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kajaaniROTARY™

1. Figure 3 2 Process coupling 70 or 150 mm 2 75 or 6 PN10 kajaaniROTARY Installation operating and service manual 1 0 SS2343 AISI 316L Y 9 a 4 wo Process conditions Pressure 10 bar Temperature 20 C N wa E E E n o v E m 2 amp E oa E o E c 3 E v 2 a oc 500 600 Nominal pipe diameter DN Figure 3 3 Sufficient pipe wall thickness for the required pressure rating PN10 Calculation parameters Outer diameter 308 mm Material thickness 5 mm Temperature 20 C Smax 147 N mm2 If the process line material thickness is close to the value given in the diagram use a valid standard for exact calculations The calculations must include the manufacturing tolerance of the selected pipe If the diagram or calculations reveal that the wall of the existing pipe is not thick enough the pipe must be strengthened The strengthened pipe section must extend at least 300 mm 12 on both sides of the process coupling Typical installations for DN300 pipes are shown in figure 3 4 Straight pipe sections Vertical installation Horizontal installation Pipe Diameter D L1 min L2 min L1 min L2 min Figure 3 4 Required lengths of straight pipe around the process coupling kajaaniROTARY Installation operating and service manual 1 1 3
2. kkk Only for MC consistencies kajaaniROTARY Installation operating amp service A1 3 Appendix 1 Technical specifications kajaaniROTARY type codes ordering codes for transmitters Transmitter Product Communication Sensing Wetted Pressure Motor element parts rating type kajaaniROTARY MA TM SS J MS ma HART MA Profibus PA PA 1 5 6 Cs TM 5 10 Cs PL 8 12 Cs PM 10 18 Cs PH AISI 316 SS 254 SMO SMO Hastelloy C 276 HC PN10 J only SS PN25 L 220 480 VAC MS 690 VAC MD 550 575 VAC MF 200 220 VAC MX NB Consistency ranges for specific sensing element are typical as well as voltage ranges for different motors For selection of mounting parts refer to document Mounting parts for kajaaniROTARY Metso Automation Field Systems Lentokentankatu 11 P O Box 237 J metso FI 33101 Tampere N Finland automat on Tel 358 20 483 170 Fax 358 20 483 171 ajaaniROTARY Installation operating amp service A1 4 Fi Appendix 2 Delivery content B E Den ree OG 9 ome e F Er ji D Metso delivers Name Symbol Sensor Unit A kajaaniROTARY Transmitter Central Unit B with a 10m sensor cable Mounting set F Installation operation and E service manual Customer delivers
3. 52 7 8 1 Replacing the drive belt and pulleys 52 7 8 2 Replacing the mechanical face seal 53 7 8 3 Replacing the flange V ring seal and cover EE arcana 54 7 8 4 Replacing the measuring shaft O ring seal 55 7 8 5 Replacing the TCU 55 8 Applications 8 1 Applications of the different sensing element LY POS SS r rn 56 9 Recycling and disposal of a device removed from service App 1 Technical specifications T00359EN VO App 2 Delivery content App 3 Spare parts App 4 HART interface App 5 EC Declaration of Conformity App 6 Questionary 1 Introduction 1 1 kajaaniROTARY consistency transmitter The kajaaniROTARY a rotating consistency transmitter based on force balance principle measures the shear force induced torque generated by the pulp fiber network The transmitter consists of a shaft pair driven by an electric motor This shaft pair comprises of two concentrically aligned flexibly connected shafts where the inner measuring shaft is allowed to have a phase shift with respect to the outer drive shaft The rotation of a mixing propeller mounted on the drive shaft draws a continuous sample from the main process line past the sensing element mounted on the measuring shaft The rotation of the sensing element in the pulp is restricted by a given torque which strives to retard the measuring shaft in relation to the drive shaft The phase shift is measured optically
4. Process conditions Pressure 25 bar Temperature 2269C Main pipe minimun material thickness mm 500 600 Nominal pipe diameter DN Figure 3 8 Sufficient pipe wall thickness for the required pressure rating PN25 Calculation parameters Outer diameter 240 mm Material thickness 10 mm Temperature 226 C Smax 95 N mm2 kajaaniROTARY Installation operating and service manual 14 If the process line material thickness is close to the value given in the diagram use a valid standard for exact calculations The calculations must include the manufacturing tolerance of the selected pipe If the diagram or calculations reveal that the wall of the existing pipe is not thick enough the pipe must be strengthened The strengthened pipe section must extend at least 250 mm 10 PN16 320 mm 13 PN25 on both sides of the process coupling Typical installations for medium consistency applications are shown in figure 3 9 Figure 3 9 Typical installations for medium consistency applications kajaaniROTARY Installation operating and service manual 1 5 3 6 Flushing water connection All kajaaniROTARY transmitters are equipped with a mechanical seal for the drive shaft The seal should be flushed with water to produce a cleaning lubricating and cooling effect Continuous water flushing is recommended See figure 3 10 Use good quality flush
5. e The type and material of the mounting chamber weld in process coupling sensing element propeller etc must be selected according to the requirements of each application to ensure PED conformity Contact your Metso representative for further information Use good quality sealing water as the flushing water for the mechanical seal Make sure that the flushing sealing water pressure is maintained at all times See figure 3 10 e The main power voltage amp frequency must be within acceptable limits and be protected against transient disturbance sources such as other equipment or electrical storms Make sure that the signal cables are located far away from the power cables If the transmitter must be installed high up or in a place where it will be difficult to reach a platform should be constructed to provide easy access during service and inspection A platform is also a good solution for positioning the sampling valve e Install a Nove sampling valve close to the transmitter This will ensure that the samples will be rep resentative of the sample measured by the consistency transmitter Reserve enough space for the sensor casing see figure 1 2 Also pay attention to the limits given in Appendix 1 Technical specifications This manual contains instructions for the planning and implementation of kajaaniROTARY in line con sistency transmitter installation The kajaaniROTARY is highly specialized transmitter optimized for several i
6. Installation operating and service manual 37 Enter filler with the number keys Example for 12 the key sequence is as follows 1 2 ENTER Enter parameters P1 and P2 in the same way and then press EDIT SAVE to save and activate your selections If you do not want to make any changes press ESC to return to the previous menu level to recipe se lection The information above deals with the predefined pulp types The special purpose pulp types are described below ULIN Unlinearized measurement The output for uncalibrated measurement is shown as a percentage of the maximum span 1 5 Nm i e 0 Nm corresponds to 0 and 1 5 Nm corresponds to 100 Otherwise ULIN is similar to the pre defined pulp types POLY Polynome If no suitable predefined calibration curve is available a special curve can be created by using the POLY pulp type in a recipe POLY is a third order polynome conversion from torque to consistency When POLY is selected for pulp type the recipe display contains the following information Pz Off 6 8666 Factor xiz 4 1 Factor x2 4 2 Factor x1 1 Factor xB In comparison to predefined pulp types this recipe contains four additional fields factors x3 to x0 for third order polynomial conversion To generate the factors for polynomial conversion several torque and consistency values are needed These can be obtained for example by taking samples that cover the entire operating range These to
7. Material Info Pcs 230 380 440VAC motor 690 VAC motor 500 VAC 50Hz 575 60Hz 200 VAC 60Hz MF with CSA approval IP56 certified motor IP56 certified motor IP56 certified motor CSA IP56 certified motor IP56 certified motor High temperature model High temperature model High temperature model CSA High temperature model High temperature model IP56 High temperature model IP56 High temperature model IP56 High temperature model CSA IP56 High temperature model IP56 High temperature model TypeA For SMO 254 and Hastelloy C 276 sensor units Type B For SMO 254 and Hastelloy C 276 sensor units AISI316 4 AISI316 4 1 Rubber Rubber AISI316 1 AISI 304 1 Appendix 3 Spare parts Transmitter Central Unit spare parts Part no Description 30 Operating unit 12 Cable assembly 9 Mounting plate 4 Cable gland 5 Blanket plug 6 Jam nut Closing flange Part no Description Closing flange Closing flange Gasket Tools Part no Description Hartmodem kajaaniROTARY Installation operating amp service Order Code T00564 T00565 T00595 Order Code 235641 Description_2 J P
8. kajaaniROTARY Installation operating amp service manual TOO358EN Ver A for version A gt metso automation 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 and frequency are correct before making any electric connections Wrong connection may damage the equipment The applicable electrical safety regulations must be closely followed in all installation work All electrical connections can be done only by authorized persons Before any welding works in the vicinity of the devices make sure that operating voltage is not connected The samplers contain moving parts DANGER Be careful when testing the sampler Do not push your fingers between any moving parts gt e e e kajaaniROTARY Installation operating and service manual CAUTION WARNING Table of contents 1 Introduction 1 1 kajaaniROTARY consistency transmitter 1 1 2 Conformity to CE directives and CSA QPPIOVAl cruna Laden ini 2 1 3 Basic transmitter dimensions 3 Ta TEU iaia 3 1 5 Materials iaia iaia 4 2 Safety recommendations 2 1 Generali ka ik suna kalana ida 5 2 2 Selecting the transmitter model and assembly parts 5 2 3 Installing the mounting parts 5 2 4 Installing and connecting the transmitter 6 2 5 Installing TOU EE
9. Housing P1 P2 kajaaniROTARY Installation operating amp service A4 1 metso automation Process data Consistency Pressure Flow velocity Process temperature Dilution water temperature creened unscreened pulp ransmitter material isk pitch nstallation Material certification requested Enough free space for installation Material certification requested Enough free space for installation Sealing water data Pressure low Electrical data Motor voltage connection Operating frequency Enclosure class Check list for kajaaniROTARY installation Mill name Process Area Description of application Date 1 4 2005 Handled by normal max NOTE min es kk k k r J J J J5J 5I ZS Z6Z Z5Z dea _ _ _ _ ms t k zk k zI z fi cu S d oe i OO dl dec NOTE Measuring chamber for PN25 not available If yes what medium DIN JIS ANSI pick one from next sheet A J yes no details in next sheet NOTE min 0 5 l min NOTE star delta 50Hz or 60Hz IP55 or IP56 optional Pulp grades and ratio at measuring point Mechanical pulp TMP EE Han EE ME ___ EE B CTMP Fillers men Dr Eo Ash Clay Chemical pulp Recycled pulp esi bleached unbleached HW Other chemicals or materials die e di DTT ie de de di If kajaaniROTARY replaces existing rotating transmitter or uses existing coupl
10. In this case the torque consistency values are included at the end of the basic recipe parameters i G 60 1 57 Z Bu Z 2 07 3 8 46 da dl 4 6 46 4 19 di 8 38 4 54 6 8 66 4 78 T GB TG 4 91 2 6 26 lf a 6 90 7 19 16 1 60 2 46 li 1 16 Ez 12 1 20 Da Pa 14 1 36 da 79 15 1 46 T B 16 1 56 a 91 kajaaniROTARY Installation operating and service manual 39 6 6 5 Sample history When a sample is taken kajaaniROTARY saves its consistency values in memory This information can be viewed in the sample history display The device contains four recipes each with a separate sample history First select the recipe before viewing sample history data The recipe selection display for sample history is shown above The recipe number is followed by a number inside brackets indicating how many samples are available for this recipe When the recipe is selected the display will show information on the latest sample taken for this recipe Filler Only the basic information is first shown on the display Additional information can be viewed by scrolling the display with the UP and DOWN keys The first line shows the recipe number index of the current sample and the number of samples available for the recipe The second line shows the sampling date and time The next three lines contain sampling data measured by kajaaniROTARY consistency torque and process temperature The last two lines show the laboratory consistenc
11. Power supply cable 90 260 VAC C Power supply cable for the motor H D Signal cable to DCS Sensor unit options refer to Technical specifications TOO359EN AISI 316 SMO 254 Hastelloy C 276 Options OUL00363 Sensor cable 30 m 98 ft Mounting chamber refer to document Mounting parts for kajaaniROTARY Process coupling refer to document Mounting parts for kajaaniROTARY kajaaniROTARY Installation operating amp service A2 al Appendix 3 Spare parts 90 89 91 oO EX 0 93 kajaaniROTARY Installation operating amp service s A3 1 Appendix 3 Spare parts Sensor unit spare part sets Part no Description 32 MOUNTING SET 33 Hexagon screw 34 Washer 35 Stud 36 Hexagon nut 32 MOUNTING SET 33 Hexagon screw 34 Washer 35 Stud 36 Hexagon nut 93 PIPE ASSEMBLY 94 Elbow fitting 95 Restricter 96 Pipe 97 Y fitting 98 Cap nut 99 Flow direction arrow 100 Hose coupling SPARE PART SET 37 O ring 90 O ring 91 V ring 92 Cover plate 105 O ring SPARE PART SET 72 Socket head screw 85 Belt roller 86 Belt 87 Belt roller 88 Taper bush kajaaniROTARY Installation operating amp service Order Code T00439 K0274 135608 T00433 560228
12. Unscrew the socket head screw 43 and detach the sensing element 40 Unscrew the three socket head screws 47 and detach the mixing propeller 45 Loosen the set screws of the mechanical seal 52 and remove the rotating part of the seal Do not apply force on the bellows part of the seal Unscrew the flush water connection pipes of the seal Unscrew the six socket head screws and detach the connection flange 50 Remove the seat and cover plate 92 from the connection flange Prior to assembly assess the condition of all mechanical parts and seals Check the connection flange and clean off any pulp discharge that may be found if the mechanical seal has leaked Check and clean the flush water pipes Check the drive shaft for any sharp edges grind marks and scratches polish it if necessary Change any worn or damaged parts kajaaniROTARY Installation operating and service manual 53 Assembling Insert the cover plate 92 into the connection flange Soapy water may be used for lubrication Insert the connection flange 50 into the bearing body and secure it with the six socket head screws Make sure to align the nipples of the flushing water pipe horizontally Insert V ring seal 91 against the cover plate 92 by sliding it down the drive shaft until the seal drops into it groove Insert the mechanical seals seat into the connection flange Use soapy water for lubrication Mount the mechanical seal 52 and secure it w
13. DTM for FieldCare e AMS Field communicator or control system using HART communication protocol Process specifications Process temperature Flow velocity Process rating PN10 150 Ibs e PN25 363 Ibs Vibration 0 120 C 32 248 F 0 3 5 m s Max 29 20 m s 10 2000 Hz Table 1 Sensors and consistency ranges min max by pulp types Chemical pulp Mechanical pulp Recycled pulp sw m P 1 5 6 5 CTMP 5 11 6 5 13 6 5 13 6 5 13 7 13 8 5 14 8 5 14 10 16 kajaaniROTARY Installation operating amp service 11 16 11 16 11 16 12 18 12 18 A1 1 Appendix 1 Technical specifications Weights and sizes Transmitter Total package size WxHxD Total package weight 35 kg PN25 38kg 60x75x40 cm 45 kg PN25 48 kg EMC test standards Radiated interference EN 50081 1 1993 Interference immunity EN 50082 2 1995 EN 61326 1997 Industrial locations Sealing water requirements Pressure 0 5 9 bar e Flow rate 0 5 1 l min e Temperature max 60 C Quality no impurities particle size lt 200 um Table 2 Motor voltages and connections Peano se am tase E np ne _ otra om ot bee us ozo seoa sen 380 420 660 690 440 480 MD MF 500 550 550 575 MX 200 220 non standard CSA safety certificate available on request non standard also available for other voltage or frequency ratings on request Options Table 3 Mounting chamber
14. Digital Inputs ENTER 6 18 mA Configuration Recipe 1000 rpm Sample History 52 2 C Calibrate 0 47 Nm Calibration History Error Log Diagnostics Alarm Limits mA Lock Sensor Values Special functions Figure 6 2 TCU menu system kajaaniROTARY Installation operating and service manual 24 6 4 Measurement displays The first measurement display shows the most important information at a glance Recipe 2 3 76 Cs 46 1 DE The top left corner shows a tag transmitter s position code in the system in this example it is POS 1234 This value can be changed in the User Setting display see below The top right corner shows the number of the currently selected recipe in this example Recipe 2 This value can be changed in the Recipe Selection display see below Letter R after the number indicates that remote recipe selection is in use In this case the active recipe is selected by two digital input signals on the TCU unit The next two lines contain data measured by the consistency transmitter consistency and process temperature pulp temperature Consistency is given in percentage points Cs pulp temperature in degrees Celsius C C or Fahrenheit F F The temperature unit can be changed in the User Setting display see below The last line shows device status information OK error or warning The second measurement display contain
15. General information 31 6 6 2 Sample taking 34 6 6 3 Calibration MENU iii 35 6 64 RECIPe zioioni ati ii ale 36 6 6 5 Sample history 36 6 0 0 Calibrate ainoana 36 6 6 7 Calibration history 36 6 7 DIAQNOSUCS croni 42 Od VENO 109 rd dr 43 6 7 2 Alarm limits 43 6 7 3 ee OE 44 6 7 4 Sensor values ereenn rrenen 44 6 8 Special functions display 45 6 8 1 Trim MA isnt Asia feted aa aa 45 7 Maintenance and diagnostics 7 1 Regular inspection 46 7 2 Long term field service 46 7 3 Process conditions U U EEEU ULUL L E E E E 46 7 4 Self diagnostioSs ii 47 7 5 Error messages i 48 7 5 1 Measurement error messages 48 7 5 2 TCU error messages 48 7 5 3 Warning messagesS 49 7 6 Troubleshooting ii 49 7 6 1 Substantial difference between kajaaniROTARY consistency reading and laboratory results ii 49 7 6 2 HART interface is not operating Proper aaa 49 7 6 3 Consistency reading is not responding to CONSIStENC lin 50 7 7 Checking the operation of force measurement and current OUtput 51 7 8 Replacing components
16. after calibration will cause a corresponding error in the total consistency measurement with respect to filler As stated above the recipe display can be used to view the recipe parameters After calibration check and write down the recipe parameters of configured transmitters including the P1 and P2 values calcu lated by kajaaniROTARY and archive them They may be needed later on for example if the TCU has to be replaced after replacement no calibration is needed as the same recipe parameter values can be entered to the new unit in the recipe display The recipe display can also be used to tune the recipe parameters For example if you increase the value of P2 by 0 1 the consistency reading will also increase by 0 1 Cs Thus you can make the re quired zero correction without other calibration measures To modify the recipe parameters press EDIT SAVE The cursor starts to blink in the Pulp type field to indicate that you can edit it Use the UP ARROW and DOWN ARROW keys to select the desired pulp type and then press ENTER to accept the selection or just press ENTER to accept the existing value The output for uncalibrated measurement pulp type ULIN is shown as a percentage of the maximum span 1 5 Nm The consistency percentage display can be activated after configuration and recipe selection When delivered the transmitter is provided with the typical default configuration and recipe i e pulp type selection kajaaniROTARY
17. and process couplings Mounting chamber Process coupling DN100 gt DN300 DN200 DN150 fF gt DN250 Only for MC consistencies kajaaniROTARY Installation operating amp service Dimensions 143 240 kajaaniROTARY 385 123 TCU 195 7 48 A A 3 8 N S N 99S9 Ox 0000 0 4 RA o o 9 Gi Lo y oi TICO _ 4 UJ UU DU io _ 98 232 lt 9 06 i A1 2 Appendix 1 Technical specifications Options Mounting chamber and process coupling horizontal and vertical installation PN10 1150 For DN lt 300 10 H 70 or 150 r DN D mm X mm 100 4 144 3 250 10 273 0 H 150 when Cs lt 5 H 70 T when Cs gt 5 N 308 308 The three deflector plates supplied should be welded when the length of the process coupling is 70 mm 2 57 Options Process coupling horizontal and vertical installation PN25 For DN gt 250 10 H 70 or 150 ___ 1T For DN 200 8
18. and service manual 47 7 5 Error messages Select Error login the DIAGNOST menu Serious faults errors The following faults are so serious that the transmitter s normal operation is terminated and an error current gives an error alarm 3 7 mA or 22 5 mA depending on ALARM TYPE selection if selected in Diagnostics Diag Alarms Less serious faults errors These faults will not trigger the error current Error message Description AD ERROR AD converter error Conversion restarted HART ERR Higher level HART communication error n a only for kajaaniROTARY MA Warnings and error messages during operation 7 5 1 Measurement error messages Sensor electronics failures In most cases the self diagnostics detects the fault and gives the corresponding alarm The following errors or malfunctions in the measurement unit are detected and displayed in TCU Error message Description ERROR NO PULSES No pulses from notched wheel motor not running or defective electronics ERROR PULSE TIMING X Pulses detected by notched wheel are too long or too short ERROR FREQUENCY Frequency of motor lt 45 Hz or gt 65 Hz ERROR MECH LIMIT Measurement shaft hit to mechanical limit ERROR COIL CURRENT X Problems with magnetic coil circuitry open circuit short circuit or current out of limits ERROR SENSOR ADC X AD converter error or converted AD value is out of error limits ERROR SENS EEPROM X Non volatile memory EEPROM fault
19. contain the starting and ending times of the error If the error is still on or if the ending time was not detected the ending timestamp is shown as The message Shutdown in the place of the error state end time indicates that the error state was on when power was shut down If the error state is still on when the power is switched on next time the error is reported as a new error A text describing the error is shown on the last line The Error log contains the 96 most recent errors You can view older errors by pressing ENTER After the oldest error the latest error will be shown again 6 7 2 Alarm limits In the alarm limits display you can set some diagnostics ON OFF and also set alarm limits for these diagnostics items The alarm limits display is shown below Proc Teme Low Limit F Proc Teme Hiah 0H Limit 176 86 Cabin T Low OFF Limit A Cabin T Hishi OFF Limit 26 8 C To change the alarm status and or limit information press EDIT SAVE The status values can be changed with the UP and DOWN keys Alarm limit values can be entered with the number keys and the LEFT and RIGHT keys Press ENTER to accept values Then press EDIT SAVE to save and activate your selections If you do not want to make any changes press ESC to return to the previous menu level to Diagnostics menu kajaaniROTARY Installation operating and service manual 43 6 7 3 mA Lock This command locks the
20. or as two point calibration where you also define the curve s slope correction P1 see figure 6 4 For more detailed descriptions of these two calibration methods see below in this section kajaaniROTARY Installation operating and service manual 31 Single point calibration Two point calibration Calibrated curve Laboratory Laboratory Basic tuning curve KajaaniROTARY KajaaniROTARY Figure 6 4 Single point and two point calibration In the original curve P1 1 and P2 0 In sample based calibration the kajaaniROTARY will itself calculate the corrections for P1 and P2 in accordance with laboratory results and samples Calibration results P1 and P2 parameters are stored in recipes A recipe is a set of information that the device needs in order to convert the measured torque value to consistency When the consistency transmitter knows the pulp recipe it can accurately convert torque to Cs You can save 1 4 recipes for different pulp types in the transmitter s memory The desired calibration can be activated either directly from the transmitter or with remote selection through binary inputs or HART Calibrations and other operations are carried out through menus no mechanical settings or changes are needed Calibration data is preserved in memory even if power is switched off Single point calibration In this calibration the selected curve which converts the torque into a consistency signal is moved in th
21. output signal to 4 mA 20 mA hold present value or some other user defined value This command can be used to check the cabling and current measuring circuits In the Diagnostics menu select mA Lock 4 The following display will appear Dutrut 15 7 mA 1 Set to 4 mA 2 Set to 24 mA UF DOWH modify When this display is activated the analog output is frozen to its present value shown on the first line of the display Press key 1 to set the analog output to 4 mA Press key 2 to set the analog output to 20 mA Pressing the UP and DOWN keys to increase and decrease the analog output value Press ENTER or ESC to return the analog output to normal what it was when the display was activ ated 6 7 4 Sensor values The sensor values display contains some raw measurement information from the sensor This information is primarily needed in order to detect faults that are hard to find without detailed knowledge of device operation and is not needed for normal operation Ref Hish Ref Low 15264 Sum Hiah 753595 Sum Low 1716949 Heas curr 15387 Proc teme 18723458 Elec teme 1875815 This information cannot be changed by the user The data in this display Ratio measured and temperature compensated pulse ratio of the toothing Raw ratio measured pulse ratio of the toothing without temperature compens ation Coil PWM output to current D A converter of coil Coil current measured coil current
22. stream If the optimum position cannot be chosen for example due to space limitations consult a Metso sales engineer If the transmitter will be installed so high up that it will be difficult to reach build a platform for easier access during service and inspection Choose a location with sufficient room around the transmitter for insertion and removal and for opening the covers The total length of the transmitter is 510 mm 20 Make sure that the trans mitter can be inserted and removed without problems Install the transmitter so that it is protected from direct mechanical damage If the place is such that it is likely to be frequently sprayed by water or pulp protect it with a suitable enclosure Protect the transmitter from heavy vibration such as cavitation or unbalanced pumps One possible method is to install rubber bellows to the line kajaaniROTARY Installation operating and service manual 8 3 4 Low pressure pipe installations The transmitter is usually installed in a vertical pipe downstream from a pump mixing dilution water into the pulp To minimize the time lag after dilution the transmitter should always be installed as close as possible to the water injection point Where the pressure is lt 10 bar at 20 C 150 psi at 68 F defined as PN10 and the pipe diameter is lt 300 mm 10 the transmitter should be connected to the pulp line with a mounting chamber See Fig 3 1 Where the pressure is lt 10 bar at
23. type kajaaniROTARY Installation operating and service manual 25 To access the configuration functions press key 1 in the operations menu TCU s main menu 1 Confisuration 2 Calibration 3 Diasnostics 4 SFecial functions The following menu will appear 1 Recire selection Current outrut 2 i settings S5 5et clock 6 Diasital inputs Each of these functions is described in the following subsections 6 5 1 Recipe selection Recipe selection function indicates which recipe is currently used If you want to change the active recipe number press EDIT SAVE once The cursor starts to blink at the recipe number to indicate that you can edit the number Current recipe 2 ixed recire F Remote sel An informative text appears on the lower part of the display Pressing keys 1 to 4 will select a fixed recipe and pressing any other number key will activate remote selection Remote selection is indicated by letter R instead of recipe number When remote selection is activated it overrides fixed recipe selections by the operator and the active recipe is selected instead by the TCU s digital inputs Press the number of the desired recipe on the TCU keyboard and then press EDIT SAVE to accept and save your selection If you do not want to make any changes press ESC to return to the previous menu level Configuration menu Remotely selected recipe is indicated in the measurement display with letter R af
24. value is C Password The access to some operations is restricted by a password Accepted values Yes No When Yes is selected a password will be required before entering Edit mode and before taking a calibration sample The password is 3121 As default the password is not in use To modify these configuration values press EDIT SAVE once The cursor starts to blink in the Tag field to indicate that you can edit the value To accept the existing value press ENTER If the tag must be modified follow the procedure below e Starting with the first character press the key that contains the desired character number or letter several times until the desired character appears on the display Press RIGHT ARROW to advance to the next character Repeat these steps for the next characters You can go back to modify the preceding characters by pressing LEFT ARROW When all the characters are selected press ENTER to accept the selection All the other settings follow the same logic use the UP ARROW and DOWN ARROW keys to change the value and press ENTER to accept the selection or just press ENTER to accept the existing value Finally press EDIT SAVE to save and activate your selections If you do not want to make any changes press ESC to return to the previous menu level Configuration menu kajaaniROTARY Installation operating and service manual 28 6 5 4 Device info In the Configuration menu press key 3 to select Device I
25. 00 T00573 T00590 162958 T00591 56022810 T00379 K0226 T00415 T00414 T00417 T00418 85548188 04053000 T00862 T00363 T00362 T00357 T00824 T00822 T00615 T00386 T00371 T00366 T00372 T00373 Description_2 J PN10 150 Ibs M8X25 DIN933 8 4DIN125 M8X40 DIN939 M8 DIN934 L PN25 363 Ibs M10X35 DIN933 10 5DIN125 M10X45 DIN939 M10DIN934 1 4NPT FLUSHING G 1 4 G 1 4 1 4X13 SEALS 215 27X5 33 160X3 VA 40 VRWS 42X60 MM 13 64X5 33 POWER TRANSMISSION M5X10DIN914 22 8M 20 656 8M 20 56 8M 20 2012 45 L 20 A3 2 Material Info ISO 3506 A4 80 AISI 316 ISO 3506 A4 80 ISO 3506 A4 80 ISO 3506 A4 80 AISI 316 ISO 3506 A4 80 ISO 3506 A4 80 AISI 316 RUBBER AISI 316 AISI 316 AISI 316 EPDM EPDM Viton EPDM AISI316 Aluminum Rubber Aluminum Aluminum Pcs AA Ss st NDJ E DY A AM _ ada n A A ALA Appendix 3 Spare parts Sensor unit spare part sets Part no Description 37 O ring 40 Sensing element 43 Socket head screw 44 Lock washer 45 Propeller 47 Socket head screw 50 Flange kajaaniROTARY Installation operating amp service Order Code T00363 T00826 T00827 T00828 T00829 T00830 T00831 T00832 T00833 T00834 T00835 197707 T00552 T00553 5060024 T00554 T00555 T00799 T00805 T00806 T00807 01101908 T00550 T00551 T00808 T00809 T00810 T00811 Description_2 215 27X5 33 TM SS PL SS PL SMO PLHC PM
26. 005 June 14 2005 the key sequence is as follows 1 4 ENTER 0 6 ENTER O 5 ENTER Enter the time in the same way Then press EDIT SAVE to save and activate your selections If you do not want to make any changes press ESC to return to the previous menu level Configuration menu 6 5 6 Digital inputs There are two digital input signals available in the TCU unit BINO and BIN1 BINO is always used for recipe selection in remote recipe selection mode while the use of BIN1 is selectable There are two alternatives If BIN1 is used for recipe selection all four recipes can be activated through input signals e If BIN1 is used for sampling information sample timing can be automated no need to press the SAMPLE key but only two recipes recipe 1 and recipe 2 can be activated through input signals In the Digital inputs display one of the following views will appear To modify the configuration press EDIT SAVE The cursor begins to blink at the BIN1 value to indicate that you can edit it Use the UP ARROW and DOWN ARROW keys to change it and then press ENTER to accept the selection or press ENTER to accept the existing value If you do not want to make any changes press ESC to return to the previous menu level Configuration menu kajaaniROTARY Installation operating and service manual 30 6 6 Calibration 6 6 1 General information Figure 6 3 shows the calibration principle As the graph shows the relationshi
27. 1 Technical specifications 2 3 Installing the mounting parts Welding or bolting and the subsequent inspection must take place in accordance with the valid standards and regulations For safety reasons only use approved lifting equipment during installation Fasten all parts well during installation The mounting chamber weighs approximately 40 kg 88 Ib Before installing any mounting parts make sure that the pipe is empty and depres surized kajaaniROTARY Installation operating and service manual 5 2 4 Installing and connecting the transmitter See the installation instructions in chapter 3 Use approved lifting equipment during installation Ensure that the transmitter is fastened properly The transmitter weighs approximately 40 kg 88 Ib Ifthe transmitter is located high up construct proper scaffolding When the transmitter has been installed make a pressure test using water in the pipeline The test pressure is adapted to standards and regulations in each country High voltage motor The connection must be made by authorized personnel The electric motor uses a hazardous voltage Only a qualified electrician may connect the motor Follow the instructions closely Make sure to connect the motor earth correctly double check after connecting 2 5 Installing TCU The TCU uses a hazardous voltage Only a qualified electrician may connect the TCU Make sure to connect the earth correctly double ch
28. 2 4 x AWG14 Shield is not required When you are satisfied that your kajaaniROTARY has been correctly installed and you are ready to power up the system for calibration please turn to section 5 1 Quick start check list NOTE Double check the items in the list before powering up This list helps to ensure a trouble free initialization of your system kajaaniROTARY Installation operating and service manual 1 7 4 TCU installation and cabling 4 1 Transmitter Central Unit TCU and shield The TCU is delivered attached to the shield Attach the shield to the wall with three mounting screws in an easily accessible place When selecting a place for the TCU remember that the length of the sensor cable is 10 m Figure 4 1 shows the mounting dimensions of the shield Figure 4 1 Mounting dimensions of TCU shield 4 2 Electric connections NOTE Make sure that the power supply cables are de energized before connecting them NOTE Make and check all connections before connecting the power supply to the cables NOTE If the TCU has been switched off for a long time it may take a few minutes before text appears on the display T
29. 20 C 150 psi at 68 F and the pipe diameter is gt 300 mm 12 the transmitter should be connected to the pulp line with a process coupling See Technical specifications 3 4 1 Installation of mounting chamber Standard mounting chambers are designed for a welded connection Flanged mounting chambers are available on request Typical installations are shown in figure 3 1 Check the free space requirements see figure 1 2 Installing 1 Turn the chamber so that the flow direction arrow points in the actual direction of the pulp flow When welding use a full penetration weld If flange mounted align the chamber and any gaskets before welding it to its process coupling joining the flanges 3 Fit the 8 mm guide bolt into the upper hole in the transmitter flange and lock it in position with thread sealant 4 Ifthe transmitter and any optional sampling valve will not be installed immediately install a closing flange instead Closing flanges are available from Metso T Minimum straight pipe sections L 1000 mm vertical L 1500 mm horizontal L 500 mm Q Oo O o Figure 3 1 Installation to lt DN300 pipes kajaaniROTARY Installation operating and service manual 9 3 4 2 Installation with process coupling Prior to installation check that the pipe wall is thick enough for the required pressure rating see figure 3 3 The length of the mounting chamber H may be either 70 or 150 mm 2 75
30. 5 Insert drive shaft pulley 87 without the Taper lock bushing 88 into the bearing body and place the belt around it Insert the bushing into pulley and press it against the drive shaft collar Tighten the two Taper lock hub screws Mount the inspection cover and secure it into place with four socket head screws Mount the belt guard 89 and secure it into place with two set screws Insert the V ring seal 91 onto the drive shaft and assure that the seal lip is pressed against the belt guard Insert cover plate 92 into the process flange press down until it snaps into place Insert the connection flange 50 into the bearing body and secure it with the six socket head screws Make sure to align the nipples of the flushing water pipe horizontally Insert V ring seal 91 against the cover plate 92 by sliding it down the drive shaft until the seal drops into it groove Insert the mechanical seals seat into the connection flange Use soapy water for lubrication Mount the mechanical seal 52 and secure with two screws Installation length for MFL85N is 31 mm 0 5 mm for HJ 977 it is 34 5 mm 0 5 mm Mount the mixing propeller 45 and secure it with three socket head screws 47 Mount the sensing element 40 and secure it with socket head screw Mount the seal flush water piping complete with thread sealant All screws must be secured with Loctite 243 or equivalent thread lock 7 8 2 Replacing the mechanical face seal
31. 5 High pressure pipe installations Where the pressure is gt 10 bar at 20 C 150 psi at 68 F and the pipe diameter is gt DN200 12 the transmitter should be connected to the pulp line with process coupling PN25 See figure 3 9 Prior to installation check that the pipe wall is thick enough for the required pressure rating see figures 3 7 and 3 8 The length of the mounting chamber H may be either 70 or 150 mm 2 75 or 6 according to consistency Always make sure that this dimension agrees with the dimension stated for the position number and in the order copy The dimension is also stated on the process coupling Installing 1 2 Cut a hole with a 220 mm 8 66 diameter in the pipe and grind and bevel the edge to receive the weld In installations where the length of the process coupling is 70 mm 2 75 the three deflector rails supplied should be welded upstream of the process coupling with their sharp ends facing upstream see figures 3 5 and 3 6 to protect the sensing element New deflector plates can be made according to pictures see figures 3 5 and 3 6 to replace any lost one To install the deflector plates cut 3 slots in the pipe and weld the plates into place Note that the deflector plates have 5 mm holes to facilitate with the installation Compare the process coupling and dimensions of the main pipeline The supplied process coupling profiling tool sticker is recommended as a guide for profiling Aft
32. 6 2 6 Starting up and servicing the transmitter 6 3 Transmitter installation 3 1 Acceptance inspection 7 3 2 Before you begin 7 3 3 Selecting the mounting location 8 3 4 Low pressure pipe installations 9 3 4 Installation of mounting chamber 9 3 4 Installation with process coupling 10 3 5 High pressure pipe installations 12 3 6 Flushing water connection 16 3 7 Connection of electric motor 17 4 TCU installation and cabling 4 1 Transmitter Central Unit TCU and shield 18 4 2 Electric connections 18 4 3 Binary iNputs ke 20 5 Setting up 5 1 Quick start checklist 21 5 2 Importanti lia 21 5 3 Basic configuration and calibration 21 6 Operation and user interface 6 1 General 22 6 2 TCU user interface 22 6 3 Operation with the TCU 23 6 4 Measurement displaye 25 6 5 Configurations ii 25 6 5 1 Recipe selection reren 26 6 5 2 Current OUtput i 27 6 5 3 User settings 28 6 5 4 Device info 29 6 5 5 Set Clock 30 6 5 6 Digital In pS ii kaza k klkek 30 6 6 Calibration 31 6 6 1
33. N10 150 Ibs L PN25 363 Ibs Closing flange Description_2 RS232 IF A3 5 Order Code Description_2 Material Info OUL00377 TCU ROTARY mA HART Version OUL00362 TCU Sensor cable 10M OUL00363 TCU Sensor cable 30M H3730131 DIN 1725 AIMgSiPb T00006 PG13 56 12MM PA 6 T00005 ECDEP 13 5 PA 6 T00007 ECROUPG13 5 PA 6 4 4 9 TYometso i iT 0000 06006 0000 906 0000 e e 30 Aa rave SS FG Material Info AISI 316 AISI 316 Garlock IFG 5500 Material Info Pcs Pcs Appendix 4 HART interface Measurement Configuration Calibration Diagnostics PV Cs Active recipe Motor Process tmp Housing tmp AO mA Torque of range Range values Detailed config Device info New recipe Sampling Lab results Special grade Tmpr calib Loop test Device status Low Rnge Upp Rnge LSL USL Min span J Damping A larm current Sensing element type Sensing element material Poll addr Manufacturer Model Sensor Tag Message Universal Fld rev Software Hardware Descriptor Date Device code Final asbly Recipe 1 Fixed Pulp Ty Filler Recipe 4 rm ATA Start sample Mee Recipe n o Select frst sec Filler Enter lab OK 1 Cs 1 Offcet 1 6 Cs 16 Offcet Process
34. SS PM SMO PM HC PH SS PH SMO PH HC M6X20DIN912 M6X20DIN912 M6X20DIN912 DIN6798 A6 4 6 4 DIN6798 A 6 4 DIN6798 A TM SS MC SS MC SMO MC HC M5X16DIN7991 M5X16DIN7991 M5X16DIN7991 SS J PN10 150 lbs SS L PN25 363 Ibs SMO L PN25 363 Ibs HC L PN25 363 Ibs A3 3 Material Info EPDM AISI 316 AISI 316 SMO 254 Hastelloy C 276 AISI 316 SMO 254 Hastelloy C 276 AISI 316 SMO 254 Hastelloy C 276 AISI 316 SMO 254 Hastelloy C 276 AISI 316 SMO 254 Hastelloy C 276 AISI 316 AISI 316 SMO 254 Hastelloy C 276 AISI 316 SMO 254 Hastelloy C 276 AISI 316 AISI 316 SMO 254 Hastelloy C 276 Pcs Appendix 3 Spare parts Sensor unit spare parts Part no Description 51 Electric motor 52 Mechanical seal 83 Hexagon screw 84 Washer 86 Belt 89 Protective plate 107 Locking ring kajaaniROTARY Installation operating amp service Order Code T00317 T00318 T00562 T00563 T00616 T00617 T00618 T00619 T00620 T00621 T00622 T00623 T00624 T00625 T00626 T00627 T00628 T00629 T00630 T00631 T00355 T00592 T00593 T00594 155812 50002610 T00366 T00596 T00389 T00821 Description_2 MF C MS T MD T MF T MF CT MX T MS H MD H MF H MF CH MX H MS TH MD TH MF TH MF CTH MX TH SS MFL85N 40 G60 HC MFL85N 40 G60 SS HJ977GN10 40 HC HJ977GN10 40 M6X16 DIN933 M6 6 4 DIN125 656 8M 20 TEMPORARY 24X1 DIN472 A3 4
35. Use the UP and DOWN keys to select the samples and then press ENTER when data on the correct sample is shown The first calibration sample is now fixed If more than two samples are available for calibration kajaaniROTARY will then ask for the next sample For two point calibration select a second sample in the same way For single point calibration no second sample is needed see below When the samples have been selected kajaaniROTARY performs calibration calculations and displays the results Press ENTER to accept the values If the values of parameters P1 and or P2 look suspiciously low high or if the difference between the two samples is less than 25 of the consistency level the display will show a warning of possible error but you can still choose to accept the calibration If the values are extremely low or high kajaaniROTARY will not accept the calibration parameters kajaaniROTARY Installation operating and service manual 41 6 6 7 Calibration history Max 16 past calibrations are recorded in the calibration history table of each recipe This calibration information can be viewed in the calibration history display The device contains four recipes each with a separate calibration history First select the recipe before viewing calibration history data When Calib history is selected in the calibration menu the following display will appear 1 Recire 2 Rercire 3 Rercire 4 Recire In the recipe select
36. amps Reference high length of the reference tooth high portion Reference low length of the reference tooth low portion Sum high sum of the high portions of all the teeth of a cycle Sum low sum of the low portions of all the teeth of a cycle Measured current measured coil current raw value from A D converter Process temperature measured process temperature raw value from A D converter Electronics temperature measured electronics temperature raw value from A D converter kajaaniROTARY Installation operating and service manual 44 6 8 Special functions display To access the special functions press key 4 in the TCU s main menu 1 Confisuration 2 Calibration a bijasnostica 4 Srecial functions The following menu will appear This menu contains onlyone function trim mA output 6 8 1 Trim mA This function requires that you connect an ammeter to the transmitter s analog output The transmitter will first send a 4 mA signal to the analog output and the display will read Dutrut set to 4 mA Give actual m 4 00 Press ENTER when reads Measure the actual current value and enter it to the device with the keypad To change the value press EDIT SAVE and the first character of the current value starts to blink Enter the measured current with the number keys Example to enter the value 3 98 mA use the following key sequence 3 9 8 ENTER If you do not want to make any changes press ESC to return to the prev
37. anual 4 2 Safety recommendations These safety recommendations are based on a risk analysis carried out in accordance with the require ments of the machinery and low voltage directives in order to comply with European standards for CE marking For the CE Declaration of conformity see Appendix 5 Read carefully all safety recommendations and instructions before installing any parts of the delivery 2 1 General In practice an operating consistency transmitter poses a risk due to moving machine parts or hazardous voltages only when its covers have been removed for installation or service operations Be sure to follow precisely the instructions and recommendations when installing connecting or servicing the transmitter These safety recommendations apply to a transmitter installed with an AC powered TCU The mounting parts e g mounting chamber and process coupling have been manufactured by Metso in accordance with the EU s Pressure Equipment Directive PED NOTE Do not use any other parts except those that are manufactured or approved by Metso Automation Follow valid instructions and standards during installation 2 2 Selecting the transmitter model and assembly parts The pressure rating of the transmitter and its mounting parts must be suited to the current maximum pipe pressure and temperature Select the material of the transmitter and its mountings parts so as to minimize the risk of corrosion See Appendix
38. ate using points whose consistency difference is less than 25 Two point calibration is recommended in cases when accurate measurement is needed over a wide measuring range when calibrating a pulp mix or pulp type that does not have a predefined calibration curve in the menu or when the pulp has a large unknown filler content Considerable differences may also occur between different recycled fiber pulps in relation to the basic slope of the calibration curve The calculation formula P1 2 Cs LAB 1 Cs LAB 2 Cs SAMPLE 1 Cs SAMPLE P2 1 Cs LAB P1 x 1 Cs SAMPLE kajaaniROTARY Installation operating and service manual 33 6 6 2 Sample taking kajaaniROTARY assists in sample taking by calculating the average consistency value and standard deviation for the sampling period kajaaniROTARY is able to calculate and remember 16 samples for each recipe To take a sample go to the first measurement display Then press the SAMPLE key on the right side of the display The display shows the current consistency and some instructions XStart loa samplo Press samele ked CS G86 X Status i WAITING The device is now waiting for the start of sampling Press SAMPLE again right before taking a pulp sample The device begins to average the measurement result and the message SAMPLING appears on the Status line Press sample kes to stor s5amFlins CS 3 26 X Status SAMPLING During the sampling period the
39. d chemical pulp e g birch pulp or eucalyptus bagasse and other agro fibers SWU Unbleached softwood chemical pulp e g pine and other softwood pulps SWB Bleached softwood chemical pulp e g pine and other softwood pulps GW Groundwood including pressure groundwood TMPL Thermomechanical pulp low freeness TMPH Thermomechanical pulp high freeness RMPL Refiner Mechanical Pulp low freeness RMPH Refiner Mechanical Pulp high freeness CTMP Chemi thermomechanical pulp RCFS Recycled fiber screened kajaaniROTARY Installation operating and service manual 36 ROCCS Recycled fiber OCC screened EUCAU Unbleached eucalyptus EUCAB Bleached eucalyptus There are three more pulp types for special purposes ULIN Unlinearized 0 1 5 Nm torque range the corresponding output display is 0 100 POLY Third order polynome conversion from torque to consistency SPG Special Grade Torque to consistency relationship is determined by a curve defined by max 16 points Between two consecutive points the values are interpolated linearly Filler Filler ash of the pulp i e the percentage of fillers from total solids P1 Curve slope correction factor In normal calibration use the default P1 1 see figure 6 3 P2 Offset term zero correction In normal calibration use the default P2 0 see figure 6 3 NOTE As kajaaniROTARY only measures fiber consistency variations in filler content
40. difference between kajaaniROTARY consistency reading and laboratory results The device is measuring in the normal manner and responding to consistency but there is a substantial difference between kajaaniROTARY s consistency reading and laboratory results The most common causes for this error Wrong recipe parameters e A change in pulp type or mix proportion The pulp contains fillers whose amount varies e kajaaniROTARY has not been installed as instructed e Flow velocity is below above the specified limit The consistency level is not suitable for the sensing element used e A change in fiber properties Accumulations of pulp on the sensing element surface Remove the transmitter from the process 7 6 2 HART interface is not operating properly The transmitter is operating correctly except for the HART interface Is the current measuring resistor s rating at least 2500 e Considering the total load is the supply voltage sufficiently high Also measure the voltage and current from the transmitter s terminal blocks Is the terminal voltage above 11V Does HART op erate at any current Disconnect the transmitter s supply then reconnect it Did HART start operat ing kajaaniROTARY Installation operating and service manual 49 7 6 3 Consistency reading is not responding to consistency Check 1 Is the transmitter rotating and is there water or pulp around the sensing element Check 2 Check coi
41. e required direction according to consistency The goal is to achieve zero offset at the calibration point thus eliminating the difference between the measured consistency and sample consistency The slope of the curve slope factor P1 does not change but the value of P2 changes in accordance with the zero offset In single point calibration you can also take two samples and use the one taken when the process was steadier The samples should preferably be taken at the so called setpoint consistency In most cases single point calibration is sufficient for consistency control applications The calculation formula P2 LAB sample average P1 unchanged kajaaniROTARY Installation operating and service manual 32 Two point calibration In this calibration the selected curve which converts the torque into a consistency signal is moved in the required direction according to consistency The goal is to achieve a zero offset at the calibration point and to change the slope of the curve as necessary so that the curve passes through two consist ency points kajaaniROTARY calculates new values for P1 and P2 IMPORTANT In two point calibration the difference between the consistency points must be at least 25 calculated from the lower point This ensures that possible errors in sampling and consistency analysis will not have a noticeable effect on the slope of the curve kajaaniROTARY will alert the operator when an attempt is made to calibr
42. eck after connecting High voltage inside the TCU 2 6 Starting up and servicing the transmitter Before starting or servicing the transmitter study carefully the instructions in chapter 3 Do not remove any covers before ensuring that the transmitter motor is switched off When the safety covers on the motor s drive belt wheel or on the measuring parts are removed there is a risk of injury by crushing or cutting NOTE Take all professional precautions before servicing Before removing the transmitter from the process line make sure that the line is empty and depressurized NOTE Hot or corrosive liquids may flow out under pressure risk of serious chemical burn injuries Be careful when opening the TCU cover The unit contains live parts that may cause electric shocks If the connections have been made correctly the live parts are protected against normal contact Transmitters located in corrosive applications should be removed regularly from the process line and their seals and other critical parts inspected carefully If corrosion damage is observed on the transmitter or its mounting parts ensure that correct material has been selected for the application NOTE Leakage may cause personal injury or equipment damage due to corrosion or burning Moving the covers may cause the injury of crushing or cutting kajaaniROTARY Installation operating and service manual 6 3 Transmitter installation 3 1 Accepta
43. enus On certain displays you can also enter letters To enter letters press a number key several times and the letters appear on the display one after another Sample Use the Sample key to start and stop a sample Edit Save Use the Edit Save key to go into Edit mode When you are in Edit mode use this key to save data ESC Use the ESC key to exit from Edit mode without saving data You can also use the key to toggle between the main display and the function menu Enter Use the Enter key to move between the main display and the Info display In Edit mode use the Enter key to jump to the next edit field kajaaniROTARY Installation operating and service manual 22 Back arrow Use the back arrow in Edit mode 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 the display contains more than four lines A downward pointing arrow in the bottom right corner of the display indicates that you can scroll down You can also use the down arrow to scroll between edit field options Up arrow Use the up arrow to scroll up if the display contains more than four lines An upward pointing arrow in the top right corner of the display indicates that you can scroll up You can also use the up arrow to scroll between edit field options 6 3 Operation with the TCU Introduction to the TCU user interface You can always return t
44. er profiling weld the process coupling to the hole see figures 3 5 and 3 6 A full penetration weld must be used Figure 3 5 Process coupling for DN200 PN25 kajaaniROTARY Installation operating and service manual 1 2 D p gt DN250 45 0 7R4 gt DN250 Ke LI Figure 3 6 Process coupling 70 or 150 mm 2 75 or 6 for gt DN250 PN25 kajaaniROTARY Installation operating and service manual 1 3 852343 AISI 316L N 9 a 4 wo Process conditions Pressure 16 bar Temperature 20 C N oO E E a a G x 2 T T g 2 E 3 E E 2 a N Q o 500 600 Nominal pipe diameter DN Figure 3 7 Sufficient pipe wall thickness for the required pressure rating PN16 Calculation parameters Outer diameter 240 mm Material thickness 10 mm Temperature 20 C Smax 147 N mm2 SS2343 AISI 316L O oa Ul w A N di O
45. erating unit a sensor to suit the process application a process coupling a process gasket and a deflector plate 8 1 Applications of the different sensing element types kajaaniROTARY is supplied with a variety of optional sensing elements The choice of an element is mainly dictated by the consistency and type of fiber The list shows the consistency ranges best suited for the different sensor options and pulp types See Appendix 1 Technical specifications The Consistency Advisor PC program supplied by Metso Automation can also be used to select the best sensor element The program also calculates and prints the required minimum lengths of straight pipe sections on both sides of the installation point When the transmitter is installed according to the instructions the effect of flow velocity variations on result accuracy will be negligible in the recommended measurement ranges kajaaniROTARY Installation operating and service manual 56 9 Recycling and disposal of a device removed from service Most device parts are recyclable when sorted according to their material A materials list must accompany the device The device manufacturer can supply you with recycling and disposal instructions You can also return the device to the manufacturer for recycling and disposal this procedure involves a recycling fee kajaaniROTARY Installation operating and service manual 57 Appendix 1 Technical specifications ka
46. ero drift on con sistency measurement kajaaniROTARY calculates and displays the consistency shear force and mA output in digital format The actual conversion of the digital value to a 4 20 mA output current is done by using factory calibrated D to A conversion electronics This system is very stable and thus the output current normally need not be trimmed However the transmitter is provided with the TRIM MA function for trimming the mA output display The TRIM MA x function requires connecting an accurate calibrated ammeter to the transmitter s output While the transmitter gives out two current values the actual current can be precisely measured and the transmitter readings corrected accordingly if necessary MA LOCK 8 This command locks the output signal to its present value and displays the mA value in stead You can then change the mA value with the arrow keys as desired This command can be used to check the cabling and current measuring circuits a only for kajaaniROTARY MA kajaaniROTARY Installation operating and service manual 51 7 8 Replacing components 7 8 1 Replacing the drive belt and pulleys e Unscrew the socket head screw 43 and detach the sensing element 40 Unscrew the three socket head screws 47 and detach the mixing propeller 45 e Loosen the set screws of the mechanical seal 52 and remove the rotating part of the seal Do not apply force on the bellows part of the
47. from toothed wheels connected to the shafts The measured signal is then converted in the transmitter electronics into a digital feedback signal to adjust the electro magnetic counterbalance force The electromagnetic field is created by two coils that induce a magnetic field of the polarity into the torque wheels connected to the shaft The strength of the electromagnetic force is adjusted by a controller to give a fixed setpoint value for the phase shift measurement The value of the current fed into the coils is converted into torque and further into consistency The signal is then converted to a 4 20 mA output signal with a superimposed digital HART Figure 1 1 kajaaniROTARY transmitter and TCU kajaaniROTARY Installation operating and service manual 1 1 2 Conformity to CE directives and CSA approval The entire system consisting of a TCU with power supply the transmitter the connecting cables see chapter 4 TCU installation and cabling has been designed to meet the following CE directives and their associated standards Machine Directive 93 44EEC PED Directive 97 23 EEC EMC Directive 89 336 EEC Low voltage directive 73 23 EEC In order to meet the EMC directive the following precautions must be taken 1 All wiring must be shielded Power supply electronics shielded coverage gt 80 Interface cable coverage 100 aluminum 2 All units have been tested as a complete system to conform with the relevan
48. he drive shaft chamber Do not twist it torsionally e Mount the mixing propeller 45 and secure it with three socket head screws 47 Mount the sensing element 40 secure with a socket head screw e Mount the seal flush water piping complete with thread sealant All screws must be secured with Loctite 243 or equivalent thread lock 7 8 5 Replacing the TCU Removing 1 Switch off the mains voltage from the TCU and disconnect the mains power lines from TCU s ter minal block 2 Disconnect the sensor cable and the factory system cable from the TCU terminal block 3 Detach the TCU from the shield Installing 1 Attach the new TCU to the shield 2 Connect the sensor cable power cable and factory system cable to the TCU terminal block 3 Switch on the mains power to the TCU NOTE It may take a few minutes before text appears on the display This delay is caused by the charging of the internal back up battery and is perfectly normal 4 lf the program asks you to select the calibration select sensor electronics calibration if you did not replace any sensor electronics default calibration if you have replaced sensor electronics as well kajaaniROTARY Installation operating and service manual 55 8 Applications The kajaaniROTARY transmitter is used for consistency measurement in the pulp and paper industry The transmitter is installed directly in the stock line kajaaniROTARY is supplied with an op
49. his delay is caused by the charging of the internal back up battery and it is perfectly normal In a normal delivery the sensor cable is already connected to the TCU The connection is shown in figure 4 2 e Insert the power supply cable 90 260 VAC as shown in figure 4 2 e Insert the current signal cable into the TCU connector casing through the inlet and connect it to the terminal block as shown in figure 4 2 Connect the voltage supply line to connector CS Connect the current output line to connector CS IN Do not connect the protective shield of the current signal cable NOTE kajaaniROTARY s current supply is passive and needs an external current source Figure 4 3 shows the load capacity of the current output as a function of voltage kajaaniROTARY Installation operating and service manual 1 8 Automation system Voltage supply VS 3 Input T 0 4 20 MA 0 VAC 17 3 Hz a FI _DBUS FIELDBUS 90 260 VAC Sensor Cable i 2x 2 1 x0 5 47 63 Hz chicks Figure 4 2 Electric connections to the TCU Figure 4 3 shows resistance as a function of supply voltage Resistance here is the sum of load resistor cable resistance and power source resistance in the current loop HART communication requires a minimum loop resistance of 250 o SN N i Figure 4 3 Current output load capacity of
50. in sensor unit ERROR SENSOR COMM X Error in communication between TCU and sensor unit FACTORY CALIBRATION Sensor unit parameters are lost default values are used 7 5 2 TCU error messages Error message Description ERROR NO SENSOR No response from sensor unit to TCU ERROR TCU EEPROM Non volatile memory EEPROM fault in TCU ERROR CLOCK Error in TCU s clock ERROR HART X Error in HART communication to TCU kajaaniROTARY Installation operating and service manual 48 7 5 3 Warning messages Warning message Description DEFAULT CALIBRATION The device has not been calibrated default calibration parameters are used CLOCK NOT SET TCU s clock is not set OUTPUT SATURATED mA output is out of range FIXED mA OUTPUT mA output fixed does not indicate consistency UNKNOWN SENS ELEMENT Sensing element is not set default TM sensor parameters are used CS OUT OF LIMITS Consistency is out of range TORQUE OUT OF LIMITS Torque is out of range PROC T OUT OF LIMITS Process temperature is out of range ELEC T OUT OF LIMITS Electronics temperature is out of range 7 6 Troubleshooting Rough categorization of the problems 1 Substantial difference between kajaaniROTARY consistency reading and laboratory results 2 HART interface is not operating properly 3 Consistency reading is not responding to consistency Check which one of the preceding conditions is ON and read the corresponding section below 7 6 1 Substantial
51. ing please check out the reasons of replacement Metso Automation Field Systems Division PL 237 Lentokentankatu 11 33101 Tampere FINLAND tel 020 48 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 Copyright November 2006 Metso Automation Inc Field Systems Division Documentation P ivi Piirainen J metso automation
52. ing water with no impurities larger than 200 um The water is discharged to a drain 3 8 plastic tube outlet a R1 4 male connection To channel J Flushing water Figure 3 10 Water flushing Water flow rate is regulated by a built in flow controller External purge meters should not be installed as they have a definite tendency to clog The flow rate is from 0 5 l min 0 13 US gal min to 1 l min 0 25 US gal min The pressure can vary from nearly zero to approximately 10 bar 150 psi A higher pressure will increase the flow rate but this is not a critical factor A flow indicator need not necessarily be installed but arrangements should be made to observe the water leaving the floor outlet Connect the incoming water supply directly to the male G 1 4 water inlet connection 1 4 in BSP at the built in flow controller The external diameter of the pipes should be at least 8 mm 0 31 wall thickness 1 mm 0 04 Install a shut off valve close to the transmitter Install the water overflow assembly Y piece to the outgoing water pipe Connect a 3 8 reinforced plastic tube to the outlet lead it to the floor outlet and fasten just above the floor outlet so that the flow can be observed The tube should not be bent anywhere so as to restrict the flow through kajaaniROTARY Installation operating and service manual 1 6 3 7 Connection of electric motor High voltage motor Only authorized personnel is permitted to
53. ion display for calibration history the recipe number is followed by a number in brackets This indicates how many calibrations have been stored in memory for this recipe When a recipe is selected information on the latest calibration will be shown 2 Point calibration The first line shows the recipe number the index of the current calibration and the number of calibrations available for the recipe The second line contains the calibration date and time The third line contains the parameters P1 and P2 from the calibration The fourth line shows whether single point or two point calibration was made You can view older calibrations by pressing ENTER After the oldest calibration the latest calibration will be shown again 6 7 Diagnostics To access the diagnostics functions press key 3 in the operations menu TCU s main menu 1 Confisuration 2 Calibration 3 Diasnostics 4 SFecial functions The following menu will appear 1 Error loa 2 Alarm limits 3 Alarms On Ott 4 MA Lock S 5ensor values Each of these functions is described below kajaaniROTARY Installation operating and service manual 42 6 7 1 Error log In the diagnostics menu press key 1 to view the error log Information on the latest error will be shown Error log 23 23 17 86 2685 12 15 48 17 66 2005 12 11 23 SENSOR ERROR 17 The first line shows the error index and the number of errors stored in the error log The next two lines
54. ious menu level Special functions menu Press ENTER to accept the value The transmitter then sends a 20 mA signal to the analog output and the display will read Dutrut set to 28 mA Give actual mA 20 GG Press ENTER when ready Measure the actual current value and enter it to the device with the keypad To change the value press EDIT SAVE and then enter the measured value as instructed above for the 4 mA signal kajaaniROTARY Installation operating and service manual 45 7 Maintenance and diagnostics NOTE Before removing the transmitter from process make sure that the process pipe is empty and unpressurized and that it is safe to proceed 7 1 Regular inspection Check transmitter performance regularly by laboratory samples e Check the flushing water supply once a week If the flushing water is colored by process chemicals or contains fibers or if the flow is blocked take action to correct the situation e Check the condition of the drive belt every six months Change it if it is cracked or damaged A tem porary split belt is available for emergency repairs If pH at the transmitter s installation point is very high or low check the condition of the measuring shaft O ring seal every year Make sure that the transmitter or TCU are not exposed to abnormal vibration or splashes these may deteriorate their performance and complicate repairs and servicing After initial start up and calibration mon
55. ith the two screws Installation length for MFL85N is 31 mm 0 5 mm for HJ 977 it is 34 5 mm 0 5 mm Mount the mixing propeller 45 and secure it with three socket head screws 47 Mount the sensing element 40 secure with socket head screw Mount the seal flush water piping complete with thread sealant All screws must be secured with Loctite 243 or equivalent thread lock 7 8 3 Replacing the flange V ring seal and cover plate Unscrew the socket head screw 43 and detach the sensing element 40 Unscrew the three socket head screws 47 and detach the mixing propeller 45 Loosen the set screws of the mechanical seal 52 and remove the rotating part of the seal Do not apply force on the bellows part of the seal Unscrew the flush water connection pipes of the seal Unscrew the six socket head screws and detach the connection flange 50 Remove the cover plate 92 and mechanical seal seat from the connection flange NOTE The silicone carbide seat is fragile Prior to assembly assess the condition of all mechanical parts and seals Check and clean the connection flange Check and clean the flush water pipes Check the drive shaft for any sharp edges grind marks and scratches polish it if necessary Change any worn or damaged parts Assembling Insert the cover plate 92 into the connection flange Insert the connection flange 50 into the bearing body and secure it with the six socket head screws Make sure
56. itor the transmitter s operation regularly with samples and readjust zero level when required All actions should be recorded in the transmitters service log 7 2 Long term field service Changing the belt pulley s and drive belt after five years Changing the mechanical seal after five years depending on circumstances e Changing the rubber seals after five years 7 3 Process conditions The kajaaniROTARY is inserted into the pipe and therefore it should not be installed in a place where the pulp may contain strings or other material that may become wrapped around the sensing element If some material is entangled in the sensor body the measurement results tend to drift upwards The speed of the drift is directly dependent on how rapidly the extra material builds up around the sensor and it may sometimes occur very quickly The sensor must be removed from the process coupling for checking kajaaniROTARY Installation operating and service manual 46 7 4 Self diagnostics The transmitter monitors its own operation continuously Any detected faults are shown in error messages that can be read from the transmitter s TCU or from serial I O HART x kajaaniROTARY s self diagnostic function monitors the internal measurements and generates error messages if the measurements exceed certain alarm limits An erroneous measurement result may also be due to contamination or some process variable that is skewing the measure
57. jaaniROTARY consistency transmitter is used for pulp consistency measurement in the pulp and paper industry The transmitter s operating princi ple is based on shear force measurement and it is installed directly to the process pipe The transmitter is supplied with an operating unit TCU The sensing element is selected based on the pulp type and the measured consistency range The optional mounting chamber process coupling is selected based on process pipe diameter and pressure rating Main features Measuring range 1 5 18 Cs Span min 0 5 Cs Repeatability 0 01 Cs Sensitivity 0 001 Cs Damping adjustable 1 to 60 s Environmental specifications Ambient temperature 20 70 C 4 158 F Storage temperature 50 80 C 50 176 F Transmitter Enclosure class IP66 NEMA 4X Enclosure material Aluminum Material of wetted parts e AISI 316L std e 254 SMO Hastelloy C 276 Sealing EPDM Kalrez Motor Enclosure class IP55 optional IP56 Power 0 36 kW Supply voltages 200 690 VAC 45 65 Hz See table 2 for motor type selection Operating unit TCU Enclosure class Operating voltage Outputs e Current output 4 20 mA HART 18 35 VDC e Profibus PA Inputs 2 galvanically isolated binary inputs for recipe selection or sampler status 12 28 VDC 10 mA Cable length 10 m 33 ft 30 m 98 ft as option IP 65 NEMA 4 90 260 VAC 25 W Configuration and diagnostics tools e
58. l current output go to the TCU main menu select 3 diagnostics then 4 sensor values Is coil PWM very small about 10 or very large about 65525 YES Coil current seems to be at the limit A likely reason is a problem with the optosensor pulse ratio controller Try to restart the transmitter and check if the problem disappears If the problem still remains the transmitter requires factory service Check 3 Check the coil current measurement in the sensor values display Is coil curr zero or about 0 7 or higher YES Probably the problem is in the coil current A D conversion Restart the transmitter and check if the problem disappears If the problem still remains the transmitter requires factory service Check 4 Check the torque Is the torque either zero exactly the same as coil current or higher than 1 2 Nm Parameters for the conversion from coil current to torque are wrong Restart the transmitter and check if the problem disappears If the problem still remains the transmitter requires factory service Check 5 Check the recipe parameters The torque seems to be OK but there is something wrong with the conversion of torque into a consistency value P1 should be about 1 0 P2 should be about 0 0 kajaaniROTARY Installation operating and service manual 50 7 7 Checking the operation of force measurement and current output A normal regular consistency calibration will rectify the effect of force measurement z
59. make the connections The motor is a standard 3 phase motor 1 Make sure that the connected motor voltage is correct If not adjust the rails in the junction box for the correct voltage according to the data on the motor type designation plate NOTE Make sure that the connected motor voltage is correct If not switch over to the correct voltage 2 Rotating direction clockwise is indicated on the motor housing When the motor has been connec ted start the motor for a moment to check the direction 3 The use of overload protection is highly recommended to protect the motor 4 Set the overload protection to the same value as the rated current for the motor indicated by the rating plate If the overload protection trips frequently it may be raised by max 20 However the external motor temperature must never exceed 80 C 176 F The temperature can be measured between the two cooling flanges on the outside of the motor 5 For practical reasons install the start stop switches safety switch and overload protection close to the motor This will facilitate calibration and maintenance when the motor must be started and stopped several times 6 The motor must be interlocked with the pump motor so that the transmitter stops when the pump stops NOTE Dry running will rapidly destroy the mechanical seal Standard motor connection See Table 2 in Appendix 1 Technical specifications Motor supply cable Min 4 x 1 5 mm
60. ment Self diagnostics may not detect such a fault Self diagnostics also detects definite faults which can be caused by sensor electronics Self diagnostics monitors the signal of the measurement channel measuring the process Self diagnostics is capable of detecting clear fault states and in such a case it generates an alarm by freezing the current signal or setting it to 3 75 or 22 5 mA according to user specifications User can also switch the alarm current OFF by selecting alarm current NONE in TCU s current output configuration display However self diagnostics may not necessarily be able to detect problems such as a drift in the meas urement that are not obvious device faults Self diagnostics measures the following values e Pulses produced by optosensor Rotation frequency of the sensing unit e Coil current A D converter of the sensor unit Memory EEPROM operation in the sensor unit and TCU e Communication between TCU and sensor unit e TCU s clock e HART communication e Current MA output e Values of consistency torque process temperature and electronics temperature 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 a only for kajaaniROTARY MA kajaaniROTARY Installation operating
61. n calibrating the transmitter make sure to take representative samples from the line The sampling and also laboratory routines should always follow exactly the same procedure 5 3 Basic configuration and calibration Select the language and temperature unit Celsius Fahrenheit see chapter 6 5 3 Set the device date and time see chapter 6 5 5 Scale the current output see chapter 6 5 2 Calibrate the consistency see chapter 6 6 Pes kajaaniROTARY Installation operating and service manual 21 6 Operation and user interface 6 1 General kajaaniROTARY can be operated either by using the local user interface TCU or remotely by digital communication over the 4 20 mA output loop HART communication protocol Total support including sophisticated calibration methods and thorough diagnostics is available from Metso Field Care Please refer to the DTM user manual Basic functionality is available for other field communicators or control systems capable of HART communication the operation menu for 275 HART Communicator is in Appendix 4 The local operation unit of kajaaniROTARY is the Transmitter Central Unit TCU see figure 6 1 Figure 6 1 Transmitter Central Unit TCU 6 2 TCU user interface TCU has a 20 column 4 line LCD display and a 20 key keypad for entering information The keypad controls are as follows Number keys Use the number keys to enter numerical data and to choose m
62. nce inspection Do not remove the cover 1 Make sure that the delivery content corresponds to the order 2 Check the device for possible transport damage 3 2 Before you begin kajaaniROTARY is a precision instrument and it must be installed correctly to ensure reliable operation Prior to the installation of the transmitter please read the following instructions This instruction manual contains installation instructions for the entire product line of Metso in line rotating consistency transmit ters The transmitter had been designed and manufactured to provide accurate and reliable measurements throughout its entire lifetime NOTE Correct installation and regular maintenance according to the Installation operating amp service manual will ensure maximum use transmitter capacity e Install the transmitter so that it is protected from direct mechanical damage If the place is such that it is likely to be frequently sprayed by water or pulp protect it with a suitable enclosure The TCU must be attached to the shield included in every delivery to protect it from water or pulp splashes If the TCU is installed outdoors the shield will also protect it from direct sunlight and rain e Protect the transmitter from heavy vibration sources such as cavitation or unbalanced pumps Install the transmitter in such a place that it is at the required distance from pumps pipe elbows valves and other changes in the pipe profile
63. ndividual application ranges NOTE If you are in doubt about whether the model you plan to install is in all respects the same as the model in this manual or if you have any questions about the installation please contact your Metso sales engineer kajaaniROTARY Installation operating and service manual 7 3 3 Selecting the mounting location Choosing the right place for the transmitter is essential for its optimum performance and ease of main tenance The transmitter can be installed in a vertical horizontal or inclined pipe When installing in a horizontal or inclined pipe make sure to choose a place where the transmitter will not measure large bubbles trapped in the pulp The mounting chamber used in low pressure installations may be left handed or right handed in design Figures 3 1 and 3 4 show typical installations Your Metso sales engineer will be pleased to assist in selecting the location that will give the best results consistent with your specific control strategy Pay attention to the following considerations 1 2 3 To ensure minimum time lag install the transmitter as close as possible to the dilution water injection point Recommended minimum distances see figures 3 1 and 3 4 Avoid proximity to pipe bends or elbows as these will cause turbulence and dewatering When the transmitter is positioned downstream from a pump or a pipe elbow the optimum place is at the theoretical outer turn of the pulp
64. nfo The following menu will appear Press key 1 to view Sensor information This data is shown for information only and cannot be changed Ture 3 MISSLMD 5 H 123456 Hi Rev Bal Sil Rew Godi Type Type describes the sensing element material etc See Technical specification for more details Default the supplied sensor S N Serial number of sensor electronics HW Rev Version number of sensor electronics SW Rev Software version of sensor electronics In the Device Info menu press key 2 to view the corresponding data for the TCU This data is shown for information only and cannot be changed 123456 Gaal Baal S N Serial number of sensor electronics HW Rev Version number of sensor electronics SW Rev Software version of sensor electronics kajaaniROTARY Installation operating and service manual 29 6 5 5 Set clock The Set clock display shows the following view Date 14 66 65 Time 15 12 47 Enter to accept The display shows the current date and time This date and time are used as a time stamp in the trend table and for calibration samples The main display status line reads Set clock until the time has been set If the date and time are correct press ENTER or ESC to exit this display To change the date and time press EDIT SAVE The first character in the field begins to blink Enter the date with the number keys first the day then month then year Example to enter the date 14 06 2
65. o perform this task The transmitter weighs approximately 36 kg 80 Ibs Figure 1 2 The dimensions of the kajaaniROTARY transmitter 1 4 TCU TCU is the user interface power supply and calculation unit of kajaaniROTARY Operations are performed by using the TCU s keys and four line display The TCU is delivered attached to the shield The TCU has the following connectors For the sensor unit sensor electronics supply voltage and RS485 serial port connectors For the 4 20 mA current output passive to DCS For digital communication using HART communication protocol e For RS232 connection to a PC for maintenance purposes For mains supply voltage NOTE Use TCU version OUL00377 with kajaaniROTARY See Appendix 2 Delivery content kajaaniROTARY Installation operating and service manual 3 1 5 Materials All the materials used in the exposed surfaces of the kajaaniROTARY system are selected and manu factured for use in pulp and paper mill environments 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 wetted parts of the transmitter i e the transmitter itself its mounting chamber if used and process coupling must be selected according to the process conditions Alternative materials stainless steel AISI316L 254 SMO or Hastelloy C 276 kajaaniROTARY Installation operating and service m
66. o the Measurement Display by pressing ESC several times The Measurement Display is the default after power up POS 1234 Recipe 2 Cs 3 7o Cs 46 1 DE The measurement display shown above is the default one and when you press ENTER the second measurement display will appear showing the following information Pressing again ENTER to return to the first Measurement Display Press ESC in either of the measurement displays to access the operations menu TCU s main menu The operations menu looks like this 1 Confisuration 2 Calibration s biasnostica 4 SFecial functions The operations menu has four menu items and fits entirely on the four line display of the TCU Some other menus have more than four items and in these cases an arrow in the top bottom right corner of the display indicates that the entire menu cannot be shown at once You can then use the UP ARROW and DOWN ARROW keys to scroll the display To access a menu function or submenu press the number key indicated before the name of the func tion submenu Press ESC to return to the previous level kajaaniROTARY Installation operating and service manual 23 All TCU functions can be accessed from the operations menu Figure 6 2 shows a map of the TCU functions and their locations in TCU display system Calibrati Recipe Selection POS 1234 Recipe 2 al pration Current Output Cs 3 78 Cs User Settings Proc T 46 1 C Device Info Set Clock Status OK
67. offset correction in the calibration curve NOTE The value for total filler sensitivity need only be entered with an accuracy of 5 points The filler components can also be entered based on an estimate kajaaniROTARY Installation operating and service manual 40 6 6 6 Calibrate Each one of kajaaniROTARY s recipes can be calibrated separately When Calibrate is selected in the calibration display you will first need to select the recipe to be calibrated 1 Recire 2 Rercire 1 Z 3 Rercire 3 4J Recire 4 The recipe number is followd by a symbol inside brackets to indicate which calibration methods are available for this recipe 1 2 both two point and single point calibrations are possible e 1 only single point calibration is possible the recipe cannot be calibrated Single point calibration requires that there must be at least one sample with laboratory consistency in TCU s memory two point calibration requires at least two samples with laboratory consistencies If the device does not allow calibration go to the sample history and check that laboratory consistencies have been entered for the samples that will be used in calibration When the recipe has been selected the top two lines of the display will instruct you to select the first sample for recipe calibration Recipe i calibration Select sample i 14 06 26685 16 83 87 Cs 3 97 Lab 4 83 The two bottom lines show information on the samples
68. or 6 according to consistency Always make sure that this dimension agrees with the dimension stated for the position number and in the order copy The dimension is also stated on the process coupling See figure 3 2 for the process coupling for PN10 Installing 1 2 Cut a hole with a 308 mm 11 81 diameter in the pipe and grind and bevel the edge to receive the weld In installations where the length of the process coupling is 70 mm 2 75 weld deflector plates to the pipeline upstream from the process coupling to protect the sensing element Install three de flector plates with the sharp ends facing upstream see figure 3 2 New deflector plates can be made according to the picture see figure 3 2 to replace any lost ones To install the plates cut 3 slots to the pipe and weld the plates into place Note that the deflector plates have 5 mm holes to facilitate installation Compare the process coupling and the pipe dimensions and pay attention to the mounting chamber dimension H to make sure that no part of the process coupling extends into the pulp line To check insert the process coupling into the hole in the pipe and mark it with a marking pen Observe that the holes for the transmitter retaining screw should be aligned with the vertical line After profiling weld the process coupling into the hole Use a full penetration weld
69. p between consistency and the torque detected by the sensor is not linear and it differs for different pulp types sensing elements etc Cs Torque Figure 6 3 Calibration principle The calibration curves determined experimentally in Metso Automation s laboratory represent consist ency Cs as a function of the torque Nm acting on the sensor kajaaniROTARY produces accurate consistency readings by compensating the detected torque with the information from a calibration curve The kajaaniROTARY is delivered with factory calibration and it thus able to measure consistency as soon as the power is switched on Factory calibration is performed on the device during final factory testing using pure water We recommend calibrating the device again when setting it up in order to optimize the device settings for the conditions in which it will be used Perform calibration by taking a consistency sample and entering its laboratory value into kajaaniROTARY as instructed below When this has been done the status line on the display will change from Factory Calibration to OK The transmitter should be calibrated for each pulp type used You can save calibrations for 4 pulps or pulp mixes in the transmitter s memory In the transmitter s post installation calibration consistency samples are used to tune the selected calibration curve for the pulp to be measured Tuning is done either as single point calibration to define the zero offset P2
70. rmine the total consistency and filler percentage of the sample These will be entered to TCU in the sample history display instructions below 6 6 3 Calibration menu To access the calibration functions press key 2 in the operations menu TCU s main menu Each of these functions is described below kajaaniROTARY Installation operating and service manual 35 6 6 4 Recipe A recipe is a set of information that the device needs to convert the measured torque value into consist ency The recipe function can be used to view and tune recipe parameters First select the recipe you wish to edit kajaaniROTARY s memory contains four recipes identified by a number and the pulp type used for it Press the number of the recipe 1 4 you wish to view The display contents may differ depending on pulp type Special fields are available for some special purpose pulp types for further information see below For the predefined pulp types HWU HWB SWU SWB GW TMPL TMPH RMPL RMPH CTMP RCFS ROCCS EUCAU and EUCAB the display contains only the basic tuning parameters Pz Offs2 A sou Pulp type There are several predefined calibration curves available for the most common pulp types These curves have been determined experimentally in Metso Automation s laboratory The available pulp types are HWU Unbleached hardwood chemical pulp e g birch pulp or eucalyptus bagasse and other agro fibers HWB Bleached hardwoo
71. rque consistency pairs are then entered into a mathematics software which fits a third order polynome into the measured data A number of different general purpose mathematics software are able to handle this Finally enter the factors of the polynome to the TCU in the recipe handling display NOTE If the data points do not cover the entire operating range there may be unexpected behavior when the torque goes out of the sampled area kajaaniROTARY Installation operating and service manual 38 SPG Special Grade In some special cases the available pulp type curves may be unsatisfactory even after two point calib ration In such cases the Special Grade function can be used to correct the curve through a max 16 point offset table In the table you can enter 16 data points giving the known consistency values relative to the torque values measured by kajaaniROTARY and thus define a curve of desired shape For consistencies below the table s minimum non zero consistency level the offset of the minimum is applied For consist encies above the maximum consistency level the offset of the maximum is applied Consistencies between the table values are calculated by linear interpolation using the offsets of the next lower and higher consistencies Figure 6 5 shows an example of a special grade calibration curve Figure 6 5 Special Grade curve The Special Grade curve is activated when pulp type SPG SPecial Grade is selected
72. s additional information The first line indicates the state of the transmitter s analog output in milliamps MA The second line gives the rotation frequency of the electric motor The third line shows cabin temperature housing temperature in degrees Celsius C C or Fahrenheit F F The temperature unit can be changed in User Setting display see below The last line shows the torque shear force detected by the device in Newton meters Nm 6 5 Configurations Here you can define and program the application s basic parameters Configuration is usually done only once before installing the transmitter When defining the upper and lower range limits take into account the measurable minimum consistencies and recommended maximum consistencies specified for each sensor pulp type see table 1 in Appendix 1 Technical specifications However in configuration it is possible for example to set 0 Cs as the lower range value regardless of warnings provided that the consistency will not actually drop below the specified measurable minimum In the same way it is possible to exceed the specified upper range value in configuration However the measurement may be affected by flow velocity if the actual consistency in the process goes above the recommended maximum limit Also take into account that the transmitter s minimum span is 0 8 Cs and its maximum span corresponds to 1 5 Nm shear force depending on the selected sensor pulp
73. sample is taken from the process pipe with a NOVE sampling valve When sample taking is completed press SAMPLE once more to stop the sampling sequence The sampling result will then appear on the display and the collected information is saved in the device s memory kajaaniROTARY Installation operating and service manual 34 In addition to the average consistency the device also shows the minimum and maximum values and process temperature during the sampling period The minimum and maximum values indicate consistency fluctuation during the sampling period This fluctuation should be small to ensure that the consistency sample is reliable If the difference between minimum and maximum consistency is very large the pulp has varied a Ito and this sample should not be used for calibration Please take another calibration sample Press ESC or ENTER to move back in the menu structure The sample is stored in the sample history of the recipe that was active during the sampling period Up to 16 samples can be saved for each recipe If more than 16 samples are taken for onerecipe the oldest samples will be written over When using a NOVE sampler equipped with a switch that applies a 24V voltage to binary input 2 when NOVE is closed the device will not collect sampling data When NOVE is open in the sampling pos ition the measurements are included in the sampling data The obtained sample will then be analyzed in the laboratory to dete
74. seal e Unscrew the flush water connection pipes of the seal e Unscrew the six socket head screws and detach the connection flange 50 Remove V ring seal 91 Unscrew the two belt guard set screws from the bearing body shell and detach belt guard 89 Unscrew the four socket head screws and detach the inspection cover e Unscrew the two set screws from the Taper lock bushing 88 of the drive shaft pulley Then insert one of the two screws into the third Taper lock bushing hole and tighten it to disassemble the bushing Detach the bushing and the drive shaft pulley 87 e Remove belt 86 Unscrew the socket head set screw 72 from engine shaft pulley Detach the pulley from motor by inserting two M6 screws into the holes on the face and tightening them Prior to assembly assess the condition of all mechanical parts and seals Check and clean the connection flange Check and clean the flush water pipes Check the drive shaft for any sharp edges grind marks and scratches and polish it if necessary kajaaniROTARY Installation operating and service manual 52 Assembling Remove cover plate 92 and the mechanical seals 52 seat from connection flange NOTE The silicone carbide seat is fragile Insert the new pulley 85 to the motor shaft Press it against the shaft collar and secure it with a socket head set screw 72 Insert the new belt to the drive shaft and fit the belt to the motor shaft pulley 8
75. t CE directives and their standards When the units are used in other combinations Metso cannot guarantee their CE directive conformity In combination with customer installed external devices the units may conform to EMC and safety re quirements when properly installed and using an adequate CE marked equipment NOTE System operator is responsible for the CE directive conformity Conformity must be checked by inspection Be careful when handling the equipment in connection with vessels containing pressurized hot ma terials Take the necessary safety precautions when mounting the equipment by using appropriate lift gear platforms and tools e The motor and TCU are powered by hazardous voltages The TCU box is CSA approved The transmitter motor can be ordered as CSA approved kajaaniROTARY Installation operating and service manual 2 1 3 Basic transmitter dimensions The dimensions of the kajaaniROTARY transmitter are given in figure 1 2 NOTE Always ensure that the system can be inserted to its full depth in the selected location before you install the transmitter TCU and necessary components The length of the transmitter including sensor and propeller is approximately 510 mm 20 The installed length of the transmitter is 385 mm 15 and there must be at least an additional 150 mm 6 room for extracting the transmitter from the pulp line Make sure to leave sufficient room around the transmitter t
76. ter the recipe number example kajaaniROTARY Installation operating and service manual 26 6 5 2 Current output Configuration Current ouput view HART addr LRV Lower range value Lower range value Cs This is the consistency percentage that produces the 4 mA analog output signal A warning is displayed if the value is lower than the sensor s lowest measurable consistency Default 3 0 Cs URV Upper range value Upper range value Cs This is the consistency percentage that produces the 20 mA analog output signal A warning is displayed if the value is higher than the sensor s recommended upper limit If the span is too wide gt 1 5 Nm kajaaniROTARY will not accept the upper limit and you will have to either lower the upper limit and or raise the lower limit The span may also be too narrow lt 0 8 Cs in which case you have to raise the upper limit and or decrease the lower limit Default 6 0 Cs Damping Damping the fluctuation of the output signal 1 to 60 seconds Define at least the minimum value required to damp harmful fluctuations Alarm current Analog output current to indicate transmitter failure Possible values are 3 75 mA 22 5 mA HOLD analog output is frozen when alarm goes on and NONE no alarm signal at all Default 3 75 mA HART address HART address of the device Acceptable values are from 0 to 15 Default 0 i e normal installation with a single transmitter analog outp
77. the TCU NY 7 kajaaniROTARY Installation operating and service manual 1 9 4 3 Binary inputs The TCU contains two galvanically isolated binary inputs BINO connector 13 can be used for recipe selection BIN1 14 can be used for recipe selection sampler status or motor running status The selection is made during configuration see chapter 6 Both binary inputs share a common ground 12 The switching device must be able to supply 12 28 VDC 10 mA to the binary input The connection principle of binary inputs is shown in figure 4 4 BINGND 12 BINO 13 aisi 12 28 VDC BIN1 14 eee Figure 4 4 Connection principle of binary inputs Operation chart Table 1 BIN1 configured for recipe selection BN pm Table 2 BIN1 configured for sampler status ENO pm SSS Table 3 BIN1 configured for motor running status BNO pm o p oS S open pen fecipe 1 selected losed open recipe 2 selected motor not running open closed recipe 1 selected motor running losed closed recipe 2 selected motor running kajaaniROTARY Installation operating and service manual 20 NOTE If the TCU has been switched off for a long time it may take a few minutes before text appears on the display This delay is caused by the charging of the internal back up battery and it is perfectly normal 5 1 Quick start checklist A pressure test with water is recommended to ensure that the mo
78. to align the nipples of the flushing water pipe horizontally Insert V ring seal 91 against the cover plate 92 by sliding it down the drive shaft until the seal drops into it groove Insert the mechanical seals seat into the connection flange Use soapy water for lubrication Mount the mechanical seal 52 and secure it with the two screws Installation length for MFL85N is 31 mm 0 5 mm for HJ 977 it is 34 5 mm 0 5 mm Mount the mixing propeller 45 and secure it with three socket head screws 47 Mount the sensing element 40 secure with a socket head screw Mount the seal flush water piping complete with thread sealant All screws must be secured with Loctite 243 or equivalent thread lock kajaaniROTARY Installation operating and service manual 54 7 8 4 Replacing the measuring shaft O ring seal Unscrew the socket head screw 43 and detach the sensing element 40 Unscrew the three socket head screws 47 and detach the mixing propeller 45 e Wrench out the O ring 105 using a screwdriver or a knife Pry out the washer 104 and inspect the space in front of the secondary seal If process media has leaked past the O ring 105 and the secondary bushing appears puffed it must be replaced A complete repair of the secondary bushing can only be done in Metso Automation s service point in Tampere Finland Assembling Insert the washer 104 into the drive shaft chamber Insert the new O ring into t
79. unting chamber process coupling and transmitter have been correctly installed and do not leak anywhere Before switching on the motor check the following 1 Make sure that the mechanical seal gets a steady supply of flushing water and also that the water drained out properly 2 Make sure that the system is turned OFF before attaching the system cable to the transmitter Tighten the system cable 3 Check all wirings 4 Switch on the main power supply and see that the TCU display lights up 5 Switch on the electric motor briefly and check its rotating direction 5 2 Important NOTE Do not rotate the sensing element The transmitter is a sensitive piece of precision equipment handle it with care When installing or re moving the transmitter only lift it by the handle Be careful not to damage the unit by overload the measuring system Before starting the motor make sure that the mechanical seal gets a steady supply of flushing water applies to this model Before starting the transmitter familiarize yourself with its operation e Make sure to check the rotating direction of the motor before admitting pulp to the line e Check that the actual Set point and Max feedback values agree with the corresponding values stated in the attached test protocol e Isa suitable Nove sampling valve for pulp located close to the transmitter This is very important for calibration and check up of the transmitter Whe
80. ut signal 4 20 mA is active Values 1 15 define a fixed 4mA current output and all communication with the device is performed through the digital HART protocol Warning Do not set values 1 15 if the 4 20 mA analog output signal is needed To modify these configuration values press EDIT SAVE once The cursor starts to blink at the LoCs value to indicate that you can edit the number Enter the new value with the number keys and press ENTER or just press ENTER to accept the existing value Follow the same procedure when entering the values for HiCs and Damping To set the Alarm Current press the UP and DOWN arrow keys to switch between the available alternat ives Enter the HART address with the number keys Press EDIT SAVE to save and activate your se lections If you do not want to make any changes press ESC to return to the previous menu level Configuration menu kajaaniROTARY Installation operating and service manual 27 6 5 3 User settings Press ESC in the main display to open the Operations menu and then select Configuration User settings The following menu will appear Taa POS 1234 Lansuase ENGLISH Teme unit i DEB Password iH Tag Transmitter s tag is a text describing the installation position of the device Max 8 characters either letters or numbers Language Display language selection Available options Finnish English Swedish French German Temp unit Temperature unit C C F F Default
81. y and filler percentage So far no laboratory results have been entered and these two fields are zero Press ENTER to view older samples After the oldest sample the information of the latest sample will be shown again When the laboratory results of a sample are available they should be entered to the device in the sample history display First select the sample for laboratory results will be entered Then press EDIT SAVE and the cursor starts to blink in the laboratory consistency field Enter the new value with the number keys and press ENTER or just press ENTER to accept the existing value The filler percentage is entered next If the pulp contains fillers enter the proportional amount of filler as a percentage of total consistency When these two fields contain the correct information press EDIT SAVE again to save the data in TCU s memory You can enter the laboratory results again as many times as necessary The samples can later on be used to calibrate the device and then their laboratory values must be correct Before calibration the samples are just stored in TCU s memory and the laboratory values entered do NOT have any effect on the operation of the device Entering the filler content is optional if the transmitter is recalibrated each time the filler content changes kajaaniROTARY does not measure fillers ash The transmitter is usually calibrated to indicate total consistency by making the required sensitivity and or zero

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