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Analytical Instruments: K-Patents Refractometer User's Manual (PR

1. A8 03114915 SNOILV2IJO3dS LYVd LYVd SIN31Vd M 83LLIASNVSI ONILVOIONI SIN31Vd M SSH 29V 7607 HOSNIS Z SIN31Vd M LINN AV 134 HSVM YOSNAS NV 831 5 1 33 138 1008 4 3199 7 SLNILVd 2 4 243 114 S 83401502 d 9 JA TVA 8 1 9 83401502 5 L 83401502 DINOILIGNO 34d 8 JA VA 34 404 318V2 414405 84 04 6 834015012 831VM 3187 114405 84 04 10 83401502 3dld 431VM 834015012 344 831 83401502 A 00 0420 114405 33M0d EL M3M3S OL MALYM OSINOLLIONOO33d Aa M31 VM Mounting summary of prism wash for water with wash control relay unit WR Figure 8 43 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective March 24 1999 bunopi eunssejd edid eq inss id jaljay uono s edid ui SAJDA p 0 SpuawWwosas 5
2. 12 9130 9 5 2 22 0 Figure 2 21 Dimensions Sensor with 212 Sanitary clamp mm in INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 3 PRINCIPLE OF MEASUREMENT The K Patents Sanitary Refractometer determines the refractive index R D of the process solution by measuring the critical angle of refraction The light from a light source L Figure 2 30 is directed against the interface between a prism P and the process solution S Two of the prism surfaces M are total reflecting mirrors bending the light rays The light rays meet the interface at different angles The reflected rays form an image ACB where C is the position of the critical angle ray The rays at A are totally reflected at the process interface the rays at B are partially reflected and partially refracted into the process solution In this way the optical image is divided into a light area A and a dark area B The position of the borderline C between the areas shows the value of the critical angle and thus of the refractive index of the process solution The refractive index normally increases with increasing concentration Figure 2 30 Refractometer principle B B Low concentration High concentration Figure 2 31 Optical images From this follows that the optical image changes with the process sol
3. 775 3 0 4 3 FLOW Figure 3 20 Sanitary clamp mounting mm in INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 20 Flow cell Pipe diameter 2 50 mm L 9485 D1 9 020 0 gt 4 965 02 6 014 5 8 89 0 3 5 i L_ 251 5 D2 FLOW Flow cell Pipe diameter 1 2 40 mm 0 14 N M ore Hed n erm E TT o J E 915 0 0 6 1 5 965 02 6 Qu gt mA A j oper 70 3 2 5 I e38 D1 5 FLOW Figure 3 21 Sanitary clamp mounting mm in INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 21 3 3 MOUNTING OF SENSOR Remove the prism protection sticker before the sensor is connected to the process line Identify the sensor by the serial number Check that it matches the serial number of the Indicating Transmitter Turn the sensor so that the cable plug socket points downwards After connecting the cable join the two connector protecting caps to keep them clean inside 3 4 WASH NOZZLES For mounting of the prism wash systems see Section 8 3 5 INDICAT
4. si eunsseud UBIY USYM uonoes edid 3 35 OL YALVM 9SINOILIQNOO33d pesojo D ul JnoDo 5 91 55924 iONINNVM 8 03114405 SNOILV2IJD3dS 18 4 18 4 SIN3IVd M HI LLINSNY HL DNILVOIONI 8 SIN3IVd M Z9V E0 Ud HOSNIS Z SIN3IVd 080 4 LINN AV 13H mn SIN3IVd M 00 8 4d HOSNIS ONY YSLLINSNVUL DNILVOIONI N334138 318V2 7 NA SIN3IVd M 08 LINN AV 134 ONY 831 LINSNVS1 DNILVOIONI N334138 3189 6 SIN3IVd M 31ZZON dH 2 04 243 1132 9 SIN3IVd M 191 9 2 1 SdWS 3A TV A ISH 5 L m du HE SIN3IVd M AOLL 9EEE Ud JA TVA DNINOLLIONO23Ud 8 x SIN3IVd M 150 JYNSSIYd 6 91 44W01SN2 A OL 5 0L GQ SIN3IVd M OLL 09E Yd LINN AV 138 u3MOd LL SIN3IVd dW31 000 302 452 172 dnd JYNSSIYd SIN3IVd M AO0LL 9EEE Hd JA TVA U31VM EL 43401502 NOILJ3NNOO 1 7L 3401502 331VM 403 318 2 14405 u3MOd SI SIN3IVd M did 380SS323d HDIH 804 318 2 14405 u3MOd 9L YIMOd 33MOd FE E xD HH K
5. TU OL Mounting summary of prism wash system for steam with relay unit PR 7080 Figure 8 40 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective March 24 1999 69 A8 0314415 SNOILV3IJD3dS LUVd 18 4 SLINILVd 8 LINSNYH L ONILVIIGNI SIN31Vd M SSH Z9V t0 4d HOSNIS Z SIN31Vd 3 LINN AV 134 HSYM SINILVd YOSNAS ONY H3LLIASNVSI ONILVIIGNI LIE 1008 4 3197 7 SIN31Vd 1 19 91 293 114 S U3A01S02 d73 4 ATEWASSV 3A TVA QION310S 3ATVA NV31S 9 YAWOLSND d 3A1VA 323H2 L YAWOLSND d dVul NV31S 8 YAWOLSND d U3NIVHIS 6 434018502 LL DMY LXE 318v GIONITOS 0L d4W015N2 WWALS LL 83401502 7 1 244 WV31S 4 834015012 A 01 02 114405 83 042 33401502 HILIMS A133VS HOLIMS AL3JVS p Mounting summary of prism wash for steam with wash control relay unit WR Figure 8 41 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective Marc
6. OV 37 9 36 SER BUS jm FBUS 4 20mA Q 2 LI 34 ESS C45 RS485 SWITCHES C28 425 15 16 17 18 C36 X C37 9 10 1 15 14 2 Paa 254567 43 444546252 47 48 49 50 FIELD BUS i RLY1 RLY2 RE2 47 c12 T2A K PATENTS PR 7030 Rev F Figure 6 40 Power supply card component lay out INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER 03 Document Revision No INM 3A Rev 1 2 Effective March 24 1999 48 C P3 2 50 CPDS 96 40 593 C P822 SW2 cou 44 COM 121R RI CPE SDDAT RELAY1 RELAY2 CP 32crs CP 39RrS CF8 3050 24 CPE 35 SGND N4148 SJ REB Di z PE DSER C P6 6 SER C P6 8 SEN 6 10 5 P6 1220UT0 SWITCHES 4 20 PROCESSOR CARD PROCESSOR CARD DATOS DAT04 PATO sov 5 S S b 5 FIELD BUS 24VB EMIFILTER FIELD BUS IN FILD BUS OUT K E 2N2222A a2 013 8v 014 A A c23 Tow Pev DRAWING No Effective March 24 1999 Document Revision No INM 3A Rev 1 2 Power supply card circuit diagram INSTRUCTION MANUAL FOR K PATENTS
7. RN P 8 133 7 poe 016 V 2 XI RI Ce C23 C24 15 24 Figure 6 43 Processor card component lay out Display controller card The Display controller card has the components surface mounted and it should be considered as one part Keyboard The Keyboard switch matrix is given by Figure 6 46 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 52 1 To processor card P3 10 EE RESET 2 e Figure 6 46 Keyboard switch matrix Transformer For transformer colour code see Figure 6 47 The leads are connected to the following Power card terminals compare to Figure 6 40 black white 32 ra ii 35 9 gray si 2x110V 37 ii 24 V 50 VA 50 60 Hz brown BS J Uo 26 6 V bl T hit PR ue white 5 88 yellow green T yellow 0 Jl 0 42 x Static Shields Figure 6 47 Transformer 6 5 SENSOR CHECK Study Figure 6 50 to get a basic understanding of how the Sensor works Select Calibrate Optical image from the Normal Display Figure 2 60 The display Figure 6 51 contains now all raw data from the Sensor including the signals from each photo cell i e the raw video signal This differs from the Optical image Figure 2 72 selected through the Display key The video signal describing the optical image should look like Figure 6 51 In that case the Sensor is O
8. 72 HOLIMS NIVW 0 Mounting summary of wash system with high pressure water Figure 8 50 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective March 24 1999 73 0 9222 3ATVA 10 3105 91 01 3515 A lddfs 34055349 H9IH E091 4d LINN AV 138 DLIMS NIVA 6 87 0804 4d LINN AV 138 9 Ad DNINOLLIGNOD 34 l LINN AV T3d 4 ONY YSLLINSNVYL ONILVOIGNI X04 AlddNS YAMOd 3AVS ASN LON OQ i3LON 1008 ree 108 4 Mm b ST N lt lt lt lt lt 1 A IddNS apaju o e e ez sz ls 1 9 5 amp 1 N 1 8 LI S3LLINSNVSL 9NILVOIONI Wiring drawing of wash system with high pressure water Figure 8 51 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective March 24 1999 74 9 RELAY UNITS The K Patents Sanitary Refractometer can be equipped with a
9. 10 1 Figure 6 52 Sensor electronics test points Figure 6 53 Scaled optical image 1 TEST calculated TEST value range 8 248 Indicated by a dotted vertical line T indicates the process temperature to facilitate field calibration 2 the value of the rightmost point in of span L A measure of the left side curvature of the optical image 4 RE A measure of the right side curvature of the optical image A zero curvature indicates a straight line Both curvature values are defined as positive for an image as Figure 6 53 5 Sensor head internal temperature in C 6 Sensor head internal relative humidity in RH 7 An L shaped corner mark For a clean prism in air the optical image should form a smooth hill and be above the corner mark INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR A 22 DocumentRevision No INM 3A Rev 1 2 Effective March 24 1999 56 Slope This display shows the slope curve of the optical image At the TEST value the SLOPE curve should have a sharp dip The following additional values are given Max The filtered value of the maximum light intensity RMX of the raw data Figure 6 51 Slope The absolute value of the slope curve dip at TEST The value of Slope must be above 1 to be acceptable Image diagnostics This display lists the critical values for TEST acceptance according to the image analyzer decision rules in Figure 6 54 Max inte
10. Concentration The concentration value is the same as in the CONC display The number of decimals is controlled by the display decimal parameter in EEPROM The range is dependent of the concentration factors in EEPROM The value is damped It is held during wash hold or recovery phases INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 26 Temperature The temperature value is the same as in the C display The value is displayed with 1 decimal Operation phase codes are Blank Walt Precondition Precondition Wash Recovery Hold No errors Process disturbances Retrying wash Solids warning Solids alarm Low concentration no sample Prism wash failure Malfunctions High process temperature High conc prism coated Instrument malfunctions External output fault Relay unit fault Divert control fault Temperature measurement fault Prism coated LED fault Not in line Detector timeout Sensor transmission error No sensor signal Wrong concentration parameters Constants error Sensor interface fault EEPROM fault Process disturbances Low light intensity Dip in image Wash stop Temp limit High internal humidity High internal temperature Instrument malfunctions 26 12 Wash stop ext stop Checksum The checksum is the arithmetic sum of ASCII codes in columns before the checksum field The range is columns 1 to 67
11. Rev 1 2 Effective March 24 1999 59 6 Remove the Image digitizer card kept by four M4 screws E 7 Remove the Image detector card kept by three M3 screws F Note Removing the screws may introduce a slight calibration error 8 Loosen carefully the six M4 screws G of the disc spring holder Turn in small steps alternating between the screws Never touch the screws G when the instrument is in the line 9 Remove the disc spring holder H the disc spring J and the thermal conductor K a b Figure 6 71 The Analyzer module 10 Lift the Analyzer module Figure 6 71 a The module does not turn due to the alignment pin R Note The thermal insulator N is permanently glued at both ends 11 Remove the Prism support U fixed by two M3 screws L Figure 6 71 b Removal insertion of prism A new prism gasket Figure 6 72 12 To remove the prism push it gently against the springs in the prism plate M as indicated by an arrow in Figure 6 72 a SENSOR ASSEMBLY 1 Clean the prism No finger prints on any of the four optical surfaces 2 Put the prism in place pushing gently against the springs of the prism plate M The direction of the force is indicated by an arrow in Figure 6 72 a To make sure the prism is in correct position press the prism in the opposite direction of the arrow 3 Cover the prism by a new prism gasket with the center hole uncut according to Figure
12. SERAL OUTPUT Q eel A AI 24 3 8 FUSES mataban asap einen ene 27 4 START UP hatuna OUI Aou qose agite m iere 28 415 CHECK u ua n n a GR A piss 28 42 CALIBRATION CHECK noe ne EET eerte S 29 4 3 DEMO MODE os a rb p EO pe n 30 5 CALIBRATION iere Aer pre REO e ec da t EA hn 31 51 OUTPUT CURRENT RANGE SELECTION 31 5 2 CONCENTRATION CALIBRATION FROM KEYBOARD 31 9 3 FIELD CALIBRATION wise nel rs 31 24 BENCH CALIBRATION S csvset Sopcast deed on ees 32 5 5 MECHANICAL ZERO ADJUSTMENT esee nennen een een een nen 33 5 6 SENSOR RANGEABILIT aen n c as ee ere EE etd 34 5 7 EEPROM PARAMETERS ite aa an it eat 34 3 8 TEMPERATURE CALIBRATION er u al 35 539 INSTRUMENT VERIFICATION etre P n eR Ue e HE Rb es 35 29 1 DEFINITIONSQ rini EH id aen Ep 35 5 9 3 VERIFICATION OF REFRACTIVE INDEX R L 36 5 9 3 CORRECTIVE ACTION IF THE VERIFICATION FAILS eee 36 6 MAINTENANCE a reote r ee re Pe tren deett neue e etes 38 6 1 REGULAR MAINTENANCE yere rece epe e hi e a nana
13. 2 years from the date of delivery INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 17 3 MOUNTING 3 1 SENSOR LOCATION The recommended mounting is in a pipe bend with a vertical flow upwards before the sensor and a horizontal pipe after see mounting recommendation Figure 3 10 By this mounting is obtained 1 Selfcleaning of prism due to the flow directed against its surface 2 Efficient drainage when the pipe is emptied The cable connector socket of the sensor should be directed downwards The sensor is designed to be installed directly in a process line If the sensor is located outdoors some basic protection against direct exposure to sunlight and rain should be provided Special care should be taken if the pipe wall is translucent e g of glassfiber because light from outside reaching the prism will disturb the measurement Air cooling Normally draught and natural convection provide sufficient air cooling There must be no obstacles to air flow around the sensor head The red sensor cover should not be exposed to high temperature radiation If the ambient temperature is higher than 45 C 113 F the air cooling should be improved by blowing pressurized air against the red sensor cover This is also recommended when the process temperature is above 110 C 230 F when the ambient temperature is above 35 C 95 F The pressurised air
14. 38 60 2 DIAGNOSTICS n or eem dU RR e a ar qu aq doe 38 6 3 DISPLAY MESSAGES src peter oh eh ee 41 6 44 INDICATING TRANSMITTER Bante ean end 46 65 SENSOR CHECK rore ipe e p e RE ash E ri 52 6 6 TEMPERATURE MEASUREMENT 5i sz on 58 6 7 PRISM GASKET REPLACEMENT sasa isisa aus 58 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A 000007 DocumentRevision No INM 3A Rev 1 2 Effective March 24 1999 PR 03 PARTS LISTS asam hte emt iod eec et i EAR eas e a o eiat 62 TA SENSOR ise eae ate a A etre m o 62 1 2 INDICATING TRANSMITTER eR eee ERREUR 64 8 PRISM WASH SYSTEM S heic beide eti ce iie 65 S1 to rp RE EE RR IER RO qa paqana 65 82 RECOMMENDED WASH PRESSURES AND TIMES eese 65 83 PRISM WASH NOZZLES eet reete arr eei e RR e ROI RE ete e ent 66 8 4 STEAM AND WATER WASH SYSTEMS entren nennen reete nenne 67 8 5 HIGH PRESSURE WATER WASH SYSTEM eene nennen nennen nennen enne 67 9 RELAY UNITS Aie e e od ege e o e E A ue tte ee te 74 91 CONNECTIONS etitm aed ehe aod ee ene eA date 75 92 RELAY CONFIGURATION eese 76 9 3 WASH LOGICS AND SMART 77 10 ACCESSORY UNITS Sus DU A Sha DE qa upas 80 10 1 EXTERNAL OUTPUT UNIT
15. 43 8 5 HIGH PRESSURE WATER WASH SYSTEM Mounting according to Figure 8 51 to 8 52 Warning Pressure increase can occur in a closed pipe section when the high pressure pump is operated K Patents recommends to mount a pressure relief valve in the pipe section Relief pressure should be according to pipe pressure rating INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 68 A8 03 44 SNOLLVOISIOAdS LYVd 1474 5 Y LI M3LLINSNVSI SNLVOIGNI SLNALVd SSH Z9V 0 3d MOSN3S Z SINALVd 080 4d LINN AVI3N SIN3LVd 3 MOSN3S YJLLINSNYML 9NILVOIONI N33M138 L008 4d 318 2 SIN3IVd 3 LINA WYJLLINSNYML ONILVOIGNI N33M138 1108 44 318 2 G SINJLVd M 19 61 943 1132 014 9 5 JAYA GIONSIOS WYALS Z d ANVIINVS 8 d dvyl 6 d Y3NIVELS OL YJNOLSNO 1 9 318 2 010 3105 Y3NOLSNI 7 1 W3IS E Y3NOLSNI v V Jdid W3IS EL YJNOLSNO 011 09 ATddNS 33MOd OV FL Gay J OL 8 4 aR ee ea
16. 80 BRIX Figure 5 60 Sensor rangeability 5 7 EEPROM PARAMETERS How to enter the calibration parameters into the non volatile EEPROM memory is described in Section 2 8 The factory settings are found in the DELIVERY DATA SHEET Figure 5 70 shows how the microprocessor program is using the parameters BIAS TNM UNIT CONC TEST sl gt TCOEFF gt DAMPING Le DECIMALS DISPLAY TCAD SQUARE CAD STAN DARD RI DISPLAY RI BIAS FIXED ZERO RI GAIN RI OUTPUT RI CUBE TEMP gt OH RI SQUARE j TMPCO TBIAS TEMP C p UNIT TEMP TMPC 1 DISPLAY DATA SENSOR ADAPTION Figure 5 70 Calculation flow diagram The ENTER procedure contains a check of the EEPROM parameters format A number outside the range limits cannot be entered Only if the range limits of a parameter contain a decimal point the parameter may contain a decimal point For some parameters the number of characters is limited character digit decimal point or minus sign Indicating Transmitter exchange If the Indicating Transmitter is exchanged then all parameters and configuration determinations have to be changed INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 35 Sensor exchange To substitute a Sensor by a spare Sensor calibrated
17. INM 3A Rev 1 2 Effective March 24 1999 13 Hormal operation Figure 2 72 The Optical Image System configuration soft key Main program and sensor processor and sensor interface processor versions Connection and processor versions of accessory units Current output scale E g 4 20 mA 40 0 60 0 CONC Two soft keys Relay configuration and Wash times For details see Section 9 2 One soft key Switch configuration see Section 2 8 Sensor head soft key Head temperature Head humidity For details see Section 6 1 2 8 CALIBRATE The soft key Calibrate brings forward two alternative soft keys Optical image and Parameters Optical image soft key Displays all raw data from the sensor including the optical image followed by the SCALED IMAGE SLOPE AND IMAGE DIAGNOSTICS screens see Section 6 5 COHC CHHHGE PARAMETERS Frism wash 6 Standard RIc25 C Relay unit Language Output signals Password Temrer ature 1 Y Switch inrutz E Divert control 5 Figure 2 81 Change parameters menu Parameters soft key Displays the CHANGE PARAMETERS menu Figure 2 81 which contains INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 14 CONC RI soft key Further by the soft key Parameters the calibration parameters for the concentration are entered see Section 5 2 Menu selected
18. RMX in the range 170 190 LED The LED exposure control signal on a light intensity scale 1 255 The flashing red light of the LED can be seen directly Figure 6 80 If the operation is correct the displayed LED value should be above 20 and below 200 Scans Number of optical images during one calculation cycle typically 1 or 2 The scan pulses with 5 V amplitude can be measured at TP 3 Figure 6 50 A D This refers to the temperature measurement Section 6 6 Sts Sensor status bits determined by the type of Image Detector Card 00h indicates a standard process refractometer PR 01 S or NO SENSOR SIGNAL 02h indicates an intrinsically safe process refractometer 01 S EX FM 04h indicates a sanitary refractometer PR 03 One bit added 01h 03h O5h indicates DETECTOR TIMEOUT respectively HT Sensor head temperature sensor reading This value is used in calculating the actual Sensor head internal temperature HH Sensor head humidity sensor reading The actual relative humidity in the Sensor is calculated from HH and HT Sensor faults Sensor faults can be distinguished by the following indications The diagnostic message No sensor signals The fault may be in the single path from Image digitizer to the interconnecting cable to the Processor card see Figure 6 22 If the signal path is OK then the Image digitizer does not work Check the 24 V and the 5 V supply to Processor card Figure 6 52 If the supply is
19. appear The diagnostic message should be Normal operation or if the process pipe is empty Low concentration no sample For any other message consult section 6 3 The display should show the current process temperature TEST value in the display should be in the range 8 248 A value near 248 indicates a clean prism in an empty process pipe For the concentration reading see Section 4 2 Press soft key Display for additional data Figure 2 71 like e g output in mA Further data is obtained by soft keys System configuration and Optical image Figures 4 10 and 4 11 show typical optical images for K Patents Sanitary Refractometer PR 03 Return to previous display by RESET key Measure the output signal It should agree with the mA display IMPORTANT If a prism wash controlled by a Relay Unit is employed press soft key Start prism wash and check the wash sequence The TEST value should clearly increase and the concentration reading decrease during wash The Start prism wash soft key does not show if no relay is specified as wash relay If the initial check is not OK turn to Section 6 D OPTICAL IMAGE TEST 245 0 30 2 G Ende 11 Li Figure 4 10 Typical optical image for PR 03 when the pipe is empty INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 29 Figure 4 11 Typical optical image for PR 03 during normal mea
20. for the same range keeping the Indicating Transmitter the ten constants in the sensor adaption zone Figure 5 70 have to be entered according to the constants of the spare sensor see the DELIVERY DATA SHEET If the Sensor is calibrated for another process medium the Bias Gain Square and Cube have to be determined by Field Calibration Section 5 3 The calibration constants Concentration linearization Bias Gain Square Cube Normally a 6 character number and included Enter from Calibration Parameters CONC Parameters Temperature compensation TNM Temp coeff Temp TC adj If Temp coeff 0 and TC adj 0 then there is no temperature compensation Enter from Calibration Parameters CONC Parameters Linearization of Standard RI 25 RI Bias Gain Square Cube The values are specific for each sensor Enter from Calibration Parameters Standard RI Temperature adjustments TMPCO TMPCI are factory adjusted and specific for each sensor For Tbias see Section 5 8 Enter from Calibration Parameters Temperature 5 8 TEMPERATURE CALIBRATION Normally the process liquid temperature is considerably higher than the ambient Then the heat loss through the Sensor may cause the temperature display to be somewhat lower than the process temperature This will not impair the measurement and the difference can be ignored If however the temperature has to show an absolutely correct value then a bias in can be add
21. functions are 1 Concentration unit can be CONC CONC g l CONC OECHSLE or BRIX Also available is the unit RI x C which is RI measured in the laboratory at x C where typically x 60 C displayed as RI 60 C The unit RI x C should not be confused with Standard RI 25 C even if the x can be chosen as 25 2 Number of CONC display decimals 3 Damping time in seconds This is the time it takes for the concentration measurement to reach half of its final value at a step change of the concentration 4 Switch selected scales Provides four additional complete sets of calibration parameters see Switch inputs below 1 Prism wash Entering of prism wash times for the Relay Unit and a wash check and wash stop functions see Section 9 2 2 Relays Provides relay configuration see Sections 2 5 and 9 2 3 Switch inputs The microprocessor accepts four switch inputs A B C and D for connections see Figure 3 64 The function of each switch can be individually defined from one of four alternatives 0 Not defined which is the factory setting 1 Remote wash start for Relay Unit wash function and external Hold The external Hold is used with a wash timer other than the Relay Unit or to hold the signal during stops in an intermittent flow e g by contact from the pump control A wash start is also initiated when the contact opens if it has been closed longer than one minute 2 Defined
22. in a feed back control loop make the time lag small E g when a dilution valve is controlled mount the refractometer as near the dilution point as possible If the temperature varies along the process pipe select the position with the highest temperature Then the risk of prism coating is minimized because higher temperature means higher solubility and also lower viscosity Often the position with the highest pressure after pump before valve has favourable flow conditions without sedimentation or air trapping risks The sensor should be conveniently accessible 3 2 MOUNTING EXAMPLES K Patents Sanitary Refractometer PR 03 is connected to the process by 212 3A Sanitary clamp Figure 3 20 and Figure 3 21 For pipe diameters of 3 or above a ferrule is welded directly to the pipe wall A ferrule lenght 21 5 mm can be ordered from K Patents Flow cells for smaller pipe diameters are available from K Patents The inlet of the flow cells is coned down to obtain a good flow velocity against the prism The flow cells are exchangeable with standard 90 bend pieces INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 19 Pipe diameter 3 80 mm or larger NOTE SENSOR SHOULD BE 45 5 TO PIPE AXIS Sy NOTE THIS SANITARY FERRULE BE ORDERED FROM K PATENTS 5 EN Flow cell Pipe diameter 2 2 65 mm
23. module Image detector Document Revision No INM 3A Rev 1 2 Effective March 24 1999 63 Item Pcs PartNo Description lem Pcs PartNo Description 29 2 Screw M3x10 DIN 7380 A2 41 1 PR 9251 PR 03 LED assembly 30 1 Prism support 42 1 LED plate 43 2 Screws M3x4 DIN 1 PR 9004 H62 Prism set 44 1 PR 7125 Image detector 31 1 PR 9003 Prism gasket 45 2 Screw M3x10 DIN 7991 A2 32 1 H62 Prism 46 1 Screw M3x10 DIN 912 A2 33 2 Screw 2 5 DIN 965A 2 34 1 Prism plate 35 1 Lens locking ring 36 1 Lens 37 2 Lens 38 2 Pressure spring 7 8x6 39 1 PR 9001 CORE Optics module 40 1 PR 9250 PR 03 Temperature element assembly INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 7 2 INDICATING TRANSMITTER Item Part No Description Item Part No Description 1 1 Enclosure 3 1 Front panel 1 1 4 Mounting feet 31 2 Hindge 12 4 Screws 10 32 pan head 3 2 4 Screws DIN 912 M3 x 10 1 3 4 Screws 10 32 pan head 3 3 1 PR 7305 Key board 1 4 4 Cable clands PG 11 European 3 4 6 Screws DIN 799 DIN 965 M3 x 12 1 5 4 Conduit hubs 1 2 NPT Type ST 1 US 3 5 2 Ferrule 3 0 x 8 x 3 3 6 2 Stand off M3 x 10 2 1 Frame plate 3 7 4 Stand off M3 x 15 2 1 1 Screw DIN 912 M5 x 50 Zn 3 8 4 DIN 912 M3x 8 2 2 1 Washer DIN 9021 5 2 x 18 Zn 3 9 2 Nut DIN 934 M3 23 1 Washer DIN 9021 5 2 x 18 Zn 3 10 2 Stand off M3 x 15 2 4 1 Nut DIN M5 Nyloc N 3 11 2 Nut DIN 934 M3 2 5 1 PR 7301 Transfo
24. optimal calibration data will be faxed to the user 5 4 BENCH CALIBRATION The calibration can be checked off line using Standard RI liquids The check should be done at room temperature but the temperature does not have to be exactly 25 as the displayed value is temperature compensated If the sensor is hot let it cool down to ambient temperature Standard RI 25 Display Show the standard refractive index value referred to 25 For exact calibration please contact K Patents or your local K Patents representative Calibration parameters are changed by pressing Calibrate Parameters Standard RI 25 C from Normal Display For RI gain 0 the indication is 0 0000 For off set adjustment like in Section 5 1 the bias change has to be multiplied by 100 E g If indication is 0 0004 low add 0 04 to the bias for RI 25 C Standard RI liquids are available from R P Cargille Laboratories Inc 55 Commerce Road Cedar Grove New Jersey 07009 1289 U S A Phone 210 239 6633 Fax 201 239 6096 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 33 A 12 bottles set of RI liquids is also available at K Patents with part number PR 2000 The complete set with 24 bottles of liquids covers the RI range 1 300 1 530 as follows 1 300 1 390 Cat No 18032 AAA 1 2 Half Set Int 0 01 10 liquids 1 400 1 450 Cat No 18065 AA 1 5 Fifth Set Int
25. output span 3 Hold function Can be selected active or inactive 4 Range Select 4 20 mA or 0 20 mA 5 Source Select one of following alternatives _ Not defined _ CONC RD Standard RI 25 Temp Temp F Example For source C zero 20 span 80 the output signal 4 20 mA corresponds to 20 100 C INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 82 11 K PATENTS SANITARY REFRACTOMETER CALIBRATION DATA REPORT CUSTOMER ADDRESS REFRACTOMETER MODEL SERIAL NO SAMPLE DESCRIPTION DISSOLVED MATERIALS SOLVENT LABORATORY METHOD DESIRED SCALE OUTPUT 0 100 4 20 MA UNIT DATE SIGNATURE DISPLAY READINGS SAMPLE SAMPLE CONC TEST SAMPLE DATE No CONC LAB AND TIME INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999
26. sample determination indicates normal concentration then check optical image Section 6 5 decision according to Figure 6 54 HIGH PROCESS TEMPERATURE The process temperature exceeds the High temperature limit set from keyboard after Calibrate Temperature Section 2 8 5 This alarm can be enabled disabled The cause may be abnormal process conditions or a leaking prism wash steam valve INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 42 LOW LIGHT INTENSITY The shadow edge is still detected but the light intensity is low see Figure 6 54 This message probably indicates onset of prism coating DIP IN IMAGE Inspect the optical image for irregularities Missing or low pulses in the light area may be caused by a speck of dust on the CCD window HIGH CONC PRISM COATED Indicates prism coating Action Clean the prism surface Use a strong solvent like nitric acid If message persists check optical image Section 6 5 decision according to Figure 6 54 Note May be caused by exceptionally high concentration WASH STOP EXT STOP Caused if an input switch is activated for external wash stop and the corresponding input switch is closed Section 2 8 PRISM WASH FAILURE The TEST value during prism wash did not exceed TEST limit or did not increase more than TEST difference Section 9 2 EXTERNAL OUTPUT FAULT The Ext
27. separate Relay unit PR 7080 4 relays or a built in wash control Relay unit WR 2 relays RELAY UNIT PR 7080 4 RELA YS The Relay unit PR 7080 contains 4 relays Figure 9 01 from left to right Relay A relay B relay C and relay D Above each relay there is a yellow LED Light indicates that the corresponding relay is ON and the output contact closed The enclosure classification is IP 65 Nema 4X 224 8 82 92 3 622 30 Bel u rm eo o z 2 3 3 Figure 9 01 Relay unit PR 7080 dimensions WASH CONTROL RELAY UNIT WR 2 RELAYS The Wash control Relay unit WR contains 2 relays Figure 9 02 from left to right Relay A and Relay B Next to each relay there is a yellow LED Light indicates that the corresponding relay is ON and the output contact is closed The enclosure classification is IP66 Nema 4X INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 75 S SL Lf T 80 Figure 9 02 Wash control Relay unit WR CABLE FITTINGS The cable fittings are delivered as one of two alternatives US 1 NPT TYPE ST 1 conduit hubs 4 pcs PR 7080 pc WR European BF11 PG11 cable glands 4 pcs PR 7080 2 pcs WR Note Seal all unused fittings with blind washers Each relay has one switch contact for max 250 V AC max 3
28. solid state light source The following rules apply Keep the sensor head and the Indicating Transmitter clean and dry Check that the ambient temperature is not above 45 C 113 F The sensor head should not be too hot to keep a hand on Check that the prism wash works see Section 8 1 a year check that the prism surface is smooth and clean To replace prism or gaskets see Section 6 7 The PR 03 sensor has an internal moisture detector see below The reading is obtained from the Indicating Transmitter display Key sequence Display Sensor Head Check that reading once a month An increasing signal indicates condensate forming in the sensor head if the process temperature is below ambient or prism leakage If the moisture reading exceeds 3096 change the drying agent If the reading exceeds 50 check the prism seals The drying agent is contained in a perforated aluminium case inside the sensor head cover The drying agent should appear blue through the window in the aluminium case Regenerate the drying agent by keeping the perforated aluminium case in a 130 150 oven for a few hours or dry it with a hot air blower 6 2 DIAGNOSTICS For a systematic approach to the identification of a faulty component a basic understanding of the operation is necessary Read sections 2 3 to 2 8 for general information Use flow diagram Figure 6 20 for guidance The trouble shooting normally starts with a
29. system and a front panel with a Liquid Crystal Display LCD and a Keyboard The output signals are a 4 20 mA concentration signal and a Serial output signal RS232 or RS485 alternatively There are also two built in signal relays Relay 1 and Relay 2 on the power supply card inside the Indicating Transmitter These two signal relays can be configured to any relay function described in Section 9 2 except preconditioning or wash control Configurations are made from the main calibration menu see Figure 2 61 Note the default setting for the built in signal relay 1 is No Malfunction and for the relay 2 Internal Humidity Above 50 A closed contact on the relay 1 indicates that the instrument works properly It is recommended to use this relay for alarm purpose in a control system For connections see Figure 3 61 The Indicating Transmitter also accepts 4 input switch closures for signal HOLD or scale selection A serial bus connects the Indicating Transmitter to the external units such as Relay Unit See Section 9 or External Current Unit Section 10 1 Unauthorized access can be prevented Knockout padlock provisions are included in both cover latches For password protection see Section 2 11 The microprocessor system linearizes the concentration reading like in the example Figure 2 51 and performs an automatic temperature compensation INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1
30. the circuit card Figure 10 10 a The green LED LI is lit if the processor on the card works correctly b The red LED L2 is lit if correct input data are missing Connections The External output unit is connected to the serial bus see Figure 3 63 and Figure 10 10 Note the 120 Ohm closing resistor in Figure 3 63 The output mA signal is connected to the terminals 42 and 43 see Figure 10 10 O OD 18 12 2415202 Xx s Wu 08 Ce B 1013 CS s z s 106 L ll 00001 a fle Sme TA amp HHO OL eS Y r e hd l e 9 10 11 12 1314 8 91011 12 1314 Rev A 42 43 4 20mA A B Figure 10 10 External output unit component lay out INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 81 Configuration To program the External output unit from the key board of the Indicating Transmitter start with the sequence Calibrate Parameters Output signals External output 1 Zero measurement value corresponding to 4 mA 2 Span measurement value span corresponding to mA
31. to be Acceptable value from Normal checked Displa below 200 Image diagnostics C A A A A Max intensity OK Endpoint below Yes 75 Slope OK Left curve OK 4 image below commer pO Right curve OK If the above checks 1 and 2 fail please contact K Patents or its international representative for corrective action If the above check criteria are met the instrument can be calibrated Calibration is done with minimum five preferably seven standard R I liquids as follows Mount the sensor on the service bench Take certified standard R I liquids The middle value should correspond to the middle value indicated in the Final test section of the latest Delivery data sheet or Standard calibration sheet of the PR 03 Then take 2 3 values above and below this middle value Record R I value and corresponding Test and Temperature values from the Normal display of PR 03 Send the values table to K Patents to K Patents international representative K Patents calculates new calibration parameters for R I measurement Key in the new parameters soft keys C B 6 1 2 3 4 and then repeat the verification check as described in section 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 38 6 MAINTENANCE 6 1 REGULAR MAINTENANCE The need for regular maintenance is minimal due to the construction with no moving parts no trimpots and with a
32. to select alternative process mediums There are all together four alternative mediums selectable by closure of the corresponding switch If no selection switch is closed the normal medium is selected Maximum number of mediums is five Normal A B D Note The range will not change Example medium 1 20 40 Sugar medium 2 20 40 Salt 3 External wash stop An input switch can be configurated to an external wash stop to prevent the prism wash when the corresponding input switch is connected External wash stop message will show when automatic wash is activated The input switch can be set to protect the refractometer e g if the process is stopped 4 Calibration stop input switch can be configurated for calibration stop Activating and connecting the input switch will prevent calibration through software INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 15 4 Output signals menu 1 Current output Sets the zero and span in concentration units that correspond to 4 20 mA output The signal range 0 20 mA can also be selected The 0 will be slightly above 0 mA typically 0 06 mA An active HOLD function locks the signal during prism wash by the Relay Unit When the HOLD function is inactive the wash results can be seen as negative peak in the output signal 2 External current output Defines the scale for the External Output Un
33. 0 01 1 460 1 530 Cat No 1809X in steps of 0 01 Std 1 4 fl oz Figure 5 40 Sample holder Use a sample holder Figure 5 40 Then just a few drops of sample are enough The sample must be covered to prevent outside light to reach the prism Sample leakage from holder may give measurement er ror Always use repeated measurements for each sample Sample holders are available at K Patents Part number PR 1010 Dispose of used RI liquids Do not put liquids back into the bottle after use Off line calibration using process liquid seldom gives reliable results problems are caused by low flow which makes sample to form an unrepresentative film on the prism sample evaporation at high temperature or undissolved solids at low temperature giving deviations from laboratory determinations anageing sample which is not representative outside light reaches the prism Calibration using the process liquid should be made in line see Field calibration Section 5 3 5 5 MECHANICAL ZERO ADJUSTMENT The model PR 03 needs no mechanical adjustments Calibration is made using the keyboard INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 34 5 6 SENSOR RANGEABILITY Gee R I rT T rT T LT 1 1 rT 1 rT 1 1 30 1 35 1 40 1 45 1 50 1 55 1 60 ANITA I 0 10 20 30 40 50 60 70
34. 0 2 TEST 155 7 Hormal operation Calibrate Figure 2 60 Normal Display INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 11 6 1eudeu ees Aejas 0 sJejoJ jun euis UI ING 01 19431 Z 10 Aejay i8 ON ISWROVSIGWGITZ SSNILHSYM O NouvunsiiNoo 5 8 4 33800 dWa1 9 WALSASTO Avidsia a WNL S 531 05 031997195 HOLIMS 5 NOMEN ENO ATES WIS 3ano t INIL DD yy FOYN vordo Y 77 STVNI03G AVI4SIG ru onoo v k INTE svia L 3ALLOV E 5 135 c dyomssva 6 lt 0 1041NOD ra 8 4 aano utk vow auvnos tule Ni 2 iu 5 9 4 svig ia Av1dsia Woud LINN pacers GHOMSSvd anale lt 914 Sual
35. 1 TABLE OF CONTENTS Il 5 1 2 GENERALINFORMATION uidet iata Ate imei 3 2 1 EQUIPMENT erem epe eR De ten bore bre itp perpe 3 2 2 STANDARD SPECIFICATIONS nerit eer ttt neret OO tese 4 221 MODEL eite inepte dete 5 2 3 PRINCIPLE OF MEASUREMENT nc ote o Der ee e etre ciens 7 2 4 SENSOR DESCRIPTION etudes eren ees 8 2 5 THEINDICATING TRANSMITTER 2 0200202000 00000000000 eene enne ene 9 2 6 DISPLAY AND KEYBONRD one e ee la na 10 225 INFORMATION DISPLAY itti ert 12 28 CALIBRATEL L nne ode ep RO RAT OI A RR REIR OU aus 13 2 9 COMPATIBILITY WITH K PATENTS PROCESS REFRACTOMETER 01 15 2 10 PROGRAM VERSIONS ies aaa Sm aa nla lo tee tete 16 2 11 PASSWORD onere met ia eras emer ets 16 2 12 WARRANTY teet nt eg or PERCHE eee nin 16 MOUNTINGI tei ht A ERU ans EE REO cs cte p s EE CREE EUER 17 31 SENSOR LOCATION beant RI eee a 17 32 MOUNTING EXAMPLBS gne dp u E E Sa DO e 18 3 3 MOUNTING SENSOR nre ppt De be beg prts ree RERO rie ST 21 34 WASH NOZA E eR UR ge mti qu neo 21 3 5 INDICATING TRANSMITTER 4 e itt nit tee Rete pne ee E G ih p ti ie 21 3 65 v ELECTRICAL CONNECTION S ea ee eere e eoa to erst 21 3 15
36. 121314 15161718 27 28293031 SENSOR FIELDBUS 4 20mA RLY1 RLY2 43 44 45 46 25 26 47 48 49 50 Figure 4 30 Demo connection INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 31 5 CALIBRATION K Patents Sanitary Refractometer is delivered precalibrated according to the DELIVERY DATA SHEET Adjustments or change of range are made by keyboard entry Sections 5 1 and 5 2 For sensor rangeability see Section 5 6 Field calibration The final calibration to obtain full accuracy is made by sending data to K Patents or local K Patents representative for calculations Section 5 3 Temperature calibration is explained in Section 5 8 5 1 OUTPUT CURRENT RANGE SELECTION It 15 possible to change the concentration range of the output current also when the instrument is installed and operating Example To change 4 20 15 25 to 4 20 mA 10 30 key in the sequence Calibrate Parameters Output signals Current output and then enter Zero 10 and Span 20 5 2 CONCENTRATION CALIBRATION FROM KEYBOARD The concentration display should be in agreement with laboratory determinations Deviations can be corrected from keyboard if the diagnostic message is Normal operation Off set adjustment A change of the calibration constant Bias influences the CONC reading the same amount Key in Calibrate Parameters CONC RI Parameters
37. 2 Effective March 24 1999 10 Raw data Curve fitted to the data Figure 2 51 BRIX diagram Figure 2 52 Image analyzing algorithm 2 6 DISPLAY AND KEYBOARD A built in Demo program can be used for training See Section 4 3 The Normal Display Figure 2 60 gives the following information Concentration large size characters in g l or other units see Section 2 8 Process temperature in C Alternatively F can be displayed see Section 2 8 TEST value The number of photocells at the light side in the optical image divided by four Diagnostic messages like Normal operation see Section 6 3 Activated alarms Soft Keys The definitions are shown above the corresponding keys A B C and D For the Normal Display Figure 2 60 pressing key A starts a prism wash cycle when a Relay Unit Section 9 is used for prism wash If a Relay Unit is not used for that purpose the soft key Start prism wash is not visible A timeout is set for all displays The timeout is one hour 60 minutes for the following displays Diagnostics Slope Scaled Image Raw Sensor Data Optical Image Normal Display The timeout is one minute 60 seconds for all other displays During the timeout the display functions the same way as pressed the Reset key The keys C and D change the Normal Display to a Calibration menu Figure 2 81 or an Information Display Figure 2 71 respectively PROCESS TEMPERATURE 3
38. 3AVuvd AV 1dSIG LINN dW3L 5 IVIWdON ANAL 318 510 8 4 svi v 114110 1viuas 4 114110 wNuapa g 4 STVNOIS 1nd1no 114110 1N3uuno L SLNANI HOLIMS lt Av13a Av i3 3ivusnvo 9 e4 uNnaviau 4 Z AV Hu HO L INIL HSVM 1uvLs V HSVM LHVNSTO ANIL HSYM lt dois Hsvm 8 3WILNOILIQNOO3ud L 4 Lj e M03HO HSVM V sousoNevia v 4015 3OVNI 031 205 JOVNI 1V01140 V Effective March 24 1999 Document Revision No INM 3A Rev 1 2 The selection tree 2 61 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER 03 Figure 12 The selection tree The display selections are structured like a tree as shown in Figure 2 61 Using the soft keys A B C D it is possible to select the next display In some cases the selection is made from a menu using a numerical key In Figure 2 61 the Soft Key selection is indicated by letters A D menu selection by numbers 1 9 The display itself provides guidance to find the right path step by step which minimizes the need to consult the manual The RESET key is used to move backwards for each RESET the next display back is selected Data entry Wh
39. 6 72 b INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 60 Put prism support U upon gasket Keep the gasket in place with a fingertip in the middle Check that the gasket is symmetrical around the middle of the prism surface Tighten the screws L to the bottom Figure 6 71 b Check that the temperature sensor P is properly springloaded In outer position the sensor tip is level with the prism surface Figure 6 71 b It should flex inwards 2 3 mm as incidated by an arrow but return to the outer position Now the CORE optics module 9001 is assembled It should be checked before mounting into the sensor head 6 7 Clean the window of the CCD element V Figure 6 71 a Attach the Image detector card to the analyzer module by the two screws F with conical heads Connect electrically all cards with connectors A B C and D Connect the indicating transmitter and inspect the optical image at the RAW SENSOR key in Calibrate Optical image The optical image must form a smooth curve Dips or separate single points indicate that the optical 8 9 10 surfaces e g the CCD window are not clean Important The prism must be covered to exclude external lieht When the image is OK switch power off and disconnect all cards Dismount the Image detector card from the analyzer module Fit the anal
40. A The Relay units have also two monitoring functions with two LEDs a The green LED L5 is lit if the regulated 5 V supply to the processor is within limits 4 7 5 4 V and the processor operates correctly Note that the 24 V supply from the serial bus has to be checked with a Volt meter b The red LED L6 is lit if correct serial data are missing but the processor operates correctly Both checks have to be OK otherwise all relays will go into OFF state 9 1 CONNECTIONS The Relay Card is connected to the serial bus for PR 7080 and to the plug connector P2 on the power supply card for wash control relay unit WR see Figure 3 63 The relay contacts go to the connector strip Figure 9 10 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 76 A BL 0 44145 46 47 34849 150 51 Figure 9 10 7080 Relay output connections In wash control relay unit WR only A and B available 9 2 RELAY CONFIGURATION The relay functions of the Relay unit and the wash timer settings can be seen from the Indicating Transmitter Press the key sequence Display System configuration Relay configuration or Wash times The relay functions can be reprogrammed any time from the calibration menu Program a relay by the following steps Press Calibrate Parameters Relays Select the relay A B C D to be programmed Note Only Relays A and B are visib
41. Bias to read and change the Bias Example If the CONC display is 26 and the laboratory determination is LAB 28 then a value Bias 23 456 should be changed to Bias LAB CONC 25 456 Note The CONC reading is restricted to positive values even if the mathematical calculation gives a negative value For a negative the display shows 0 0 For BIAS adjustment it is useful to know the real CONC value For this reason the calculated negative CONC reading is shown in the Calibration branch of the Selection tree Figure 2 61 Warning Never try to change Bias in a day to day manner or week to week Frequent bias changes will increase the measurement variation not decrease it Amplification adjustment The size of CONC changes are directly proportional to the calibration constant Gain The point where TEST 128 is not influenced by Gain From two measurement points the new Gain can be estimated by the formula Gain LAB 1 LAB 2 CONC 1 CONC 2 After the change of the Gain the Bias has to be determined by a new sample The constants Square and Cube are linearity corrections that can be provided by K Patents see Section 5 3 5 3 FIELD CALIBRATION The most accurate calibration is made under normal process conditions employing the users standard laboratory determinations of sample concentration K Patents provides a FIELD CALIBRATION service to optimize calibration constants based on data supplied by the user INSTRU
42. CTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 32 The user should systematically record calibrating data by CALIBRATION DATA last page in this manual Each data point consists of LAB Sample concentration determined by the user From refractometer display Section 2 7 CONC Measurement in concentration units TEST Number of photocells divided by 4 in model PR 03 on the light side of the optical image primary measurement TEMP Process temperature measurement in centigrades Note A data point is of use for calibration only when the diagnostic message is Normal operation Do not take samples during the prism wash A data point is useful even if the concentration value is outside the range of the output current To achieve an accurate calibration the sample has to be taken correctly sampling valve and the refractometer should be installed in the same place in the process Take the sample and read the display at exactly the same time For hot samples use a tight container avoid evaporation Run the sample before starting to collect avoid old sample that has remained in the sampling valve A completed CALIBRATION DATA REPORT with 5 15 calibration points covering the measurement range can be sent to K Patents or local K Patents representative by fax A computer analyses of the data will be made at K Patents and an
43. ER MODULE PRISM Figure 6 21 Information and power flow INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 41 4 o 00 c zim Image Digitizer Indicating transmitter Figure 6 22 Cable signals 6 3 DISPLAY MESSAGES The diagnostic messages and the phase codes are listed in Table 6 30 The diagnostic messages are listed by increasing priority E g if we simultaneously have Temp measurement fault condition and No sensor signal condition the display message will be No sensor signal NORMAL OPERATION If the CONC display is not according to specifications take samples and use Calibration Data Report Section 5 3 Also check that the prism surface is clean DIVERT CONTROL Divert control is not used in the PR 03 If such message occurs then deactivate according to Section 2 8 RETRYING WASH The prism wash has failed the wash check and will repeat the wash as many times as is set by the parameter Wash retry Section 9 2 WASH STOP TEMP LIMIT Caused when the Wash stop is active and the process temperature is below temperature limit Section 9 2 The message is shown until wash succeeds or the RESET key is pushed LOW CONCENTRATION NO SAMPLE Probably caused by exceptionally low concentration or empty process pipe Action If
44. ING TRANSMITTER The Indicating Transmitter should preferably be located in an easily accessible well lighted and dry area The enclosure must not be exposed to rain or direct sunlight Avoid vibration Take interconnecting cable length into consideration The enclosure is mounted on a wall using four mounting feet Figure 2 20 Do not drill mounting holes in the enclosure Note The LCD display has an operating temperature range of 0 50 C and a storage temperature range of 20 60 C Check the serial number from the label Figure 2 11 An Indicating Transmitter can be exchanged for another of the same model but the current calibration constants have then to be entered by the keyboard Section 5 7 For compatibility information see Section 2 9 3 6 ELECTRICAL CONNECTIONS The electric terminals of the Indicating Transmitters are all on the Power Supply card Figure 6 40 This is accessible by opening the enclosure and the front panel The front panel swings out after the two screws to the right have been loosened Section 7 Parts list Indicating Transmitter item 3 14 Power The power is specified in the DELIVERY DATA SHEET and on the Label Figure 2 11 The position of the power select switch on the Power Supply card Figure 6 40 SW2 should also be checked The power select switch has two positions 220 240 V 50 60 Hz or 100 115 V 50 60 Hz The primary AC power is connected to a separate terminal strip 39 40 41 on the Pow
45. K and it should not be touched If the concentration output does not agree with laboratory values a Field calibration Section 5 3 should be done The video signal can also be measured directly by an oscilloscope Use an oscilloscope with a 10 MOhm probe 10x in AC mode Connect the signal ground to TP and the channel to TP4 see Figures 6 52 and 6 50 The duration of one image is 3 ms The voltage amplitude is 2 5 3 7 V corresponding to Indicating Transmitter display 0 255 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 53 IMAGE DIGITIZER CARD PROCESSOR TO INDICATING TRANSMITTER pa 5V SCAN LED A D 7N 7N 7N p 9 o gt T IMAGE DETECTOR CARD 1 CCD 1 1 1 1 1 1 1 1 1 1 1 1 Y A I 1 1 1 1 1 1 1 1 1 1 A 2 5 7 Figure 6 50 Sensor information power flow 5 F F L 5 H s H H Figure 6 51 Optical image and raw data INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 54 Raw data explanations RMN RMX Minimum and maximum of the raw video signal This signal is calculated on the Processor card from the video signal The scale is 0 255 corresponding to full scale on display The light intensity is controlled to keep
46. Least significant 7 bits are taken into the sum the parity bits are zeroed INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 27 Record terminator The record is terminated with ASCII characters CR 0d hex and LF 0a hex to make the record a text line 3 8 FUSES Fuses printed on circuit board PR 7030 Fuse 22 5 x 20 mm TIA slow AC Main power protects electronics against wrong primary voltage Fuse F3 5 x 20 mm T63 mA slow 4 20 mA output protection Fuse F4 5 x 20 mm T2A slow Secondary main fuse Fuse F5 5 x 20 mm T500 mA slow Sensor power protection Fuse F6 5 x 20 mm T500 mA slow Serial bus protection Fuse F7 5 x 20 mm TIA slow Processor card protection Note For a CSA Certified instrument use only CSA Certified fuses F1 F2 F4 F7 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 28 4 START 41 INITIAL CHECK Check that the Serial Numbers of the Sensor and the Indicating Transmitter match Section 2 1 Check wiring and supply voltage Section 3 6 Press the main power switch to ON position The three green LEDs LD1 LD2 LD3 on the Power Supply card Figure 6 40 are then turned on The display will first show which sensor the microprosessor has identified 01 or PR 03 Then the Normal display Figure 2 60 will
47. OK change the Image digitizer card The diagnostic message Detector timeout The scan pulses Figure 6 50 are missing at TP 3 Figure 6 52 Check the 15 V supply to the Image detector card Figure 6 52 If the 15 V supply is OK but the sync signal TP2 is absent then change the Image detector card The sync signal is similar to the video signal but the pulse amplitude is constant Check also the main power selection switch position see Section 3 6 Scaled image The following display is the scaled image Figure 6 53 The optical image is now modified mathematically The following information is provided where the numbers refer to Figure 6 53 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 55 L1 LED PT100 CI BLACK md RED woe RED L3 5 L4 321 321 c S O MAGE DETECTOR O O O 2 OO 3 3 5 6 7 8 IMAGE 9 DIGITIZER
48. PR27090 2 1 n E eternitu 80 11 K PATENTS SANITARY REFRACTOMETER CALIBRATION DATA 82 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A DocumentRevision No INM 3A Rev 1 2 Effective March 24 1999 2 GENERAL INFORMATION 2 1 EQUIPMENT The K Patents Sanitary Refractometer consists of three parts Figure 2 10 the Sensor A the Interconnecting Cable B and the Indicating Transmitter C SERIAL NUMBER A B Figure 2 10 Equipment The K Patents Sanitary Refractometer provides a 4 to 20 mA DC output signal proportional to process solution concentration serial output is also available as a standard Identification By Serial Number S N label Figure 2 11 on the Indicating Transmitter front panel and by Serial number on sensor label Figure 2 10 Figure 2 12 e g 97A25 1029 SANITARY REFRACTOMETER IT RE GP S N 97A25 1029 100 115 220 240 V AC 50 60 Hz 15VA TAG Figure 2 11 Identification label Indicating Transmitter 46 00 KPATENTS SANITARY REFRACTOMETER 03 62 O S N 97425 1029 Figure 2 12 Identification label Sensor INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 2 STANDARD SPECIFICATIONS Refractive Index range Accuracy Speed of response Damping time constant Process temperature Temperature compensation Ambien
49. SANITARY REFRACTOMETER PR 03 A Figure 6 41 49 Processor card The function of the Processor card is described by the block diagram Figure 6 42 and the component lay out Figure 6 43 When measuring voltages on the Processor card it is important to remember that some parts are galvanically separated form each other see Figure 6 42 It is essential to use the right ground for measurement OV for processor and also for DC power supply Serial bus and Sensor TP CLGND is 4 20 mA current loop ground SGND is RS 232 RS 485 serial output ground is switch input common terminal Diagnostic LEDs Two LEDs on the Processor card indicate the CPU 80C186 activity see Figure 6 43 LED D3 is lit when the processor is running LED D4 is lit during interrupt service Both LEDs should show a blinking light if the processor is working normally Four rythms with different intervals are overlapping 10 ms clock 150 ms new sensor data 1200 ms new value calculation 1 s timer count The most obvious rythm is th 1200 ms first a short D4 blink then a 200 ms D3 flash For PR 01 the measurement interval is 800 ms Processor startup errors The processor hardware is checked on startup The startup failures are announced as blinking codes on the LED D3 The error code is 1 to 5 blinks on D3 with D4 dark The error code is the following 1 blink The chip select unit on the CPU chip 80C186EB is faulty 2 blin
50. ST values even TEST 8 High LED value press Calibrate Optical image especially LED 255 max See Section 6 5 Prism wash e g by press Start prism wash does not increase the TEST value the appropriate amount For steam wash TEST should be close to 248 for water wash close to the TEST value for water Dropin the Slope value e g from 2 to close 1 press Calibrate Optical image Scaled image Slope In most of the applications the prism will keep clean but if coating occurs check the following Sensor mounted correctly in respect to flow direction arrow on sensor head Sufficient flow velocity Section 3 1 A temperature difference between process fluid and sensor probe may cause coating This may happen for small flows if the thermal insulation is inadequate In some cases it helps to insulate also the clamp connector If there is a coating problem it is recommended to try to increase the flow velocity e g by installing a pipe portion with smaller diameter If this cannot be done the prism should be automatically washed at regular intervals e g by steam or hot water 8 2 RECOMMENDED WASH PRESSURES AND TIMES To select a recommended wash pressure use the following table Pressure Nozzle Wash medium Wash time Normal over Maximum seconds process pressure PR 3366 pressure water 15 40 bar 600 psi 70 bar 1000 psi PR 3365 steam 3 2 bar 30 psi 4 bar 70 p
51. Use a cleaning solvent appropriate for the process medium 4 Use the certified standard R I liquids which corresponds to the values indicated in the Final test section of the latest Delivery data sheet or Standard calibration sheet of the PR 03 The three values are selected by K Patents calibration software to represent the used range 5 Check calibration with the three liquids The use of K Patents PR 03 sample holder PR 1010 is recommended to ensure a right portion of liquid on the prism 6 The R I calibration can be checked against the standard R I liquid values as follows Display Key in sequence Value to be Acceptable value from Normal checked Displa Information display D Standard RI 25 Sample R I 0 0006 5 9 3 CORRECTIVE ACTION IF THE VERIFICATION FAILS If the verification does not meet the acceptance criteria defined in section 3 then the following steps can be taken to correct the calibration of PR 03 1 Ensure that the prism is in good condition See Section 6 7 for more details of prism mounting and dismounting INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 3 1 3 2 3 3 3 4 3 6 37 The following values and diagnostics should be checked from the Indicating transmitter displays with the standard liquid on the prism Display Key in sequence Value
52. ady Figure 3 71 RS 232 connection to DTE type equipment e g computer The character structure conforms to the ISO 1177 standard It is compatible with the RS 232 interfaces of personal computers The character parameters are configuration selectable speed 1200 to 9600 bits s parity odd even or none stop bits 1 or 2 flow control hardware XON XOFF none The set of measurement results is output in a fixed length record The record consists of variable length numeric fields at fixed locations in the record The gaps are filled with ASCII spaces code 20 hex The record format is TEST float 1 decimal raw refraction value CONC float selected decimals concentration value temp C float 1 decimal temperature degrees centigrade RI25C float 4 decimals standard RI at 25 C phase 1 digit operation phase code error integer error code divert integer divert control status code checksum integer terminator CR and LF If a float value is too large for its field it is output in raw decimal floating point format 1234567 12 The first sign is the sign of the value The 7 digit field is the mantissa value after the decimal point The second sign is the exponent sign The 2 digit field is the decimal exponent The example value 1234567 12 is to be interpreted as 0 1234567E12 ie 123456700000 TEST The raw refraction value is the same as in the TEST display The value is displayed with 1 decimal The range is 8 0 248 0
53. ash wash failure failure Y Figure 9 31 Wash decision logics AUTOMATIC WASH START 1 The wash interval timer starts a wash at a preset interval after last wash independetly of how the last wash was initiated If the wash interval is set to zero the timer will not initiate a wash How to set the wash times is described in Section 9 2 2 The Smart wash starts the wash when the prism shows signs of being coated An early indicator of beginning coating is that the Slope decreases Slope is a measure of the sharpness of the optical image Section 6 5 The settings are made at Calibrate Parameters Prism Wash C Smart wash Slope limit A wash is initiated when the Slope value goes below this limit The Slope limit has to be set based on observations of slope values both at clean prism and at slight coating When the slope limit is set to zero this Smart wash function is inactive Minimum time 0 1440 min This parameter sets a limit to how often the Smart wash is allowed to start a wash When this parameter is zero the Smart wash function is inactive Maximum Test INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 79 This parameter should normally be set to zero Then it will not influence the Smart wash function It may be used for fine tuning The Smart wash will initiate Wash only if the Test value
54. ated from the keyboard Section 2 8 The concentration display is never locked but a large WASH will flash when the wash starts RECOVERY Shown during the time delay after end of prism wash when the concentration output signal is still locked HOLD Caused by input switch closure when the switch has been configurated as a Hold switch Section 2 8 NO MESSAGES No message Measure the mA output signal If this is OK then the display is probably faulty Note Ambient temperature above specifications may dim the display INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 45 Removed from divert control iority 6 High process temperature Temperature above set limit 6 ERE Equipment malfunctions 19 17 Wriong concentration parameters Makes outside range High internal humidity Sensor internal humidity too high Table 6 30 PR 03 messages INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 46 6 4 INDICATING TRANSMITTER Before investigating the Sensor it is advisable to make sure that the Indicating Transmitter is working The Indicating Transmitter can be tested separated from the Sensor by the following procedure Power off Disconnect cable to sensor Power on Then the diagnostic message should be No Senso
55. can be supplied by the ventilation system If no air is available it is possible to wind a copper coil for cooling water around the sensor head cover Process flow conditions The sensor is designed to make the prism self cleaning To ensure a representative sample and also prism cleaning action a good process flow should be directed against the prism surface A flow velocity above 1 5 m s 5 ft s is recommended For lower velocities prism wash Section 8 should be considered Flow velocity is calculated from v m s 21 2 Flow lit min d mm v m s 0 125 Flow Gpm d in Accumulation of sediment or of gas bubbles should be prevented If the process pipe vibrates support the pipe INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 18 lt CHECK CABLE LENGTH gt Figure 3 10 Mounting recommendations Selection of location To decide Where to mount use the following criteria 1 Process pipe is preferred to process vessel because favorable flow conditions are difficult to ensure in a vessel If the process pipe diameter varies select the position with the smallest diameter and accordingly highest velocity Then the prism keeps better clean If the pipe is coned up after a pump valve or magnetic flow meter then add a length of straight pipe before the coning up and mount the refractometer there If the refractometer is used
56. check of the Diagnostic message Table 6 30 Remember that a sluggish or irregular output signal can result from unfavourable process flow conditions section 3 1 Figure 6 21 gives a general description of the information and power flow between different parts of the total system Section 6 4 gives a complete description of the Indicating Transmitter Figure 6 22 shows the signals cable Section 6 5 describes the Sensor and the optical image Section 6 6 gives the details of the temperature measurement INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 39 TROUBLE TROUBLE FOLLOW NORMAL TOLD BY MANUAL OPERA DISPLAY SECTION TION MESSAGE 6 3 SIGNAL PRISM S OW DRIFTS SECTION UPWARDS NEEDS CLEANING PRISM WASH SECTION 8 1 MAKE A FIELD CALIBRATION SECTION 5 3 Figure 6 20 Diagnostics guide INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 40 POWER SUPPLY CARD PROCESSOR CARD lt SWITCHES j CURRENT OUTPUT SERIAL OUTPUT SERIAL DATA SERIAL BUS LD1 102 45V DC 24V SENSOR DATA AC DC INDICATING TRANSMITTER SENSOR IMAGE DIGI TIZER CARD IMAGE i DETECTOR SENSOR ANALYZ
57. cision according to Figure 6 54 HIGH INTERNAL HUMIDITY Caused when humidity inside the sensor is higher than 50 Action Remove the sensor from the process line and check it see Section 6 1 HIGH INTERNAL TEMPERATURE Caused when the temperature inside the sensor is higher than 60 C 140 F Action Improved air cooling is recommended see Section 3 1 DETECTOR TIMEOUT The fault is in the sensor Section 6 5 No signal from the Image detector card received by the Image digitizer card Probably CCD element or Image detector card failure The 15 V supply to the Image detector card may be incorrect due to a wrong position of the main power switch see Section 3 6 Action 1 Check the position of the main power switch 2 Change the Image detector card SENSOR TRANSMISSION ERROR The signal from the Sensor to the Indicating Transmitter is irregular The sensor transmission has overrun or there is a checksum error on the received message Error is caused by noise in the sensor transmission NO SENSOR SIGNAL There is a sensor signal timeout No signals have arrived during the 1200 ms measurement interval normally about 5 scans Probably the interconnecting cable is not connected properly WRONG CONCENTRATION PARAMETERS This occurs only if the output unit is selected to be RI x C Then this message occurs if CONC RI parameters give a value below 1 or above 2 To reset this message either k
58. ctive March 24 1999 36 Refractive Index R I calibration Calibration of PR 03 with standard refractive index liquids As a result of calibration procedure a set of R I parameters are calculated RIBias RIGain RISquare and RiCube These parameters define the calibration polynome used for refractive index measurement with a reference temperature of 25 C The Refractive Index R I calibration can be traced to national standards whenever certified standard liquids are used in the calibration Accuracy of calibration Maximum deviation accepted in calibration The total acceptable deviation for PR 03 is 0 0006 This comes from the accuracy of PR 03 R I 0 0002 and from the accuracy of the standard R I liquids used in the calibration R I 0 0002 Repeatability of the R I calibration Deviation from the latest R I calibration of PR 03 The repeatability of PR 03 is R I 0 0002 This can be verified as described in the following section 5 9 2 VERIFICATION OF REFRACTIVE INDEX R I CALIBRATION The R I calibration can be verified with three certified standard liquids as follows 1 Take the sensor from the process and mount it on a service bench 2 Allow the sensor temperature to settle close to 25 C The temperature does not have to be exactly 25 C since the differences in the calibration temperature are compensated by the software 3 Ensure that the prism is clean from process medium
59. dicating Transmitter Note K Patents Sanitary Refractometer PR 03 is using a 1024 pixel CCD element To keep the supporting computer software compatible for all K Patents Refractometers the TEST value number of photocells at the light side is scaled to the range 0 256 That is for PR 03 the number of high pulses Figure 2 41 is divided by four For automatic temperature compensation the sensor tip contains a process temperature probe F Pt 100 The response time is 1 65 a Optical image b Detector window and the photocells 0 c Pulse train from detector c TIME Figure 2 41 Image detector system INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 5 THE INDICATING TRANSMITTER c gt KPATENTS HOC DJ Figure 2 50 The Indicating Transmitter The Indicating Transmitter Figure 2 50 receives a serial signal from the Sensor describing the optical image and also giving the process temperature The microprocessor system displays the optical image Figure 2 72 and implements an image analyzing algorithm Figure 2 52 which identifies the exact position of the shadow shown in Figure 2 41 The Indicating Transmitter contains a power supply a microprocessor
60. e keys 4 20 mA 0 20 mA max load 1000 Ohm Galvanic isolation 1500 V DC or AC peak Built in hold function during prism wash RS485 RS232 Foundation Fieldbus Galvanic isolation 500 V DC or AC peak 100 115 V 220 240 V 50 60 Hz 15 VA Two built in signal relays max 24 V 500 mA DC AC Shielded cable 2 twisted pairs with individual shields 0 5 mm Digital transmission according to RS485 Standard 10 m 33 ft max 100 m 330 ft gt Cable fittings to the Indicating Transmitter European cable glands or US conduit hubs see Section 7 3 External output unit Section 10 1 Relay units for prism wash alarm Section 9 Prism wash nozzles for steam and hot water Section 8 Flow cells according to separate drawings available from K Patents Supply voltage and frequency Options and accessories User tag We reserve right to technical alterations INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 2 1 MODEL CODE Model and Description PR 03 A Sensor Refractive Index range limits 62 1 310 1 540 0 100 Brix Process connection Sanitary 3A clamp 2 inch Sensor wetted parts material SS AISI 316 L IT R Indicating Transmitter A A 1 2 inch NPT type conduit hubs BF11 PG11 Cable with GP option Electrical classification GP General pu
61. ed to the temperature reading Temperature bias Note A change of Temperature bias will cause a small change in the concentration output due to the temperature compensation 5 9 INSTRUMENT VERIFICATION A company maintaining its quality system according to ISO 9000 quality standards must have defined procedures for control and calibration of its measuring equipment This is for demonstrating the conformance of final product to specified requirements The company should identify the accuracy required and select an appropriate equipment for the measurements establish calibration procedures including check method and acceptance criteria calibrate the equipment at prescribed intervals against certified equipment having a known valid relationship to nationally recognized standards Where no such standard exists the basis used for calibration shall be documented This Section serves the users of K Patents Process Refractometer PR 03 in meeting the above requirements K Patents quality system is certified against ISO 9001 by Det Norske Veritas K Patents verifies the calibration of all delivered instruments according to similar procedure as described in this section 5 9 1 DEFINITIONS Many of the definitions used in this instruction have a special meaning related to the instrument The terms defined below apply to PR 03 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effe
62. en New value _ _ _ _ is displayed new parameter values can be entered by the numerical keys Erroneous numbers are erased by RESET Press ENTER when the number is complete After this ENTER as well as after any change there appears on the display Press ENTER to change Otherwise press RESET 2 7 INFORMATION DISPLAY The Information Display Figure 2 71 is selected by the soft key Display at the Normal Display Figure 2 60 This Display branch of the selection tree is safe because here no changes can be made to the system TEMPERATURE 30 2 C _ 86 4 F STANDARD 224 2 1 5960 TEST 133 6 Hormal operation ptical System image configsur ation Figure 2 71 The Information Display The Information Display contains additional data compared to the Normal Display The PROCESS TEMPERATURE in both C and F The STANDARD 25 C This shows the Refractive Index of a standard RI liquid applied to the prism see Section 5 4 output current in mA Optical image soft key Shows the Optical Image Figure 2 72 The light area high pulses is to the left the dark area low pulses is to the right compare to Figure 2 41 The vertical scale is 0 100 of highest pulse amplitude the horizontal scale expresses the numbers of the photocells 0 1024 The three leftmost pulses represent additional dark reference cells INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No
63. er Supply card marked POWER Figure 6 40 The terminals are marked 39 L 40 N and 41 ground symbol The power terminals L and N are directly connected to the transformer primary loop and galvanically separated from the rest of the instrument The ground terminal 41 is connected to the bottom plate of the Indicating Transmitter to the transformer shield winding and to the outer shield of the interconnecting cable Terminal strip The rest of the connections are made to the terminal strip Figure 3 61 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 22 SERIAL BUS RS 485 SWITCHES 8 9 10 11 12 13 14 15 16 17 18 27 28 29 30 31 SENSOR FIELDBUS 4 20mA RLY1 RLY2 43 44 45 46 25 26 47 48 49 50 Figure 3 61 Terminal strip Sensor The Indicating Transmitter end of the interconnecting cable has leads numbered from 1 to 7 to be connected to the terminals with the same numbers The sensor end of the interconnecting cable is terminated by a plug Figure 6 22 The interconnecting cable may be shortened or lengthened up to the limit specified Section 2 2 The interconnecting cable should be installed in a separate metal conduit For cable specifications see Section 2 2 Current output The terminal 25 is plus and 26 minus for the 4 20 mA output signal The signal i
64. ernal Output unit Section 10 1 did not acknowledge the transmission Serial bus or Output unit failure or the Output unit is disconnected To prevent this message when the Output unit is disconnected key in Calibrate Parameters Output signals External output Source and select Not defined RELAY UNIT FAULT The Relay unit Section 9 did not acknowledge the transmission Serial bus or Relay unit failure Maybe the Relay unit is not connected To prevent this message when the Relay unit is disconnected key in Calibrate Parameters Relays Relay unit and select Not defined for each relay TEMP MEASUREMENT FAULT Indicates that the temperature value reported by the sensor corresponds to a value below 50 C or above 250 C by a margin of 10 Probably temperature sensor failure see Section 6 6 If Temp measurement fault the temperature will be set to TNM one of the CONC RI parameters This value is then also used in the temperature compensation which means that the output will be reasonable even at temperature measurement failure Action Change temperature sensor INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 43 PRISM COATED LED FAULT Light intensity too low probably due to coating Action Clean the prism surface Use a strong solvent like nitric acid If message persists check optical image Section 6 5 de
65. ey in correct CONC RI parameters or change the concentration unit Select Calibrate Parameters CONC RD Unit Section 2 8 CONSTANTS ERROR There are constants in the EEPROM outside allowed range This error stops the measurement process Action Switch power OFF ON Then one of two alternatives will occur 1 If the EEPROM has been changed or the program upgraded Constants are not available Press ENTER to load default settings Press RESET not to change INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 44 2 If only some constants are wrong There are erroneous constants The bad constants can be set to default setting Press ENTER to correct bad constants SENSOR INTERFACE FAULT Error on the processor card in the Indicating Transmitter Section 6 4 The sensor interface processor 87C51 did not respond properly Probably failure of this processor Action Change the processor card EEPROM WRITE ERROR Error on the processor card The EEPROM did not write constants correctly Probably component failure Action Change the processor card PRECONDITIONING Shown when the preconditioning valve is activated by the Relay Unit Section 9 0 WASH Shown when the prism wash valve is activated by the Relay Unit The concentration output signal is locked if the HOLD function is active The HOLD function can be inactiv
66. h 24 1999 70 A8 5 SNOLLVOISIOAdS 14Vd 1 SLN3IVd 11 M3LLINSNVSL ONILVOIGNI SINJLVd M SSH 29V 0 4d 405535 Z SINJLVd M 0804 4d LINN SIN3LVd M MOSN3S YJLLINSNYML 9NILVOIONI N33M138 1008 3d 318VO SINSLVd LIND M3LLINSNVSL 9NILVOIONI N33M138 1108 44 318V2 G SIN3I Vd 2 51 243 1132 MO 9 M3WOlsno 7 d 9 IVA 331VA Z J3Wolsno d 23 2 ANVIINVS 8 J3Wolsno d 4d JAYA 9NINOILIINOO33d 6 1 9NINOILIONOO3Nd 304 318 2 AlddNS 33MOd YJNOLSNI YALYM 803 318 2 14405 N3MOd 01509 YSWOLSNO EL YJNOLSNO 011 02 A1ddns YaMOd OV 5 OL SINOLLIQNO033d Mounting summary of prism wash system for water with relay unit PR 7080 Figure 8 42 Document Revision No INM 3A Rev 1 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Effective March 24 1999 71
67. hich model is connected and adapts the software accordingly INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 16 2 10 PROGRAM VERSIONS The program version number consists of two digits The first digit is the major version the latter is the minor version Programs with the same major versions are compatible Also earlier major versions can usually be substituted with later major versions Before you upgrade any program versions write down all current parameters from the calibration screen of the Indicating Transmitter Then insert the new program version Choose the Default parameter load at start and enter the old parameters in 2 11 PASSWORD The CHANGE PARAMETERS screen can be optionally locked behind a password function When the password function is activated entry to this screen is not allowed without a correct password see Figure 2 61 The password function can be activated or inactivated by selecting Calibrate Parameters 9 Password 0 Inactive or 1 Active The password for K Patents PR 03 is printed on the front page of this manual 2 12 WARRANTY K Patents warrants that all products made by K Patents shall be free of defects in material and workmanship K Patents agrees to either replace or repair free of charge any such product or part thereof which shall be returned to the nearest authorized K Patents repair facility within two
68. ing transmitter External output unit Relay unit 8 14 8 14 Indicating Relay unit transmitter 8 14 8 14 Indicating External output unit transmitter 8 14 Ohm Figure 3 63 Serial bus connections Input switches Altogether four input switches A B C and D Figure 3 64 can be connected Terminals 27 28 B 29 30 D 31 Common The switches may be separate or together in one rotary switch Input switches can be configured through software Section 2 8 A 5V voltage is provided over each switch The switch terminals are all galvanically isolated from ground and from the rest of the electronics INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 24 SWITCHES SWITCHES Figure 3 64 Connections to input switches 3 7 SERIAL OUTPUT A remote display unit a computer or a terminal can be connected to the Indicating Transmitter serial output terminals In the Indicating Transmitter either RS 232 or RS 485 interface may be used The output measurement results are sent in ASCII code ISO 646 CCITT V 3 using a standard asynchronous interface The output consists of fixed length text records record is sent for every measurement interval 1200 ms RS 232 Conforms to the EIA RS 232 C and CCITT V 24 standards The
69. is below Maximum Test WASH STOP LOGICS 1 The preconditioning and wash relays are not activated by automatic wash start under Low conc no sample Section 6 30 as this indicates a clean prism in an empty process line 2 Wash can be prevented when the process temperature is below a limit The Wash stop function is used to prevent steam wash when the process pipe is empty or when the process is stopped To activate the wash stop key sequence Calibrate Parameters 1 Prism wash Wash stop l Activate and set the temperature limit The default value for wash stop is inactive When the wash is not accepted the diagnostics message is Wash stop temp limit see Section 6 3 3 Wash can also be prevented by an external contact closure telling e g that the process pump has stopped See Section 2 8 paragraph 3 3 MANUAL WASH Wash can be initiated from the key A Start prism wash This manual wash over rides the wash stop logics REMOTE WASH START EXTERNAL HOLD This input switch function is described in Section 2 8 paragraph 3 2 It is useful for an intermittent process The prism is washed when the process stops and again when it starts Between those two washes the output signal is on Hold During Hold the wash cannot be initiated neither automatically nor manually WASH CHECK This function can be defined from the prism wash menu Calibrate Parameters Prism wash A prism wash is accepted if one of the two conditions are sati
70. it Section 10 1 the same way as above In addition the source has to be selected from the list Concentration Standard RI 25 C Temp C Temp F 3 Serial output The format is to be defined see Section 3 7 5 Temperature menu The temperature calibration is made through this menu see Section 5 8 It is also possible to select the temperature display unit in the normal display as C F A high temperature limit can be activated and set for a High process temperature message Section 6 3 6 Standard RI 25 Gives the calibration parameters for the bench calibration value with standard RI liquids Section 5 4 The RI 25 O can also be added to the normal display 7 Language Selection of display language 1 English 2 German S Divert control Not in use for K Patents Sanitary Refractometer PR 03 Must be deactivated 9 Password A software password can be selected to prohibit unauthorized calibration see Section 2 11 2 9 COMPATIBILITY WITH K PATENTS PROCESS REFRACTOMETER PR 01 Sensor The K Patents Process Refractometer PR 01 with a Sanitary clamp connection uses a 4 clamp which is larger than the 2 2 clamp used by K Patents Sanitary Refractometer PR 03 Interconnecting cable The plug at the sensor end is different for PR 03 and PR 01 Indicating Transmitter The models PR 03 and 01 use the same Indicating Transmitter IT R When the power is switched on the microprocessor checks w
71. ks The CPU failed the register test The CPU chip is faulty 3 blinks The RAM memory failed the address uniqueness test The memory or its bus interface is faulty 4blinks The RAM memory failed the pattern test There is a bad RAM chip 5 blinks The code in ROM failed the CRC check The code is protected with a CRC check The ROM chip or program pattern in it is faulty INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 50 DISPLAY DISPLAY CONTROLLER KEYBOARD CARD PROCESSOR CARD SRAM CPU EPHOM 80C186 EEPROM 4 20 mA OUTPUT Xm 2 SERIAL SWITCHES BUS SERIAL OUTPUT RS 485 232 SENSOR DATA SENSOR INTERFACE Figure 6 42 Processor card block diagram INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 51 NDD 2 LEJ 6r 8 014 g th 94 i 92 gt re 8 eld SI GG 1041 C9 V J IK VL VF 4 pra a J V V _ __ 07 1031 9 C13 C10 001 60 18 V 1 V 1 106 SI 12 C8 1 c20 109 7 100 C6
72. le for Wash control relay unit WR For built in relays select Relay and Relay2 Select the relay function 0 1 2 7 8 Not defined Processor OK The relay is ON if the processor is running Normal operation The relay is ON if the diagnostic message is Normal operation No malfunction The relay is ON if the diagnostic message is Normal operation or Low conc no sample Low limit Low alarm relay relay is ON if value below limit High limit High alarm relay relay is ON if value above limit Preconditioning preconditioning relay Figure 9 21 Not used for built in relays Wash wash relay Figure 9 21 Not used for built in relays In divert control Not used with PR 03 After a Low limit High limit decision the display asks for the alarm source alternatively SED TE o pars CONC Standard RI 25 TEMP TEMP F TEST Sensor temperature Sensor humidity Note The alarm source can be changed by selecting relay function 9 for the alarm relay INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 77 When the source is decided the alarm limit has to be entered The default value of the limit is zero Note To be complete the specification of an alarm relay requires decision of High Low source and limit value To prevent the alarms to be too sensitive an alarm delay in seconds can be set common
73. libration was treated in Section 5 8 The temperature correction parameters TMPC0 and 1 are specific for the Image digitizer card not for the Pt100 element To check the temperature measurement the Pt100 element can be disconnected from the terminal L4 and substituted by a Pt100 calibrator Alternatively terminal 3 and 2 are connected by a jumper and 2 and 1 by suitable resistors e g 100 Ohm for 0 C and 138 5 Ohm for 100 C 6 7 PRISM GASKET REPLACEMENT To change the prism gaskets or the prism use the following procedure SENSOR DISASSEMBLY 1 Disconnect the cable Apply the two connector protection caps Remove the sensor from the process and rinse 2 Fix the sensor by the sensor head T in a vertical position nameplate upwards Figure 6 70 K Patents Service stand PR 1002 can be used 7 um E SS P lt A N S J Y DHL 5 2 2222 e ZAM A lt gt Z 5 ki gt Figure 6 70 Sensor in dissassembly position 3 Remove the nut of the Vee clamp Move the Vee clamp one step downwards 4 Lift the sensor cover and disconnect the cable A from the image digitizer card 5 Disconnect the ribbon cable B the LED lead C and the temperature element lead D INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A
74. nsity OK above 100 Yes No Endpoint below 75 Yes No Image below corner Yes No Slope OK above 1 Yes No Left curve OK above 1 Yes No Right curve OK above 1 Yes No For measurement with a normal sample all answers should be Yes A message Dips in image appears if the optical image is irregular INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 PRISM COATED LED FAULT TEST 8 Figure 6 54 YES MAX BELOW 50 2 NO YES BELOW 100 2 NO ENDPOINT BELOW 75 96 NO IMAGE BELOW NO CORNER YES m O NO NO SLOPE O ABOVE 1 YES LEFT CURVE ABOVE 1 YES HIGH CONC PRISM COATED TEST 8 SLOPE NO ABOVE 1 O YES YES NO RIGHT CURVE s BELOW 0 RIGHT CURVE ABOVE 1 YES LOW CONC NO SAMPLE Image analyzer decision rules INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 57 58 6 6 TEMPERATURE MEASUREMENT The temperature is measured by a Pt100 platinum resistance element see Figure 6 52 The connector is marked by D in Figure 6 70 The Sensor raw data Section 6 5 gives the A D value which refers to the temperature A D converter 0 1023 corresponds to 1 8 3 0 V corresponding to 75 C 300 C The temperature bias ca
75. r piece of the gasket covering the prism Support the knife on the prism surface only The knife will scratch the steel 17 Now the sensor is ready for process installation Remember to check the calibration Section 5 2 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 62 7 PR 03 PARTS LISTS 7 1 SENSOR Item Pcs PartNo Description Item Pes 1 1 PR 9205 2 5 Sanitary ferrule 2 1 PR 9201 2 5 Sanitary clamp 17 2 18 3 1 PR 9202 2 5 Sanitary gasket EPDM 19 3 1 PR 9203 2 5 Sanitary gasket NBR 24 2 3 1 PR 9204 2 5 Sanitary gasket Teflon 25 20 2 4 1 PR 9002 PR 03 Head 21 2 5 1 Thermal insulator Teflon 22 6 1 Alignment pin 23 7 1 PR 03 Base 26 8 6 Screw M5x10 DIN 7991 A2 27 9 1 PR 9011 Thermal conductor 28 4 39 1 PR 9010 Disc spring set 44 10 2 Disc spring 11 1 Disc spring holder 12 6 Screw M5x10 DIN912 A2 13 4 Screw M4x12 DIN 14 1 PR 7133 Image analyzer 15 4 Screw M4x8 DIN 912 A2 16 1 PR 5012 Vee clamp 11 130 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER 03 Part No PR 9106 PR 5011 PR 9107 PR 9110 PR 9001 PR 7125 Description PR 03 Connector complete Screw M3x8 DIN 912 Bushing holder Bushing Screw M3x16 DIN 912 A4 Connector Screw M4x8 DIN 912 A2 Washer M4 DIN 125 O ring seal 108x3 Dryer PR 03 Cover PR 03 Sensor label Screw M3x5 DIN 7380 A4 CORE Optics
76. r signal Any other message indicates fault in the Indicating Transmitter The Demo mode Section 4 3 Disconnect all connections to terminals 1 14 and make connection as in Figure 4 30 Then the Serial bus output will work as a sensor head simulator and the whole Processor card will be checked see the block diagram Figure 6 42 Power supply card The Power supply card is described by Figure 6 40 component lay out and Figure 6 41 circuit diagram The following DC powers are supplied by the card 1 5V to Processor card Should be 5V 5 96 Typical load about 350 mA should be below 500 mA Indicated by the green LED LD3 see Figure 6 40 2 24V to Sensor Typical value 25V 10 46 indicated by the green LED LD2 3 24 to serial bus to supply accessory units as the Relay unit Section 9 Typical value 25 V 10 indicated by the green LED LD1 The Test point see Figure 6 40 is also the OV at the Processor Card in the Sensor and in the serial bus to accessory units INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 Tu 20 e wn 2 06 RB o Fa E 2 a gt e gt TIA O id 2 92 92 wn O S O R4R3 C18 ach C27 38 OR
77. rmer 3 12 2 Ferrule 5 x 8 x 2 6 4 Nuts DIN 934 M4 313 2 Screw DIN 912 M3 x 10 27 4 Stand off x 15 314 2 Locking screw 2 8 4 Screws DIN 912 M4 x 8 315 2 Locking washer 2 9 1 PR 7030 Power supply card 3 16 1 PR 7315 Display 2 10 1 Switch actuator 3 17 1 PR 7019 Display cable 2 11 1 PR 7028 Ribbon cable 3 18 1 PR 7020 Display controller card PR 7029 Fuse set 10 Fuses 4 x 1 x 63 mA 2 2A 3 3 19 1 PR 7010 Processor x 0 5 320 1 PR 7009 Program memory 321 1 Cover INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 65 8 PRISM WASH SYSTEMS The use of a Relay Unit to control prism wash cycle is described in Sections 9 2 and 9 3 Three alternative media can be used for wash steam water and high pressure water In most of the applications the prism wash is not necessary However installing the wash nozzle can be considered for other reasons A prism wash nozzle Section 8 3 can be useful in cases where normally no prism coating occurs e g to clean the prism after a process stop using a manual wash valve Washing can also be used for operational check Test value increases during wash or as a part of maintenance schedule 81 PRISM COATING Deposit build up on the prism surface disturbs the measurement Look out for the following indications of coating Abnormally high concentration reading or upward CONC drift Low TE
78. rpose CS CSA appr for use in M purpose MA locations Transmitter options WR Wash control relay unit 2 Part Number Description PR 8300 He A cable between transmitter and sensor Cable length ies austin acs 010 10 meters 5 33 standard length Specify cable length in meters with 10 meters increments Maximum length is 100 meters 330 feet Model and Description Part No EFC Elbow Flowcell EFC Sensor connection i zr i selves ri ni ev vases pas H Sanitary 3A clamp 2 inch H Material of Construction SS AISI 316 SS Process connection u u u ed e EE ER tet Eus H Sanitary clamp H Pipe section diameter o ul ede a Naata Waaa puas 15 40 mm inch 15 20 50 mm 2 inch 20 25 65 mm 2 inch with SI option only 25 Blowcell inletty pes as a NE o abate SI Straight pipe SI RI Reduced pipe cone RI Example PR 03 A62 H ET SC IT RE GP WR FB PR 8300 050 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 6 25 Figure 2 20 Indicating Transmitter Dimensions mm in and mounting feet measures 125 4 9 982 7 3 3
79. s specified in Section 2 2 Recorders controllers indicators etc shall be connected to form a closed current loop starting from terminal 25 passing each device in at plus and out at minus ending at terminal 26 Be careful not to exceed the specified load resistance The range of the output signal can be set to 0 20 mA from the keyboard Section 2 8 select Calibrate Output signals Current output Range Serial output RS 232 RS 485 Terminals 15 18 and Plug connector P3 see Serial output Section 3 7 INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 23 Serial bus Terminals 8 14 provide connection to K Patents accessory units like the Relay unit Section 9 and External Output Unit Section 10 1 The same type of cable is used as for the interconnecting cable to the sensor specified in Section 2 2 The terminals 8 14 are connected to the same numbers in the external units Connect the external units in a chain beginning from the Indicating Transmitter and ending at the Relay unit Figure 3 63 For an intermediate unit e g External output unit the Serial bus input is terminals 8 14 A and output 8 14 B If there is no Relay Unit to complete the chain connect a 120 Ohm resistor over the terminals 8 B and 9 B at the last unit Note The current loop of the Serial bus must always be closed by a Relay Unit or the 120 Ohm resistor Indicat
80. sfied a TEST exceeds TEST limit b TEST increases more than TEST difference The default values of TEST limit and TEST difference are zero which makes the Wash check inactive If one of the conditions are set to zero the other condition is valid alone A typical case is TEST limit 230 TEST difference 0 The wash is accepted if the Test value exceeds 230 during wash and the Test difference condition is invalid If the wash is not accepted the diagnostic message will be Prism wash failure Section 6 3 This message is reset from the keyboard Reset or by a succesful wash A Wash retries parameter can also be set for repeated wash actions if the wash check fails The default value is zero INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 80 10 ACCESSORY UNITS 10 1 EXTERNAL OUTPUT UNIT PR 7090 The K Patents Sanitary Refractometer can be provided with a separate current output unit to give e g a temperature mA signal Cable fittings The cable fittings are delivered as one of two alternatives US NPT TYPE ST 1 conduit hubs European BF11 PG11 cable glands Note Seal all unused fittings with blind washers The dimensions are the same as for the Relay unit see Figure 9 01 The mA output specifications are the same as for the built in mA output of the Indicating Transmitter see Section 2 2 Two monitoring LEDs are on
81. si PR 3364 water 10 2 bar 30 psi 4 bar 70 psi Table 8 20 Recommended wash pressures and times Note Steam wash Do not use longer wash times than is recommended in the Table 8 20 In case of coating adjust the wash interval INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 66 Note Water wash Water temperature should be above the process temperature Precondition should be used to keep the water pipe hot 8 3 PRISM WASH NOZZLES The three versions of a prism wash nozzle are shown in Figure 8 30 How they are mounted to the process is shown in Figure 8 31 which also shows the connection of a check valve K Patents provides flow cells with stud for a wash nozzle Figure 8 32 shows an example with the correct position of the nozzle in relation to the prism surface STEAM SANITARY NOZZLE 5565 66 4 2 61 DIMENSIONS mm in WATER SANITARY NOZZLE PR 3364 Figure 8 30 Prism wash nozzles INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 67 0 5 SANITARY GASKET J 2 277272227 m NN v PROCESS LIQUID LEAKAGE PORT Figure 8 31 Process connection of a wash nozzle Figure 8 32 Example of wash nozzle installed in a flow cell 8 4 STEAM AND WATER WASH SYSTEMS Mounting according to Figures 8 40 to 8
82. signals are available at plug terminal P3 Cable diagrams are shown in figure 3 70 for modems and figure 3 71 for computers Both 25 pin and 9 pin D shell connector pin numbers are given If the ITR is to be connected to a computer connections 4 5 and 6 8 20 see figure 3 70 may be omitted in most cases Note RS 232 C specifies a maximum cable length of 15 m RS 485 The physical interface conforms to the EIA RS 485 The cable should be a shielded twisted pair The RS 485 signals are available at P3 DAT and DAT in figure 3 70 or strip terminals 15 18 For a shielded cable connection recommended see figure 3 61 K Patents recommends a cable length not exceeding 200 m INDICATING TRANSMITTER DCE D25 D9 3 2 Receive data gt 2 3 Transmit data 7 5 Signal ground RD SD senp SGND DAT Figure 3 70 RS 232 connection to DCE type eguipment e g modem INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 25 INDICATING TRANSMITTER DTE D25 D9 2 3 Transmit data 3 2 Receive data ET 7 5 Signal ground lt _ 4 7 Request to send BD SD BOND 5 8 Clear to send SGND DAT m gt 6 6 Data set ready gt 8 1 Data carrier detect lt 20 4 Data terminal re
83. surement 4 2 CALIBRATION CHECK Wait until normal process conditions occur The instrument is precalibrated at delivery DELIVER Y DATA SHEET Hence an on scale output should be obtained If not take a few samples and check that the process conditions are normal If the diagnostic message is Normal operation but the concentration reading is at the wrong level correction can be entered by the keyboard Section 5 2 If the concentration reading is correct but not the output mA see Section 5 1 The damping of the concentration measurement may be increased e g if necessary to get a smoother recorder track see Section 2 8 A damping time of 15 seconds is normally the best WARNING Avoid overdamping the signal should not be insensitive INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 30 4 3 The Indicating Transmitter can be used as stand alone for training of keyboard handling The built in Demo program contains a sensor simulator To activate the Demo mode a Disconnect the sensor cable 1 7 and all connections to the Serial bus 8 14 from the Indicating Transmitter b Connect terminal 1 to 8 and terminal 2 to 9 Figure 4 30 When the Demo mode is active a small star appears in the top left corner of the display SERIAL BUS RS 485 SWITCHES tle 2 Z lt 4822 8 9 1011
84. t temperature Process pressure Recommended flow velocity Quality certificate Sensor Wetted parts Sensor weight Sensor protection class Process connection Temperature measurement Image detector Light source Indicating Transmitter Indicating Transmitter weight Display Keypad Current output Serial output Power Alarms Interconnecting cable Interconnecting cable length Options Ordering information Desired scale properties of process solution Process temperature and pressure range Process flow range and pipe diameter Length of interconnecting cable R L 1 3100 1 5400 corresponds to hot water 100 Brix 0 0002 corresponds typically to 0 1 by weight Repeatability and stability correspond to accuracy 1 2 s undamped Selectable up to 5 min 20 C 130 C 4 F 266 F Automatic Sensor max 45 C 113 F min 20 C 4 F Indicating transmitter max 50 C 122 F min 0 C 32 F Sanitary clamp max 15 bar 200 psi at 20 C 70 F 9 bar 125 psi at 120 C 250 F Above 1 5 m s 5 ft s ISO 9001 Meets the requirements of the 3 A Sanitary Standard AISI 316L stainless steel prism gaskets teflon prism spinel 3 kg 7 Ibs IP67 Nema 4X 2 Sanitary clamp Built in Pt 100 1024 pixel CCD element Light emitting diode LED Enclosure IP66 Nema 4X 4 5 kg 10 Ibs 256 x 128 pixels graphic liquid crystal LCD 18 membran
85. to all relays The source value has to be out of limits during the whole delay time to activate the relay The default value is ten seconds Ifthe Relay unit is used as a wash timer the time settings Figure 9 21 are entered after the sequence Calibrate Parameters Prism wash 1 Preconditioning time s 10 2 Wash time s 3 3 Recovery time s 30 4 Wash interval min 20 The default values are in parenthesis The output signal is locked during Recovery and Wash if not otherwise specified Section 2 8 current output See Section 8 2 for recommended time settings PRECOND WASH RECOVERY INTERVAL Figure 9 21 Prism wash sequence 9 3 WASH LOGICS AND SMART WASH Figure 9 21 describes the standard prism wash sequence Preconditioning Wash Recovery Interval In some cases the wash routine should be modified to better fit the application The Wash decision logics Figure 9 31 of K Patents refractometer covers a wide range of options INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 78 Automatic Wash start 1 Wash interval timer 2 Smart Wash 3 I I REMOTE WASH I SWITCH I 1 PRECONDITIONING WASH RECOVERY YES NO Reset Prism Prism w
86. ution concentration as shown in Figure 2 31 The optical image is converted to an electric signal by an image detector By this method the concentration of the solution is measured The colour of the solution gas bubbles or undissolved particles do not interfere with the result INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 2 4 SENSOR DESCRIPTION In the K Patents Sanitary Refractometer Sensor Figure 2 40 the measurement prism A is flush mounted to the surface of the probe tip The prism is fixed to the analyzer module C which is sringloaded D against the prism gasket B The light source is a light emitting diode K The digital Image sensor G is a CCD element consisting of 1024 photocells in a row integrated on one chip The image sensor G is protected from the process heat by two isolating parts H Excess heat is transfered by a heat conductor T to the air cooled sensor cover J Figure 2 40 Sensor structure The image detector output is a pulse train as shown in Figure 2 41 This number of high pulses corresponds to the position of the shadow edge in the optical image The number of high pulses is a direct measure of the critical angle The image digitizer E transforms this pulse train to a serial digital signal This serial signal transmits a package containing a complete description of the optical image and temperature data to the In
87. yzer module into the sensor head Note the alignment pin R Figure 6 70 Mount the thermal conductor with the holes aligned to the screw holes Mount the disk spring J Note the position of the disk spring on the detail J Figure 6 70 Figure 6 73 Tightening of the disk spring holder screws 11 12 13 14 Mount the disk spring holder H Faster the six screws G in small steps following the pattern of numbers in Figure 6 73 Continue until the holder surface is flush to the surfaces of the three notches S No step should be felt with the finger tip Mount the Image detector card with the screws F Figure 6 70 First tighten the two guiding screws with conical heads then the third screw Lock the screws with e g nail polish Mount the Image digitizer card with the screws E Connect B C and D Check the dryer Figure 6 70 Remove the dryer held by two screws and inspect the window at the back It should be blue If it is pink regenerate according to the last paragraph in Section 6 1 before mounting INSTRUCTION MANUAL FOR K PATENTS SANITARY REFRACTOMETER PR 03 A Document Revision No INM 3A Rev 1 2 Effective March 24 1999 61 15 Connect A close the sensor cover and mount the Vee clamp The nut bolt of the clamp should be on the same side as the cable connector 16 Place the sensor on a table with the prism upwards Use a sharp knife with a curved edge to cut away the circula

Analytical Instruments: K-Patents Refractometer User's Manual (PR

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