KPS Turbidity Meter User's Manual
Contents
1. Sensor Offset and Span Calibration The KPS sensor is typically prepared at the factory with a default value of 4 00 mA output for the base reference position 0 and 20 00 mA for span position 9 For most applications it is recommended that the unit be used in this configuration The following procedure illustrates steps to either verify or modify these values Remove the screw cap on sensor Use caution so as not to damage rubber o ring Refer to the picture shown on page 6 of this manual to locate calibration switch entry key and offset adjustment keys If you wish to change the span value place Calibration switch in Position 9 and simply press the up or down offset adjustment keys until desired value is obtained then press and hold the ENRTY key for approximately 2 seconds If you wish to change the base reference value place Calibration switch in Position 0 and simply press the up or down offset adjustment keys until desired value is obtained then press and hold the ENTRY key for approximately 2 seconds Examples for a Multi Point Calibration For this example milk samples were used Water 4 mA skim milk 8 mA 1 milk 12 mA 2 milk 16 mA and whole milk 20 mA The calibration selector switch was 0 position for water 1 position for skim milk 2 position for 1 milk 3 position for 2 milk and 4 position for whole milk Calibration point Calibration switch Medium Fat in Analogue2. and when below range the green and yellow LED s will blink The resulting profile will correspond to the outputs from the unit at each of the various products These values can now be used as the reference for programming a receiver or to verify calibration of the KPS sensor Changes in product properties solids content are a common cause for discrepancy If observed follow the CALIBRATION section of this manual see next page KEM 7 KPS Turbidity Meter User s Manual Calibration Procedure If you want to adjust the calibration first remove the KPS lid by turning it counterclockwise This will allow access to the KPS electronics board Next assemble the desired calibration fluids It is advisable to calibrate them in increasing order of concentration KPS allows you to choose a variety of calibrations from a 2 point calibration to a 9 point calibration First obtain samples of all products that will be processed in this system If using liquid sample you will need sufficient volume of each to fill the tee Be sure the unit is properly wired to either the receiver or to a multimeter so that you are able to view the corresponding signal output from the unit Remove screw cap on sensor Use caution so as not to damage rubber o ring Refer to the picture shown on page 6 to locate calibration switch entry key and offset adjustment keys up down As shown fill the tee with clean water or another fluid that you desire
3. out mA 0 Water 0 4 2 1 Skim Milk 0 5 8 3 2 Milk 1 12 4 3 Milk 2 16 5 4 whole milk 3 5 20 A slightly different example of a multi point calibration is shown now In this case a dairy customer wanted a greater degree of sensitivity near 1 milkfat a 6 point calibration was used which emphasized the 1 to 1 3 milkfat concentration All that was necessary was to prepare samples of the proper concentration The KPS calibration linearizer divided the 4 to 20 mA span into five sections of 3 2 mA each including the key range in the middle of the graph This illustrates how the KPS calibration can be tailored to meet different process control needs KEM 11 KPS Turbidity Meter User s Manual Installation KPS has a conventional sanitary clamp connector that attaches directly to a tee or saddle in the process line or vessel KPS comes in standard 1 5 2 2 5 and 3 inch sizes KPS can be successfully installed in a wide variety of configurations including vertical and horizontal process lines and tanks To optimize the performance of the sensor it is important to keep the deadleg as short as possible on the tee connection and choose an installation site that will minimize air or sediment from collecting on the sensor s lens Deadleg It is advisable to have the tee cut back so the KPS lens is as close as possible to the process stream and deadleg is minimized Nevertheless keep a minimum distance of 5 cm In most ca
4. to be the 4 mA reference if a value other than 4 mA is desired for the base value please see SENSOR OFFSET and SPAN CALIBRATION section page 11 Observe the mA reading that KPS produces with the 4 mA reference sample If the output is 4 mA there is no need to adjust If you desire to change the zero point turn the calibration switch to position 0 and press and hold the ENTRY key for approximately two seconds This will store the new value as 4 mA Remove the water or optional base product and fill the tee with the next highest solids content So as not to introduce error in calibration it is recommended that the tee be rinsed with water to clean any residue of the previous product from the face of the sensor Turn the CALIBRATION SWITCH to position 1 Press and hold the ENTRY key for approximately two seconds The sensor output will now be set to 20 00 mA or the span setting Repeat step 7 incrementing the CALIBRATION SWITCH by one until all points have been calibrated maximum is to point 8 As points are added each addition becomes the new 20 00 mA top end Each previously entered point is linearly re scaled see graphic next page In general a five 5 point calibration is sufficient to provide proper output resolution You may use calibration point 0 to 8 Point 9 is reserved for the Sensor Output Reference described below 10 To verify output values the sensor should be placed again into each of the test l
5. KPS Turbidity Meter User s Manual K ppers Elektromechanik GmbH HE ar KPS 1 5 FT 172 S 1 kK E K ppers Elektromechanik GmbH Quality system certified to DIN ISO 9001 KPS Turbidity Meter User s Manual Contents Product description eeeeeeeseeeeeeee page Technical data ehem umm page Dimensions esee e page Getting started dI ee etes page Electrical connections s str srties kek a ER ree page Operation asriar eaen rnaar ASASEN AEREE LOLAS page Calibration verification or test sssssssesssessrersrrer errete page Calibration procedure sssssesseee e page Typical TES PONSES os ie AE OH eee vasa SERVE page Sensor offset and span calibration page Examples for a multi point calibration ssssss page Installation sire aite hoes eek ee os ene page Warranty arte he Pek a aE E EE i page Oo N DU uU BPW WwW 10 KEM KPS Turbidity Meter User s Manual Product Description KPS is an in line optical sensor that mounts directly to the process line and provides real time information about the process KPS emits a beam of NIR light into the product and in turn measures the amount of backscatter produced by solids suspended in the product The resulting degree of light scatter is converted to a 4 20 mA signal output Using the above operating principals KPS can accurately detect the point of transition from water to product This is consi
6. dered the primary application Depending on the degree of solids difference between two materials a product to product transition may also be detected And for products such as skim 1 percent 2 percent and whole milk KPS can act as a monitor of milkfat percentage and an indicator of product quality The most common calibration entered into KPS includes points for water skim milk 1percent milk 2 percent milk whole milk and a maximum response standard equal to 20 mA Technical Data Mechanical Materials Dimensions Connections Weight Ratings Optical Lens Lens Seal Lens Surface Finish Performance Electrical Accuracy Repeatability Process Temp Range Process Temp Shock Temperature Effect Process Pressure Limits Output Power Connection 316 series stainless steel housing and fittings sapphire and FDA approved silicone product contact surface see next page Varivent Milchrohr oder Tri Clamp 1 4 kg approx NEMA 4X water tight corrosion proof authorized to carry 3 A symbol Standard 46 03 uncoated optical sapphire aluminum oxide min thickness 2 3 mm minimum distance to the process stream 5 cm 60 durometer FDA approved silicone rubber meets ZZR 765 E Class 2 A amp B 0 1 microns inch 0 2 of span at 4 00 mA water 1 0 of span in any target fluid 0 up to 100 C continuous intermittent 149 C withstands instantaneous changes of up to 52 C e g from 4 4
7. iquids With each product record the resulting current output from the transmitter The resulting profile will correspond to the outputs from the unit at each of the various products These values can now be used as the reference for programming a receiver 8 KEM KPS Turbidity Meter User s Manual In accordance with the no of calibration points the analogue span is divided into corresponding intervals 45 6 05 gt c Co 4 0 20 mA Interval 12 mA Interval 4mA 16 mA 4 mA 8 0 mA Interval 8 mA Interval 5 3 mA 20 mA 16 8 mA Interval 6 67 mA Interval 3 2 mA 4 mA 2 67 mA 17 74 mA 16 mA 20 mA 18 mA 20 mA Interval Interval 2 29 mA 2 0 mA KEM KPS Turbidity Meter User s Manual Typical Responses on various Dairy Products ProScan In Line Sensor Response on Various Dairy Products 181 161 MEINT 141 l 124 T ea f mA 10 Hl sy EN 6 3 2 T E T T T Water Skim 1 Milk 296 Milk Whole Evap Milk Whip Crm Note Sensor zeroed on clean water and calibrated with standard procedure from water 4 mA to white standard 20 mA Testing conducted 11 4 03 ProScan Turbidity Readings 20 18 161 14 125 mA 1043 8 c B 44d 24 j i i 0 l l l l d 100 500 1000 1500 2000 2500 3000 3500 4000 Turbidity Standard NTU 10 KEM KPS Turbidity Meter User s Manual
8. lied to the KPS sensor the green LED on the unit s internal electronics board will blink To view this board remove the screw cap on the sensor Please note When the sensor is operating within the current calibration range the green LED on the sensor s electronics board will blink alone When over range the red and green LED s will blink and when below range the green and yellow LED s will blink calibration switch LEDs entry key up down Begin by placing a white paper towel on a table Next with the lens facing down place the sensor on the towel This should produce an output of approximately 17 mA The actual output may range from 16 to 19 mA this is normal Next lift the sensor straight up approximately 5 cm above the towel This should yield a signal of 4 to 4 5 mA Now slowly lower the sensor back to the towel the mA output will increase as the sensor gets closer to the towel eventually reaching approximately 17 mA If your sensor performs as stated it is ready for installation If not call the supplier for technical assistance 6 KEM KPS Turbidity Meter User s Manual Calibration Verification or Test with Your Samples KPS is normally calibrated at the factory according to the customer s specifications If it is desirable to check or adjust the calibration on site the user can do so by following these instructions Connect KPS to the required power supply and display with mA input Attach the sensor t
9. nector it should easily mate with the connector pins on the sensor body The threaded collar should also allow a snug secure fit when fully engaged Electrical Connections KPS has a 5 pin plug 5 pin socket PIN2 PIN 1 PIN 5 PIN 3 PIN 4 PIN 1 mA brown wire PIN 2 mA white wire PIN 3 UB 15 to 24 VDC blue wire PIN 4 GROUND black wire PIN 5 nc The most common wiring scheme for KPS is a 3 wire connection pin 2 is the mA output pin 3 is the 15 to 24 VDC power supply and pin 4 is the ground negative side of the supply Pin 1 is the negative side of the mA output and is connected internally to pin 4 This is done to make it more convenient for users who want to make a 4 wire connection pin 5 located in the center of the connector is not used Once the connections have been made inside the electrical connector make sure to tighten the threaded cord grip on the connector This will help keep moisture from entering the connector KEM 5 KPS Turbidity Meter User s Manual Operation Once KPS has been calibrated and the proper electrical connections have been made the sensor is ready for operation Before attaching the sensor to the process line however it is advisable to perform a quick check of the unit s operation The sensor output must be connected to a digital display multimeter or some other electronics that will allow the user to monitor the KPS mA output When power has been supp
10. o a suitable test stand such as a sanitary tee A common set up is to close off the bottom leg of the tee with an end cap attach KPS to the middle leg and pour the sample in the top leg In most cases the factory calibration is sufficient for your application If you simply want to verify the calibration or determine the sensor s response on your samples follow the steps below and record the KPS response Be careful not to dilute or otherwise contaminate the samples between readings Also if the highest degree of accuracy is desired make sure the samples are at the same temperature as they will be in the process line First obtain samples of all products that will be processed in this system You will need enough of each to fill a tee as shown Be sure the unit is properly wired to either the receiver or to a Multi meter so that you are able to view the corresponding signal output from the unit When power has been supplied to the unit the green LED on the electronics board will blink Starting with the product containing the least amount of solids or of lowest turbidity fill the tee as described above Record the output for this product then move to the next ending with the product containing the greatest amount of solids Please note When the sensor is operating within the current calibration range the green LED on the sensor s electronics board will blink alone When over range the red and green LED s will blink
11. r points toward the floor 12 KEM KPS Turbidity Meter User s Manual Warranty The system meets or exceeds the stated specifications and all of components of KPS are guaranteed against failure and manufacturing defects for a period of one 1 year from the date of delivery KEM is not responsible for any indirect damages resulting from the operation of KPS For the guarantee to be valid the equipment must be installed and operated in accordance with the supplied Operation Manual and within normal and specified conditions KEM retains the right to either replace or repair any defective part The warranty does not cover the sensor if alterations are made to it without prior written consent by KEM KEM K ppers Elektromechanik GmbH Liebigstr 2 D 85757 Karlsfeld Germany Tel 49 81 31 59 39 10 Fax 49 81 31 9 26 04 E Mail infoGkem kueppers com web www kem kueppers com Copyright KEM Zi Rev 001 08 07 KEM 13
12. ses it is possible to cut the tee back and have a resulting deadleg of 1 to 2 inches When it comes to deadleg the shorter the better Installation Site It is important to select an installation site and orientation that will minimize the possibility that air or sediment will interfere with the sensor s readings Vertical sections of process lines offer excellent installation sites whether the flow is down or up Another excellent installation site is a 90 degree elbow on a horizontal line position the KPS so the process fluid flows directly at the sensor s lens If installed on a straight section of horizontal process line it is advisable to place KPS so it looks sideways into the process stream not up or down Two installations that are not recommended are on the top of horizontal process lines where air has a tendency to accumulate and on the bottom of horizontal process lines where sediment can accumulate The clamp connection requires a gasket between KPS and the tee In most cases the customer provides the gasket and the tee These products can be supplied on request Connect the sensor to the process pipe with the appropriate sanitary gasket and clamp Important The sapphire lens can be damaged if struck by sharp or hard objects or if the sensor is dropped during installation Take care when connecting the sensor to the tee so that the lens is not damaged It is advisable to orient the sensor so that the electrical connecto
13. to 74 C during CIP or from 52 to 121 C during SIP 0 9 of span 12 C process and or ambient maximum vacuum to 13 8 bar at rated temperature 4 20 mA 3 wire 15 24 VDC at 35 mA 5 pin water tight with quick disconnect cabling KEM KPS Turbidity Meter User s Manual Dimensions mm uri Ld a Tri Clamp Typ KPS 1 5 KPS 2 0 KPS 2 5 KPS 3 0 FT flange as per DIN 32676 76 7 100 for DN 50 104 for DN 65 Union nut as per DIN 11851 Flan Varivent N O FT flange 50 4 mm 63 9 mm 77 4 mm 90 9 mm Dairy connections VARIVENT KEM KPS Turbidity Meter User s Manual KPS Getting Started Unless otherwise specified by the customer the sensors are shipped with a standard calibration covering a span of 4 to 20 mA and representing clean water at 4 mA and a maximum white standard at 20 mA A calibration document will be included in the shipment to inform you of the calibration date and details Upon receipt of the shipment carefully remove all items from the shipping package and ensure the contents are complete against the shipping documents Also please check the KPS sensor and other components for any damage that may have occurred during shipping Make sure the sapphire lens is clean and undamaged If it needs to be cleaned you may use a mild soap solution and soft clean cloth to gently clean the lens Also check the sensor s electrical con
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