CTX Suspended Solids Sensors - Cerlic Enviromental Controls
Contents
1. 2011 08 24 MANE 08 11 Vers 3 23 CTX TABLE OF CONTENTS 1s Niroduelion an aiaiai eiaa i sarina ri sasinan 3 2 Afew words about this 3 3 DESIGN aticinicinncicntinncinnsasisinncnsinnnntidaninndieniiendinninentinaliensinncnandinatiensimnsnantinepice 3 4 Measuring 3 5 Unpacking 8 4 6 MOUNTING Sensor anna 5 Fe REMOVING SENnsHr anna 7 8 Service and 7 9 Sensor information 7 10 Sensor 8 8 8 9 Ea E a E E N ee Inneren A EA 9 EET R r A T T 10 11 Cal brai O aaa 11 OVEIVIEW E E E ee ee E E re er 11 I OOO AET 11 Calibrating suspended 501105 E E E i 12 Adjusting calibration of suspended solids 12 Calibration EE E EEEE E2. pipe With larger pipes a by pass line should be used The sensor shall always be mounted with the cable connector pointing downwards There are three ways to mount the sensors butt weld end connection NPT couplings US or hose connections See Dimensions section for more information In all applications the valve after the sensor shall be used for throttling Never throttle prior to sensor The BB2 control box can control flushing automatically with the cleaning relay Please carefully study these installation guidelines to reach maximum performance The inlet to the by pass pipe should be located where the suspension is well mixed and the flow is turbulent Appropriate distance from a pump discharge or a pipe elbow is about five pipe diameters downstream The by pass pipe should be as short and straight as possible A turbulent flow gives a better representation of the suspended solids In order to obtain the highest possible flow rate in the by pass pipe install the by pass pipe inlet before an elbow or pipe reduction For CTX 20 25 and CTX 20 50 the by pass pipe should be 25 mm 1 and 50 mm 2 respectively The by pass pipe should not have any throttling valve or pipe bend closer than 0 5 m 20 before the sensor The by pass pipe should be made to avoid dewatering of the suspended solids during a shutdown If there is a risk for this then the valve upstream the sensor should be closed automatically when the pump
3. 000 47 500 2 500 light unit loss and SAO 0 light loss e Actual measured value at this time is displayed on the top left of the graph and with the arrow to the left of the Y axis e Samples outside the min amp max scale are not displayed but are still used in the graph calculations If you want to see a point outside the scale you may temporarily change the scale in the Scale Alarm sensor menu Two samples have probably been exchanged when entering the lab results The Y value must always increase with increasing X value Page 14 CTX Multiple Calibration Graphs only used for multiple types of liquid applications The sensor can handle four independent calibration sets for different types and qualities of liquid with suspended solids Each set has up to five calibration points All four sets have a common zero calibration The selection of calibration set is done in the menu for setup and calibration or from an external device DCS At external selection e The external selection overrides the manual selection e If two sensors are connected to one common BB2 both sensors will change simultaneously to the set selected A D BB2 digital inputs A B D Extern 12 Deposits alarm and compensation BB2 has a choice to output the measured value during the last flushing on its second 4 20 mA output This is useful in demanding applications where it can be used to trigger an alarm to manually clean the s
4. allow remote selection of calibration set from DCS Normally only use one calibration curve unless you are measuring different type of solids or liquid with the same sensor Integration time dampening the output signal 0 999 normally 15 sec 9 solids mg l or ppm or Extra for 0 1 intervals number of decimals on the reading Ch1 Ch2 Ch3 Ch4 Ch1 2 Ch3 4 Pick the analog output s to be used with sensor Ch3 4 are optional Prim or Clean If two outputs are chosen the first will always give the primary value The second will either give the temperature 0 100 C of the internal sensor temperature Prim gives the same signal as the Analog 1 and Clean shows the measured value at the last flushing or Extern selection of calibration curve Selected calibration set A D Contact Factory Prior to using Adjust Store or Lab Store stores the present reading of the sensor and after input of the corresponding lab result through Lab the old lab result under Sample 1 is automatically adjusted No Zero 1 5 see Calibration section Actual suspended solids reading Lab test sample 1 Lab test sample 2 Lab test sample 3 Lab test sample 4 Lab test sample 5 Page 8 CTX Cleaning Cleaner B
5. reliable measurement with minimum maintenance possible even in critical applications The measuring lenses in the sensor are made of sapphire glass in order to withstand abrasive liquids Electronic and optical components are well protected within the SS enclosure to handle very demanding environments The sensors are available with 50 mm 2 NPT in US connections for CTX20 50 and 25 mm 1 NPT in US connections for CTX20 25 CTX20 25LC amp CTX03 25 The LC sensor is a special design for very low suspended solids concentrations like 0 10 ppm up to 2 000 ppm The CTX03 25 is a high solids sensor with 3 mm lens gap rather than 20 mm like the other units A shielded M12 10 m 33 ft cable is used for communication between the sensor and the BB2 control box The cable is made of polyurethane and highly resistant to aggressive substances Other Cable lengths are available 4 Measuring principle The CTX measures transmitted light through the liquid The measuring principle is based on the suspended particles ability to absorb and reflect light The light source is a light emitting diode LED that pulses monochromatic NIR light at high power The detected measuring signal is inversely logarithmical proportional to the suspended solids Signal treatment is done by the BB2 control box The temperature is measured by the transmitter to be used for temperature compensation of the measured value Temperature is temperature inside sensor head and
6. stops The flow rate in the by pass pipe should be at least equivalent to the main pipe but not less than 20 l min 10 gpm for CTX20 25 and 40 l min 20 gpm for CTX 20 50 sensors At lower rates there is a risk for dewatering and build up on the sapphire windows With automatic flushing then the flushing water pressure should be at least the same pressure as the air pressure to the cleaning device Page 5 The temperature of the sensor must not exceed 95 C 203 F Install the sensor to avoid exposure to considerable and fast changes in temperature Avoid installation where the sensor is exposed to severe cold weather or direct sunlight Protect the sensor from high pressure water spraying The sensor should never be submerged under water or put into water Always install the cables between sensor and control box in conduit when possible Install the sensor to avoid extreme vibrations The sensor must not be removed while still under process pressure The sensor must not be used as a ground point for welding If welding is to be done on the pipe system the cable and the sensor should be removed Always install the M12 protective cover on the sensor when the M12 cable is removed Automatic flushing Two three way valves can be used to automatically flush the sensor with water The flush water temperature shall be close to the temperature of the measured media to avoid temperature stress of the sensor In some applications where dilution
7. suspended solids can be delivered on a common mounting plate ready for installation The equipment is normally supplied with an automatic brush cleaning system to be controlled by the BB2 control box Ref drawing 102 S 625 mm 25 2215 mim 8 4 Compressed air Inlet 400 mm 1 6 39 Installation Outlet The mounting plate is hung onto a handrail or mounted on a wall Free space to the left is necessary for removal of brush for cleaning and maintenance Cleaning brush e The cleaning is done by a brush which is pushed into the sensor cell by a SS piston controlled from the BB2 control box Typical interval is 45 min e During the brush cleaning the output signal is frozen e brush should be changed depending on the wear caused by the liquid typically once per year e The compressed air to the 4 way solenoid valve should be about 80 psig Changing the brush 1 Close the valves before and after the sensor and the 80 psig air supply 2 Loosen the nut that holds the piston assembly to the T pipe 3 Pull out the piston assembly from the T pipe 4 Loosen the locking nut on the brush and remove the brush from the piston 5 Attach the new brush and tighten the locking nut 6 Push the assembly back in the T pipe and tighten the nut Confirm you have the Teflon gasket 7 Open the valves and the air supply Check th
8. SE ESTES 12 Automatic adjustment of the calibration 13 Calibration with multiple 13 Calibration east 14 Multiple Calibration graphs curves 15 12 Deposits alarm and compensation 15 13 Technical 16 14 DIMENSIONS 18 Appendix 1 Low suspended solids with brush 20 Page 2 CTX 1 Introduction The CTX flow through sensor is used to measure suspended solids in liquids Combined with the BB2 control box the sensor is used to measure suspended solids in liquids Examples of applications are suspended solids in Water Treatment Plants Waste Water Treatment Plants Industrial applications like slurry s or process applications 2 few words about this manual The manual primarily contains information about the Cerlic CTX sensors Menu functions and technical data of the BB2 control box can be found in the BB2 service manual 3 Design The CTX sensor is made in 316 stainless steel and is mounted with pipe fittings DN25 directly onto a 25 mm 1 pipe or 1 npt fitting US market The sensor has a self cleaning design since it necks down to 20 mm at the lenses from 25 mm or 1 inlet which permits precise and
9. X CTX20 50 P N 11305506 2 sensor Process connection 2 NPT connections in US or DN50 butt weld ends 54x50 mm outside US Measuring range Min 0 100 mg l Max 5 in by pass pipe or 8 directly in pipe depending on type of suspended solids being measured Other technical data Refer to CTX 20 25 Certificate of conformity The CTX sensors along with their central unit BB2 are in conformance with the following EC Directive s when installed in accordance with the installation instructions contained in the product documentation 73 23 EEC Low Voltage Directive as amended by 93 68 EEC 89 336 EEC EMC Directive as amended by 92 31 EEC and 93 68 EEC The following standards and or technical specifications have been applied EN 61000 6 4 2001 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments EN 61000 6 2 2001 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN 61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use Page 17 CTX 14 Dimensions 20125 20 251 amp CTX03 25 ww DE X Gg SPE 8951 Page 18 CTX CTX20 50 13 94 354 10 87 275 7 87 200 x 09 SPE 9961 19 CTX Appendix 1 Low suspended solids sensor with brush cleaning CTX20 25LC sensor Complete package for measuring of the
10. calibration will restart from scratch An Excel sheet to help doing statistical adjustment of the calibration can be downloaded from http www cerlic com Calibration points The calibration curve is built from the zero calibration point and at least one calibration point A calibration point can be disabled or not used by setting the suspended solids value to zero or Sensor Light Loss 0 Suspended Solids Page 12 CTX Automatic adjustment of the calibration The function Adjust in the calibration menu is used to automatically adjust the calibration in an easy way When a sample is taken for the lab BB2 stores the reading When the sample has been analyzed the result is keyed into the BB2 who will compare it to the stored reading and calculate a new sample 1 value Automatic adjustment only works for single point calibration and is primarily intended as an easy way to get started with a new sensor Once the automatic adjustment is done and the sensor gives a sensible reading statistical adjustment is recommended e Select sensor in the menu using t or e Press ENTER for five seconds to enter the sensor menu e Select Calibrate Adjust and then Store e Press ENTER when taking the sample for the lab e Get the sample analyzed e Select Calibrate Adjust and then Lab e Press ENTER e Key in the lab result then press ENTER to store e 2 will show current and sugges
11. e function by going to the cleaning menu Select Next time and push Enter to activate a cleaning cycle Page 20
12. ensor The signal can also be used to compensate the reading for deposits in the sensor extending the interval between manual cleaning Page 15 CTX 13 Technical data CTX20 25 Process connection Material Pressure rating Enclosure Process temperature Process pressure Light source Measuring principle Connection cable Weight Measuring range CTX20 25 LC Process temperature Flow Measuring range Other technical data CTX03 25 Process temperature Flow Measuring range Measuring principle Other technical data P N 11305503 1 NPT connection in US or DN25 butt weld ends 30x25 mm outside US 5152343 31655 PN25 365 psig IP65 NEMA4X 0 95 C 32 203 F Min 1 bar 15 psig GaAs diode 880 nm monochromatic Straight transmission 20 mm measuring gap 5 pin M12 connector 3 7 kg 8 lbs Min 0 100 mg l Max 3 suspended solids depending on type of solids P N 11305531 low suspended solids sensor 0 50 C 32 122 F 15 100 l min 4 25 gpm Min 0 10 mg l resolution 0 1 mg l 0 200 mg l measures up to 2000 mg l but not fully linear Refer to CTX20 25 P N 11305682 high suspended solids sensor 0 50 C 32 122 F 15 100 l min 4 25 gpm 7 times higher than CTX20 25 due to 3 mm lens gap Max 15 70 suspended solids depending on to type of solids being measured Straight transmission 3 mm measuring gap Refer to CTX20 25 Page 16 CT
13. le point calibration sample 2 5 can be calibrated when steps 1 4 above are finalized for sample 1 Zero Calibration The sensor is zero calibrated at the factory and does normally not need recalibration Before doing a zero calibration make sure that it is really needed The zero point is common for all four calibration sets If the zero point is recalibrated it will affect all other calibration points in all calibration sets of the sensor The CTX 20 25 LC sensor cannot be zero calibrated in the plant it has to be performed by Cerlic Make sure the windows are clean and use clean de aerated water to check the meter reading Tap water is best de aerated in an open bucket for at least two hours To run a zero calibration e Remove the sensor from the process and clean it thoroughly e Plug one end of the sensor and fill the cell with clean de aerated water NOTE The sensor must not be submerged into the bucket e Select the sensor to be calibrated in the menu by using t arrows e Press ENTER for five seconds to enter sensor menu e Use t and arrows to select Calibrate and select Take sample e Select Zero and press ENTER e If you really want to destroy the existing calibrations change No to Yes then press ENTER e After you have filled the sensor with water press ENTER again e Wait for the zero calibration to finish It will take approximately thirty seconds before the unit returns to
14. not true liquid temperature U Page 3 CTX 5 Unpacking sensor The unit has been tested and approved before shipping Content Please check that the content corresponds to your order and packing list Damages If damages occurred during the shipment immediately contact the carrier as well as your Cerlic representative The shipment can be returned only after contact has been made with Cerlic Packaging The original packaging is designed to protect the equipment and should be used for storage or if the goods must be returned Optional parts can be ordered P N e 1 npt x 25 mm union with nut 31655 for CTX 20 25 31104016 e Gasket teflon for 25 mm union 21603365 e 2 npt x 50 mm union with nut 31655 for CTX 20 50 31104017 e Gasket teflon for 50 mm union 21603319 e 25 mm hose adapter DN25 for CTX 20 25 10305122 e 0 66 m 2 ft M12 signal cable 30804063 e 10m 33 ft M12 signal cable 20805510 e 30m 100 ft M12 signal cable 30804062 e M12 Y splitter for two sensors 24 long 30804065 e Brush cleaning assembly for CTX 20 25 and CTX 20 25 LC 11203178B e Brush for cleaning device SS shaft 10603261 e Mounting plate for CTX with brush cleaning device outside US 12705528 e Mounting plate for CTX with brush cleaning device US 31204066 e Solenoid valve for flushing US 1705516B Page 4 CTX 6 Mounting sensor The CTX20 25 can be mounted directly in a 25mm 1 pipe CTX20 50 in a 50mm 2
15. of the measured media is allowed only one three way valve can be used and the flush water can go out the same way as the media The valves before the sensor must not in any way reduce the flow when open If there is a risk of turbulence in the valve it must be placed more than 0 5 20 before the sensor Sometimes the sensor may need manual cleaning using a bottle brush and diluted acid 5 hydrochloric acid or sulphamic acid For further instructions on white and green liquor applications please refer to Appendix 1 Page 6 CTX 7 Removing sensor e Close all valves to isolate the sensor e Disconnect the sensor from the by pass pipe by using the couplings on each side of the sensor Remove the sensor and save the Teflon gaskets for reassembly e Clean the sensor with a clean cloth Do not use a wire brush e Flush through the sensor thoroughly Before the sensor is disconnected the valves in the by pass pipes must be closed Make sure that no flow passes through the pipe If the sensor is disconnected under process pressure this could cause serious injury or even death Cerlic does not accept any responsibility for accidents caused when the sensor is disconnected while still under line pressure 8 Service and maintenance In some applications the measuring cell may need to be cleaned Use warm water and a small bottle brush to clean the cell do not use a metallic brush or sharp tools An acid solution can be
16. rush or Flush Brush for CTX20 25 or CTX20 25LC sensors only Interval min Time minutes between cleaning cycles Length sec Duration seconds of flushing cycle or strokes of brush like 5 sec 3 strokes Freeze sec Extra freeze time or recovery of output signal after a flushing brush cycle Relay 2 Along 1 or Along 2 Select relay to operate solenoid for flush brush cycle if this sensor is a master with its own relay or relay used by master if this sensor is a slave These same relays could be used as Alarm relay below Next time The next scheduled cleaning time Pushing Enter on this line will set the time to current time and start a cleaning cycle This could be used to test the Flush cycle Clean Reading at the end of the last flushing cycle Scale Alarm Max Reading corresponding to 20 mA output signal Min Reading corresponding to 4 mA output signal Hi Alarm Reading to activate high alarm all 5075 inactivates the alarm Low Alarm Reading to activate low alarm all 5075 inactivates the alarm Alarm Relay 4 and 2 1 or 2 Check that it is not being used for cleaning Page 9 System Type Serial SoftW Temp MaxTemp Samples Selected Cal Used Cal SA0 SA 1 Cons 1 MS Con SA 0 SA 1 Cons 1 Chia Ch1 Intens Zero Int l offset Temp Calib Samp s Service Type of sensor Serial number of sensor Software version of sensor Sen
17. sor temperature The highest sensor temperature recorded Sub menu to view SA values and suspended solids values for this calibration set or Extern selection of calibration set Selected calibration set A D SA value zero sample clean water SA value sample 1 Lab test sample 1 And so on for sample 2 5 Menu for Cerlic internal use Linearized light signal which are SA values in calibration chart Suspended Solids reading SA value for zero sample on clean water SA value sample 1 Lab test sample 1 Raw value channel 1 1000 40000 Raw value channel 1 compensated for intensity Current intensity 150 25000 Intensity for clean water set during zero calibration Intensity offset set during zero calibration Temperature compensation constant Samples per second Not accessible for users Page 10 CTX CTX 11 Calibration Overview Calibration is made in a number of steps performed in a consecutive order Each step is described further down If one step is redone all later steps have to be redone 1 Zero calibration made on clean water by Cerlic before shipping 2 Calibrating suspended solids 3 Adjusting calibration of suspended solids CONTACT FACTORY BEFORE USING THIS OPTION e Warm Up of Sensor It is important that the sensor has been in operation for at least 30 minutes before calibration to have a stable operation e Single point calibration is recommended In case of multip
18. ted new value for Sample 1 acknowledge the change by pressing ENTER or abort using 9 9 Calibration with multiple points The only cases where multiple calibration point is useful are when the sensor signal is non linear or when the sensor has to be very accurate at widely separated suspended solids concentrations Use the same procedure described in Calibrating Suspended Solids sample 1 but select sample 2 3 4 or 5 Page 13 CTX Calibration display Press and ENTER simultaneously to switch between main menu and the sensor display 1 This first display shows some additional readings to the main value temperature the value measured during last cleaning raw value of the measurement Press 4 and ENTER simultaneously again to reach the display 2 showing the current calibration graph By pressing 9 and ENTER simultaneously third time you return to the main display Single point calibration Multiple point calibration A calibration set normally consists of zero point SAO and one suspended solids sample single point calibration like SA1 Up to five samples may be used to create a calibration curve multiple point calibration The samples are sorted internally in order of signal inten sity The calibration display shows the calibration set in a graph e X scale displays suspended solids concentration from Min 4 mA to Max 20 mA e Y scale displays the raw sensor signal loss like SAO SA1 or 50
19. the menu For more information concerning use of menu dialogues refer to the manual for BB2 Page 11 Calibrating Samples 81 85 for suspended solids concentrations e Select Calibrate Take sample select 1 thru 5 and press ENTER e Press again to calibrate and grab sample of liquid at the same time for the lab e Take the sample to the lab for analyzing of the suspended solids e The lab results are entered under Calibrate and Sample 1 thru 5 Note Sensor remembers SA or light value at the time you told it to calibrate You enter lab value for suspended solids at any time after this like 2 hours or 2 days Sensor compares light loss from SAO SA1 to lab value Adjusting calibration of suspended solids Consult Factory prior to using this option Statistic adjustment of the lab sample value is a much better way to good measurement than frequent recalibration This is done comparing the lab results with the instrument readings over time If a systematic discrepancy is detected the value of the lab sample used in BB2 is changed accordingly If for example several lab results for a period of time in average shows 5 more than the instrument the sample value in BB2 shall be increased 5 of its value e g if the sample value is 1 000 ppm it shall be changed to 1 050 ppm Using statistic adjustment will gradually improve the accuracy and reliability while a new
20. used to dissolve coating in the measure cell Plug one end of the cell and fill it with 5 hydrochloric acid or sulphamic acid Leave the sensor for a couple of hours and then flush the cell with plenty of clean water Repeat the treatment if necessary If hydrochloric acid does not dissolve the coating other chemicals may be used as long as they don t affect the O rings made of Viton The sensor housing may not be opened except by Cerlic service personel Opening the sensor housing will void all warrenty 9 Sensor information displays Press and ENTER simultaneously to switch between main menu and the sensor display 1 This first display shows some additional readings to the main values temperature the value measured during last cleaning Press and ENTER simultaneously again to reach the display 2 showing the current calibration set graphically By pressing and ENTER simultaneously a third time you return to the main display Page 7 CTX 10 Sensor menu Use to select the sensor in the main display Press ENTER for five seconds to access the menu for the selected sensor Settings Tag Calibration I Time s Unit Decimals Analog Second Calibrate Selected Cal Used Cal Adjust Take sample Cons Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Name of the sensor 10 alpha numeric characters shown on the main display Calibration set or Extern Extern will
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