor electronic failure e VCO drift VCO drift shows the drift in sensor electronics signal generator A VCO drift alarm is caused by sensor electronic failure 6 3 6 C Replacing Components 6 C 1 Sensor Electronics Removal 1 E N Disconnect the electricity by separating the sensor cable from the connector at the edge of the base plate Remove the electronics protective cover Disconnect the sensor cable and Pt 100 sensor connectors from the electronics and bend them to the side Loosen the three mounting screws and lift the sensor electronics evenly out of its position by pulling on the mounting screws NOTE Sensor electronics is aligned into place by three guide pins which keep it in place even when the mounting screws are loosened Installation 1 Align the groove in the edge of the electronics with the connector on the edge of the base plate Move the electronics and press gently until the guide pins on the base plate are aligned with the holes on the base of the electronics Then press the electronic evenly onto the base plate Screw in the three sensor electronics mounting screws Connect the sensor cable and Pt 100 sensor connectors to the electronics Place the sensor cov
58. v min 10 ON R Lev min 100 0 ON Mstab max 20 ON Rstab max 2 ON Eldr abs 80 0 ON vcOdr abs 50 ON The display shows the error limit for each diagnostics measurement as well as its effect on the current signal ON OFF If necessary you can change these as follows press the EDIT button and then enter a new error limit or use the up arrow and down arrow buttons to change the ON OFF setting Even if the effect of the limit on the current signal is blocked by an OFF setting an error message still appears on the main display status line and error data is entered into the error table 5 5 5 F Special Functions The Special Functions menu contains the following functions 1 Chemical comp 2 Temperature comp 3 Sensitivity corr 4 Recipes 5 F 1 Chemical compensation Large fluctuations in chemical content may cause errors in kajaaniTS dry solids content measurements These errors can be compensated for with chemical compensation based on microwave damping measurement You can use chemical compensation as described in the following two sections Entering Laboratory Values Take a sample as described in section 5 C 1 Determine the sample s dry solids content and its filtrate conductivity at room temperature Go to the menu Enter Lab press the Edit button and enter the laboratory dry solids content information Press the Enter button to scroll the display down after the last line Select the chemical type with the
Download Pdf Manuals
Related Search