instruction manual for inline refractometer pr-03 - K

instruction manual for inline refractometer pr-03 - K
Protected by one or more of
the following U.S. patents:
Patent No. 4,571,075
Patent No. 5,563,737
Patent No. 5,009,113
Patent No. 5,617,201
Patent No. 5,309,288
Patent No. 6,067,151
INSTRUCTION MANUAL
FOR INLINE REFRACTOMETER
PR-03
WARNING
The process medium may be hot or otherwise hazardous.
Precautions when removing the sensor from the process line:
Make positively sure that the process line is not under pressure. Open a vent valve to the atmosphere.
For a prism wash system, close a hand valve for the wash medium and disable the wash valve.
Loosen the clamp cautiously, be prepared to tighten again.
Be out of the way of any possible splash and ensure the possibility of escape.
Use shields and protective clothing adequate for the process medium.
Do not rely on avoidance of contact with the process medium.
After removal of the sensor, it may be necessary to mount a blind cover for security reasons.
Effective: February 15th, 2005
Document/Revision No. INM-3: Rev. 2/4
This product manual is delivered to the end user with a K-Patents product.
Information in this manual is subject to change without notice. When the manual is changed,
a revised copy is made available at http://www.kpatents.com/.
Feedback on this manual can be sent by email to [email protected]
THE PASSWORD FOR PR-03 IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.
K-PATENTS OY
Postal address:
K-PATENTS OY
Street address:
P.O. Box 77
FIN-01511 Vantaa, Finland
Tel. + 358-9-825 6640
Fax +358-9-8256 6461
[email protected]
www.kpatents.com
Elannontie 5
FIN-01510 Vantaa, Finland
K-PATENTS, INC.
1804 Centre Point Circle,
Suite 106,
Naperville, IL 60563
Tel. +1-630-955 1545
Fax +1-630-955 1585
[email protected]
www.kpatents.com
Table of contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
PR-03 refractometer models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
General safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
3
3
3
2
Inline refractometer sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Mounting the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1
Choosing sensor mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2
Check list for pipe mounting (PR-03-A, PR-03-D, PR-03-M) . . . . . . . . . . . . . . . . . . . . .
2.2.3
Check list for mounting in a tank, a vessel or a large pipe (PR-03-P) . . . . . . . . . . . . . . .
5
5
6
6
7
8
3
Indicating transmitter (IT-R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Indicating transmitter description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Mounting Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Mounting the Interconnecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.1
Connecting with sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.2
AC power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.3
+24 V DC power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.4
Current output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.5
Serial bus connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.6
Input switch connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Serial output connections: connecting a computer with the IT-R . . . . . . . . . . . . . . . . .
3.2.4
Demo mode connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Cable signals between IT-R and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
11
12
12
12
13
13
13
14
15
16
4
Accessory units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Separate relay units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1
Relay unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1.1
Relay unit PR-7080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1.2
Relay unit -WR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2
Prism wash system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3
Relay unit mounting and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3.1
Mounting and connecting Relay unit PR-7080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3.2
Mounting and connecting Relay unit -WR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4
Mounting and connecting prism wash systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4.1
Recommended wash pressures and times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4.2
Prism wash nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4.3
Mounting of prism wash systems with steam and water . . . . . . . . . . . . . . . . . . . . . . .
4.1.4.4
Mounting of prism wash systems with high pressure water . . . . . . . . . . . . . . . . . . . .
4.2
External output unit PR-7090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2
External output unit mounting and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
17
18
18
18
18
18
20
20
20
20
23
25
26
26
26
5
6
Startup, configuration and calibration adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
System check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1
Checking accessory units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2
Testing prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Using Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1
Keyboard functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Soft key Display: Getting information on the process
and the settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1
Viewing the Optical image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2
Viewing System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3
Checking conditions inside sensor head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Soft key Calibrate: Viewing and changing system settings . . . . . . . . . . . . . . . . . . .
5.5.1
Viewing Optical image and raw data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2
Raw data explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.3
Viewing Scaled image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.4
Viewing slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.5
Viewing Image diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6
Configuring input switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7
Configuring relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8
Configuring external output unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9
Configuring automatic prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.1
Timed wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.2
Smart wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.3
Preventing automatic wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.9.4
Prism wash check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10 Adjusting concentration calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.1
Checking current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.2
Concentration calibration from keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.3
Output current range selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.4
Temperature calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.5
Adjusting damping time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.6
Field calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.10.7
Bench calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
29
30
30
31
31
Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
Checking the sensor moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
Checking and replacing prism or prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
Disassembling and assembling a standard length sensor . . . . . . . . . . . . . . . . . . . . . . .
6.3.1
Disassembling the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2
Replacing the prism and prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3
Assembling the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Disassembling and assembling a probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1
Disassembling the probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2
Replacing the prism and prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.3
Assembling the probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
47
48
48
49
50
51
51
52
54
32
33
33
33
34
34
34
35
35
36
36
37
39
39
40
40
41
41
43
43
43
44
44
44
45
46
7
Troubleshooting and correcting problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
Troubleshooting Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2
Troubleshooting sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
LED value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Sensor temperature and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3
Slope value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.4
Image diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
55
55
56
56
57
8
Sensor specifications and
other sensor information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
Sensor labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Sensor compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
Sanitary refractometer PR-03-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1
PR-03-A sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2
PR-03-A mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3
PR-03-A specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.4
PR-03-A parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.5
PR-03-A mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
Probe refractometer PR-03-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1
PR-03-P sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2
PR-03-P mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.3
PR-03-P specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.4
PR-03-P parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.5
PR-03-P mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.6
PR-03-P programming specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5
Compact process refractometer PR-03-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.1
PR-03-D sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.2
PR-03-D mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.3
PR-03-D specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.4
PR-03-D parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.5
PR-03-D mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
Process refractometer PR-03-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.1
PR-03-M sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.2
PR-03-M specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.3
PR-03-M parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.4
PR-03-M mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7
Valve body refractometer PR-03-W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1
PR-03-W sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.2
PR-03-W specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.3
PR-03-W parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.4
PR-03-W mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
59
59
59
60
60
62
63
65
68
68
68
69
70
72
74
75
75
75
76
77
79
81
81
82
83
85
85
86
87
88
89
9
Indicating transmitter specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
IT-R label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2
IT-R compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1
Upgrading IT-R program version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3
Model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1
IT-R model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2
Interconnecting cable model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4
IT-R Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2
Serial output specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5
IT-R Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6
Command selection tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 PR-03 process refractometers in potentially explosive atmosphere . . . . . . . . . . . . .
10.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 PR-03-...-AX parts list: differences to standard sensors . . . . . . . . . . . . . . . . . . . . . . .
91
91
91
91
92
92
93
93
93
94
94
95
96
97
101
101
102
103
A
Glossary and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
B
Information about Delivery data sheet (DDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
C
K-Patents inline refractometer calibration data report
D
Instrument verification ISO 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Index
. . . . . . . . . . . . . . . . . . . . . . . . . 109
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Introduction
1
1 Introduction
The K-Patents inline refractometer is an instrument for measuring liquid concentration in the process line.
The measurement is based on the refraction of light in the process medium, an accurate and safe way of
measuring liquid concentration.
The refractometer sensor (A in figure Figure 1.1), mounted inline, sends a ray of light into the process
medium and measures the angle in which the light is refracted back from the liquid. This information is
then sent via the interconnecting cable (B) to the Indicating transmitter (C). The Indicating transmitter (ITR) then calculates the concentration of the process liquid based on the refractive angle, taking temperature
and pre-defined process conditions into account. The output the IT-R provides is a 4 to 20 mA DC output
signal proportional to process solution concentration, but a serial output is also available as a standard.
A
A: Sensor
B: Interconnecting cable
Figure 1.1
B
C
7
8
9
4
5
6
1
2
3
0
.
-
D
K-PATENTS
PROCESS INSTRUMENTS
ENTER
RESET
C: Indicating Transmitter
Refractometer equipment.
1.1 PR-03 refractometer models
The basic system of a sensor and an Indicating transmitter connected with a cable is the same in all PR-03
Inline refractometer models. However, there are different sensor models, each adapted for different process
requirements.
The Sanitary refractometer sensor PR-03-A and the Probe refractometer sensor PR-03-P both meet
the 3-A Sanitary Standard requirements. The model PR-03-A is an all-purpose instrument for a variety of
alimentary processes while the PR-03-P is especially designed for cookers and tanks and can even be used
in combination with a scraper in alimentary as well as other processes.
The Compact process refractometer PR-03-D is an all-round instrument for measuring the concentration
of a wide range of chemicals and liquids. The Process refractometer PR-03-M is built for chemically
aggressive solutions and ultra-pure processes, all of its wetted parts are made of non-metallic materials.
The Valve body refractometer PR-03-W is very similar to the Process refractometer PR-03-M, but the
special valve body makes it possibly to use it in large-scale production and large pipelines.
The model number of a refractometer system is displayed on the serial number label on the sensor head
(see Chapter 8, “Sensor specifications and other sensor information”). The serial numbers on the sensor
identification label (see Chapter 8) and the transmitter’s identification label (see Chapter 9) should always
match.
PR-03 instruction manual
2
1.2 Principle of measurement
The K-Patents inline refractometer sensor determines the refractive index (R.I.) of the process solution by
measuring the critical angle of refraction. Light from a light source ((L) in Figure 1.2) in the sensor is
directed to this interface. Two of the prism surfaces (M) are total-reflecting mirrors bending the light rays
that thus meet the interface at different angles.
A
C
B
L
P
M
M
S
Figure 1.2
Refractometer principle
The reflected rays of light 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 (R.I.) of the process solution.
The R.I. changes with the process solution temperature and concentration. In higher temperatures the R.I. is
smaller than in room temperature (standard R.I. 25◦ C). When the concentration changes, the R.I. normally
increases when the concentration increases. From this follows that the optical image changes with the
process solution concentration as shown in Figure 1.3. The color of the solution, gas bubbles or undissolved
particles do not affect the result.
B
C
B
A
C
A
Low concentration
Figure 1.3
High concentration
Optical images
The optical image thus achieved is converted to an electric signal by a digitizer inside the sensor. This
electric signal is then sent via an interconnecting cable to the Indicating transmitter’s microprocessor for
further processing, displaying and transmitting.
1 Introduction
1.3 General safety considerations
The process medium may be hot or otherwise hazardous. Use shields and protective clothing adequate for
the process medium - do not rely on avoidance of contact with the process medium.
Precautions when removing the sensor from the process line:
•
Make positively sure that the process line is not under pressure. Open a vent valve to the atmosphere.
•
For a prism wash system, close a hand valve for the wash medium and disable the wash valve.
•
Loosen the clamp cautiously, be prepared to tighten again.
•
Be out of the way of any possible splash and ensure the possibility of escape.
•
After removal of the sensor, it may be necessary to mount a blind cover for security reasons.
1.4 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 (2) years from the date of delivery.
Before returning a defective product for service or replacement, please contact K-Patents or your nearest
K-Patents representative (see http://www.kpatents.com/ for contact information). For the health and safety
of personnel handling your return, clean the instrument, especially the parts that have been in contact with
the process liquid, before packing it. Ship the cleaned instrument to the address given to you.
1.5 Disposal
When disposing of an obsolete instrument or any parts of an instrument, please observe the local and national requirements for the disposal of electrical and electronic equipment. The steel Indicating transmitter
enclosure and the aluminium or stainless steel sensor housing can be recycled with other metallic waste of
the same type.
3
4
PR-03 instruction manual
2 Inline refractometer sensor
5
2 Inline refractometer sensor
2.1 Sensor description
Figure 2.1 below shows cutaway pictures of two refractometer sensors. These sensors are otherwise similar in structure, but the sensor on the right has a longer probe. The short probe is the more common
refractometer sensor design, only the Probe Refractometer PR-03-P is built like the sensor to the right in
Figure 2.1.
In the sensor 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 spring-loaded (D) against the prism gasket (B). The light source is a
light emitting diode (K). The digital image detector (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 transferred by a heat conductor (I) to the air cooled sensor cover (J). For automatic
temperature compensation, the sensor tip contains a process temperature probe (F), Pt-100.
Figure 2.1
PR-03 sensor structure
The image detector output is a pulse train as shown in Figure 2.2. The number of high pulses corresponds
to the position of the shadow edge in the optical image and is thus a direct measure of the critical angle.
The image digitizer (E) transforms this pulse train to a serial digital signal. This serial signal transmits to
the Indicating transmitter a package containing temperature data and a complete description of the optical
image.
Note: K-Patents in-line refractometer PR-03 is using a 1024-pixel CCD-element. To keep the supporting
transmitter software compatible for all K-Patents refractometers, the TEST value (= number of photocells
at the light side) is scaled to the range 8-248. That is, for PR-03 the number of high pulses (Figure 2.2) is
divided by four.
PR-03 instruction manual
6
a: optical image
b: detector window and the photocells
V
c: pulse train from detector
TIME
Figure 2.2
Image detector system
Note: In the Probe refractometer PR-03-P the image is inverted by the optics. That is, the shadow comes
in from the left. The image is inverted back to normal (as in Figure 2.2) by the indicating transmitter before
any further processing.
2.2 Mounting the sensor
The sensor mounting location should be chosen with care to ensure that you get reliable readings from
your process. Some basic rules, described in this section, apply to all sensor models. The model specific
instructions can be found in Chapter 8.
2.2.1 Choosing sensor mounting location
A K-Patents in-line refractometer sensor can be located either indoors or outdoors in most climates. However, 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 fiberglass), because
light from outside reaching the prism will disturb the measurement.
The mounting location needs to be such that sediments or gas bubbles cannot accumulate by the sensor.
Good flow velocity is essential in keeping the prism clean.
Always check that the sensor head is kept cool enough, the sensor head should not be too hot to keep a hand
on. The red sensor cover should not be exposed to high temperature radiation. Normally, draft and natural
convection provide sufficient air cooling if the air gets to flow freely around the sensor head.
Additional cooling is necessary when the ambient temperature is higher than 45 ◦ C (113 ◦ F) or when the
process temperature is above 110 ◦ C (230 ◦ F) and the ambient temperature is above 35 ◦ C (95 ◦ F). The aircooling is improved by blowing pressurized air against the red sensor cover. The pressurized air can be
supplied by the ventilation system. If no air is available it is also possible to wind a copper coil for cooling
water around the sensor head cover.
2 Inline refractometer sensor
7
Important: Always mount the sensor so that the cable plug socket on the sensor head points downwards,
i.e. so that when the interconnecting cable is plugged into the sensor, the cable hangs down.
Figure 2.3
Refractometer cable plug direction
2.2.2 Check list for pipe mounting (PR-03-A, PR-03-D, PR-03-M)
1. 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.
2. If the refractometer is used in a feed-back control loop, make the time lag short. E.g. when a dilution
valve is controlled, mount the refractometer as near the dilution point as possible.
3. 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.
4. Often the position with the highest pressure (= after pump + before valve) has favorable flow conditions
without sedimentation or air trapping risks.
5. The sensor should be conveniently accessible for service.
Important: If the process pipe vibrates, support the pipe. A vibrating pipe might damage the inline sensor
mounted on it.
PR-03 instruction manual
8
2.2.3 Check list for mounting in a tank, a vessel or a large pipe (PR-03-P)
A Probe sensor PR-03-P can be inserted with a sanitary clamp into tanks and vessels which either don’t
have a scraper or where the mixer doesn’t touch the vessel wall. A Probe sensor can also be flush mounted
in a cooker where the scraper touches the wall.
1. Both the inserted and the flush mounted Probe sensor are mounted on the vessel wall with the cable
socket downwards.
2. The inserted probe sensor is mounted close to a stirrer to ensure representative sample of the process
liquid and to keep the prism clean.
3. The sensor should be conveniently accessible for service.
3 Indicating transmitter (IT-R)
9
3 Indicating transmitter (IT-R)
3.1 Indicating transmitter description
The indicating transmitter (abbr. IT-R) is a small, specialized computer designed to process data received
from the sensor. The Indicating transmitter enclosure (see Figure 3.1) contains a front panel with a Liquid
Crystal Display (LCD) and a keyboard. The IT-R’s microprocessor system and the power supply are hidden
under the front panel that swings open for service. Knockout padlock provisions for locks are included in
the enclosure’s both cover latches to prevent unauthorized access.
A
Figure 3.1
B
C
7
8
9
4
5
6
1
2
3
0
.
-
D
K-PATENTS
PROCESS INSTRUMENTS
ENTER
RESET
The Indicating transmitter enclosure
The IT-R receives from the sensor data that describes the optical image and gives the process temperature.
It then displays the optical image (Figure 1.3) and implements an image analyzing algorithm (Figure 3.2),
which identifies the exact position of the shadow edge (Figure 2.2). Finally, the microprocessor system
linearizes the concentration reading (example in Figure 3.3), and performs an automatic temperature compensation.
70
BRIX
60
50
40
30
20
Raw data
10
R.I.
Curve fitted to the data
1.35
Figure 3.2
Image analyzing algorithm
Figure 3.3
1.40
1.45
A Brix diagram
The IT-R output signals are a 4-20 mA concentration signal and a serial output signal, RS232 or RS485
alternatively, which enables connections to for example a PC (See Section 3.2.3).
In the IT-R there are also two built-in signal relays on the power supply card. These signal relays can
be configured to any relay function except preconditioning or wash control (see Section 5.7, “Configuring
relays”).
PR-03 instruction manual
10
Furthermore, the Indicating transmitter accepts four input switches which can be configured for example to
signal HOLD during external wash or to contain different scale settings each (see Section 5.6, “Configuring
input switches”).
3.2 Mounting Indicating 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 when choosing mounting location.
The enclosure is mounted vertically on an upright surface (wall) using four mounting feet, see Figure 3.4.
Important: Do not drill mounting holes in the enclosure as that will affect the protection class of the
enclosure and may expose the electronics of the IT-R.
Figure 3.4
Mounting the Indicating transmitter
Note: The LCD display has an operating temperature range of 0–50 ◦ C and a storage temperature range of
-20–60 ◦ C. If exposed to very low storage temperatures, let the IT-R reach the ambient temperature before
turning it on, as the LCD may not be able to display anything in temperatures below zero.
3.2.1 Mounting the Interconnecting cable
The interconnecting cable PR-8300 is made at the K-Patents factory according to the specifications given
in your order (see Section 9.4). The maximum length of an interconnecting cable is 100 meters (330 feet).
When mounting the cable, check that the ends easily reach the sensor respectively the IT-R.
! Warning! Do not try to shorten or lengthen the interconnecting cable! If a new cable is needed for example
after the IT-R has been moved further away from the process line, you can order a spare part cable from
K-Patents or your local K-Patents representative.
3 Indicating transmitter (IT-R)
11
3.2.2 Electrical connections
All the electric terminals of the Indicating transmitter are on the Power supply card (Figure 3.5).
SWITCHES
SERIAL CABLE
(pc)
POWER
SELECTOR
ACCESSORY UNIT
(serial bus)
RELAYS
11
SENSOR
CABLE
Figure 3.5
POWER
CONNECTION
Power supply card layout
To access the Power supply card, first open the enclosure cover. Then loosen the two screws on the righthand corners of the front panel and swing open the front panel to see the card.
Figure 3.6
IT-R with opened front panel.
PR-03 instruction manual
12
3.2.2.1 Connecting with sensor
The sensor end of the interconnecting cable is terminated by a plug. The plug goes into the cable plug
socket on the sensor head. After connecting the cable with the sensor, join the two connector protecting
caps to keep them clean inside.
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 on the Power supply card. The seven leads to the plug on the cable
are colored Red, Blue, Black, Red, Blue, Black and Black.
3.2.2.2 AC power connection
The primary AC power is connected to a separate terminal strip 39/40/41 marked POWER in the lower
right-hand corner of the Power supply card (Figure 3.5). The three terminals are marked 39/L, 40/N and
41/ground symbol. The connection is made by inserting each lead into the corresponding slot and tightening
the screws above the slots (Figure 3.7).
The power terminals Line and Neutral 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.
NEUTRAL
LINE
Figure 3.7
GROUND
Power terminals on the Power supply card
Important: Before connecting the IT-R power, check the position of the power selector switch, marked
SW2 on the Power supply card. The power selector switch has two positions: 220–240 V/50–60 Hz or
100–115 V/50–60 Hz.
Figure 3.8
Power selector switch in the 220 V position
3.2.2.3 +24 V DC power connection
The primary DC power is connected to a separate terminal strip 39/40/41 marked POWER in the lower righthand corner of the Power supply card (Figure 3.5). The terminals are marked 39/+24V, 40/0 and 41/ground
3 Indicating transmitter (IT-R)
13
symbol. The connection is made by inserting each lead into the corresponding slot and tightening the screws
above the slots (Figure 3.7).
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.
Important: The power selector switch on the Power supply card, marked SW2, must be in 110 position
(Figure 3.9) when input voltage is +24 V DC. If the switch is in the wrong position, the refractometer system
does not work.
Figure 3.9
Power selector switch in the 110 V +24 V DC position
3.2.2.4 Current output connection
The current output connection terminals are 25 and 26. The terminal 25 is plus (+) and 26 minus (-) for the
4-20 mA output signal (The detailed signal specifications are listed in Section 9.4, “IT-R Specifications”).
Recorders, controllers, indicators etc. must 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.
Important: Be careful not to exceed the specified load resistance, 1800 Ohm.
3.2.2.5 Serial bus connections
Terminals 8-14 on the Power supply card provide connection to K-Patents accessory units, like a Relay Unit
(see Section 4.1) and External output unit (see Section 4.2). The connection cable is of the same type as the
interconnecting cable and follows the same specifications (see Section 9.4). See Section 4.1.3, “Relay unit
mounting and connections” and Section 4.2.2, “External output unit mounting and connections” for more
information.
3.2.2.6 Input switch connections
Altogether four input switches A, B, C and D can be connected: Terminals 27-A, 28-B, 29-C, 30-D, 31Common, Figure 3.10. To use a switch, you will have to connect that switch with terminal 31, which short
circuits that switch. Thus, to use switch A, connect terminal 27 with terminal 31.
The switches may be separate, or together in one rotary switch. Input switch functions are configured
through software, Section 5.6. Most commonly input switches are used for easy switching between calibration settings for different process mediums or for preventing accidental or unauthorized calibration changes.
A 5V voltage is provided over each switch. The switch terminals are all galvanically isolated from ground
and from the rest of the electronics.
PR-03 instruction manual
14
SWITCHES
SWITCHES
27 28 29 30 31
27 28 29 30 31
A B C
A B C D
Figure 3.10
D
Input switch connections
3.2.3 Serial output connections: connecting a computer with the IT-R
The serial output connections on the Power supply card allow you to download information from the IT-R
with a PC computer that has a 9-pin COM port (or a USB-to-COM adapter that simulates a 9-pin COM
port).
Note: The serial output connection is for output only, i.e. it cannot be used to give commands to the IT-R.
To connect your PC with an IT-R to download process data, you need to order a communications package
from K-Patents. The package contains a cable with a plug for the P3 plug connector on the Indicating
transmitter Power supply card. The other end of the cable is a 9-hole COM plug for your computer’s COM
port.
Serial connection cable plugs
Figure 3.11
Cable plugged into an IT-R
Serial (PC) connection
3 Indicating transmitter (IT-R)
15
The K-Patents communications package contains Windows software for downloading data from the IT-R.
The software has been preset so that it normally starts directly after the installation and it has built-in
instructions. However, you can also use any standard communications software to download data. In
such case see Section 9.4.2, “Serial output specifications” for more information on the data format and
the communications settings.
3.2.4 Demo mode connection
The Indicating transmitter can be used as stand-alone for demos and to train keyboard handling. The built-in
Demo program contains a sensor simulator, so when the demo connection is on, you only need an IT-R to
show how the refractometer system works.
The Demo mode is activated by changing connections on the Power supply card:
1. Turn off the power from the IT-R. Open the enclosure cover and the front panel.
2. Disconnect the sensor cable (connections 1-7) (Section 3.2.2.1) and all connections to Serial bus (connections 8-14), i.e. all external units (see Section 4.1.3 and Section 4.2.2).
3. Connect terminal 1 to terminal 8 and terminal 2 to terminal 9, Figure 3.12
SERIAL BUS
RS-485
SWITCHES
8 9 10 11 12 13 14
15 16 17 18
27 28 29 30 31
4-20mA
SENSOR
RLY1 RLY2
+ 1 2 3 4 5 6 7
43 44 45 46 25 26
Figure 3.12
4. Close the front panel and turn on the IT-R.
Making demo connection
47 48 49 50
PR-03 instruction manual
16
Note: When the IT-R has been turned on in demo mode, a small star appears in the top left corner of the
display. Because the external units have been disconnected, the Normal display will not have a soft key for
Prism wash. Other than that, the Indicating transmitter will behave as if it was connected to a sensor in the
process line.
68.0%
*
CONC
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
TEST: 115.7
Normal operation
Calibrate
B
A
Figure 3.13
Display
D
C
IT-R display when in demo mode
Note: For more information on how to use the Indicating transmitter, see Section 5.3, “Using Indicating
transmitter”.
3.3 Cable signals between IT-R and sensor
SEN+
SENGND
+24V
0V
GND
PGND
1
2
3
4
5
6
7
RED
BLUE
RED
BLUE
RED
BLUE
RED
BLUE
Cable
Plug
Indicating transmitter
Figure 3.14
1
2
3
4
5
6
Cable signals
WHITE
BLACK
BLUE
BROWN
1
2
3
4
5
6
Image Digitizer
4 Accessory units
17
4 Accessory units
4.1 Separate relay units
When necessary, a K-Patents inline refractometer system can be equipped with a separate relay unit with
either four (PR-7080) or two (-WR) relays. The separate relay units can be added to any refractometer model
when additional relays are needed.
Unlike the built-in relays, both separate relay units can be configured for preconditioning and prism wash.
That is, if a prism wash (Sanitary refractometer PR-03-A and Probe refractometer PR-03-P only) is installed
because of sticky process medium, a separate relay unit is also needed.
4.1.1 Relay unit description
Both separate relay units are built in an enclosure with IP 65 (Nema 4X) classification. Figure 4.1 shows
the dimensions of the four-relay unit PR-7080 and the two-relay unit -WR.
PR-7080
-WR
Figure 4.1
Relay unit dimensions
To see the relays and to make all necessary connections, open the screws in the four top corners of the relay
enclosure and lift off the enclosure cover.
The cable fittings are delivered as one of the three alternatives:
US
1/2 NPT-TYPE ST-1 conduit hubs
European BF11/PG11 cable glands
M20x1.5 cable glands
4 pcs
4 pcs
4 pcs
PR-03 instruction manual
18
4.1.1.1 Relay unit PR-7080
The Relay unit PR-7080 contains 4 relays from left to right: Relay A, relay B, relay C and relay D. There is
a yellow LED above each relay. If the LED is lighted, the corresponding relay is ON and the output contact
is closed. There is also one green and one red indicator led to inform on system status. After startup the red
led is lighted only when the relay unit has problem.
The Relay unit PR-7080 is connected with the IT-R with an interconnecting cable PR-8011 . The last three
numbers in the cable code indicate the cable length in meters, the shortest available cable is PR-8011-001
(1 meter; 3.3 feet) and the longest possible cable is PR-8011-100 (100 meters; 330 feet).
4.1.1.2 Relay unit -WR
The Relay Unit -WR contains 2 relays from left to right: Relay A and Relay B. There is a yellow LED
above each relay. If the LED is lighted, the corresponding relay is ON and the output contact is closed.
4.1.2 Prism wash system description
Deposit build-up on the prism surface disturbs the measurement. Look out for an abnormally high concentration reading, low slope value or an upward CONC drift.
In most applications the prism will keep clean due to the self-cleaning effect. If coating occurs, check the
following:
− Sufficient flow velocity, see Section 2.2.2, “Check list for pipe mounting (PR-03-A, PR-03-D, PR-03-M)”.
− A temperature difference between process fluid and sensor probe may cause coating. This may happen
with small flows if the thermal insulation is inadequate. In some cases it helps to insulate also the clamp
connector.
In case of a coating problem, the preferred solution is to try to increase the flow velocity, e.g. by installing
a pipe portion with smaller diameter. Installing a wash nozzle can be considered, if increasing the velocity
does not provide a solution (Section 4.1.4).
Three alternative media can be used for prism wash: steam, water, high pressure water. Only external relays
(accessory units) can be configured to control the prism wash cycle, see Section 5.9 “Configuring automatic
prism wash”.
4.1.3 Relay unit mounting and connections
Note: When mounting a separate relay unit, seal all unused fittings with blind washers.
4.1.3.1 Mounting and connecting Relay unit PR-7080
The four-relay Relay unit PR-7080 is mounted on a wall or similar vertical surface using its four mounting
feet. Take the length of the interconnecting cable PR-8011 and easy access for service into account when
choosing mounting spot for the Relay unit.
Open the screws on the Relay unit and lift off cover to get access to the relay card to make the connections.
The relay contacts go to the connector strip (Figure 4.2) on the relay unit card.
4 Accessory units
19
A
B
C
D
44 45
46 47
48 49
50 51
Figure 4.2
Relay unit PR-7080 connector strip
Connect the numbered leads of the interconnecting cable with the same numbers (8-14) on the serial bus.
Then proceed to connect the cable with your refractometer system. If you have an External output unit, the
Relay unit is connected to that. If no other external units are used, the Relay unit connects directly with the
IT-R (Figure 4.3).
Indicating
transmitter
Relay unit
External output unit
A
8-14
8-14
B
8-14
8-14
PR-8011
PR-8011
Relay unit
Indicating
transmitter
8-14
8-14
PR-8011
Figure 4.3
Connecting Relay unit PR-7080
Important: Before connecting the relay unit with your refractometer system, power off your system. If you
have an external output unit, open its cover to access the card inside for connections. If you don’t have an
external output unit, open the IT-R’s enclosure and display panel to access the processor card.
Connect the numbered leads of the free cable end with terminals with the same numbers (8-14) on the
serial bus output (serial bus B) on the Output unit card or on the serial bus on the Indicating transmitter’s
processor card.
PR-03 instruction manual
20
4.1.3.2 Mounting and connecting Relay unit -WR
The Relay unit -WR is always mounted directly underneath the IT-R. If the IT-R and the Relay unit -WR are
delivered together, they are already fully connected. If the Relay unit is delivered separately, the connection
cable is included in the Relay unit delivery. The cable is plugged in the P2 plug on the IT-R’s processor
card (next to the sensor cable, see Figure 3.5). The relay contacts go to the connector strip.
4.1.4 Mounting and connecting prism wash systems
The prism wash system for steam is described by Figures 4.7 and 4.8 and for high pressure water by Figure 4.9.
4.1.4.1 Recommended wash pressures and times
The recommended wash pressures and times are given in Table 4.1 below.
Wash medium pressure
Minimum
Maximum
above process
allowed
pressure
pressure
Wash time
Recovery
Interval
Steam
2 bar (30 psi)
6 bar (90 psi)
3–5 s
20–30 s
20–30 min
Water
2 bar (30 psi)
6 bar (90 psi)
10–15 s
20–30 s
10–20 min
40 bar (600 psi)
70 bar (1000 psi)
10–15 s
20–30 s
10–20 min
High pressure water
Table 4.1
Recommended prism wash parameters
Important: In steam wash, do not exceed the recommended wash times, because some process media may
burn to the prism surface if steamed for longer time. In case of coating, shorten the wash interval.
Note: In water wash, water temperature should be above the process temperature.
Note: The check valve pressure drop is 0.7 bar (10 psi).
4.1.4.2 Prism wash nozzles
Select wash nozzle according to wash medium and refractometer model, Table 4.2.
PR-03-A
Pressurized water sanitary nozzle -WP
PR-3366
Steam sanitary nozzle -SN
PR-3365
Water nozzle -WN
PR-3364
Table 4.2
Prism wash nozzle selection
4 Accessory units
21
The three versions of a prism wash nozzle are shown in Figure 4.4. How they are mounted to the process is
shown in Figure 4.5, which also shows the connection of a check valve. K-Patents provides flow cells with
stud for a wash nozzle. Figure 4.6 shows an example with the correct position of the nozzle in relation to
the prism surface.
Figure 4.4
Wash nozzle selection
PR-03 instruction manual
22
Figure 4.5
Figure 4.6
Process connection of a wash nozzle
Example of wash nozzle installed in a flow cell
Figure 4.7
12
8
6
7
TO DRAIN
FLOW
2
Mounting of a prism wash system with steam and Relay unit PR-7080
STEAM
10
5
13
4
3
AC POWER SUPPLY 230/110 V
STEAM PIPE 1/4"
STEAM PIPE 1/2"
SOLENOID CABLE, 3x1 (AWG 17)
STRAINER PR-3342
CHECK VALVE PR-3302
SHUT-OFF VALVE&STEAM TRAP PR-3340-230/110
EFC (ELBOW FLOW CELL)
CABLE PR-8011 BETWEEN INDICATING TRANSMITTER AND RELAY UNIT
CABLE PR-8300 BETWEEN INDICATING TRANSMITTER AND SENSOR
RELAY UNIT PR-7080
SENSOR PR-03-A62-HSS
INDICATING TRANSMITTER IT-R
11
PART PART SPECIFICATIONS
13
12
11
10
9
8
7
6
5
4
3
2
1
9
1/2"
AIR
RELAY UNIT PR-7080
SUPPLIED BY
CUSTOMER
CUSTOMER
CUSTOMER
CUSTOMER
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
2
1
1
1
1
1
1
1
1
1
1
1
1
WIRING SEE WRG-314
13
1
4 Accessory units
23
4.1.4.3 Mounting of prism wash systems with steam and water
11
7
5
Figure 4.8
6
TO DRAIN
FLOW
2
Mounting of a prism wash system with steam and Relay unit -WR
10
STEAM
12
POWER
9
13
4
CABLE 2x1 (AWG 17)
SAFETY SWITCH
AC POWER SUPPLY 230/110 V
STEAM PIPE 1/4"
STEAM PIPE 1/2"
SOLENOID CABLE, 3x1 (AWG 17)
STRAINER PR-3342
CHECK VALVE PR-3302
SHUT-OFF VALVE&STEAM TRAP PR-3340-230/110
EFC (ELBOW FLOW CELL)
CABLE PR-8300 BETWEEN INDICATING TRANSMITTER AND SENSOR
WASH RELAY UNIT
SENSOR PR-03-A62-HSS
INDICATING TRANSMITTER IT-R
PART PART SPECIFICATIONS
14
13
12
11
10
9
8
7
6
5
4
3
2
1
8
1/2"
AIR
I
SAFETY
SWITCH
0
SUPPLIED BY
CUSTOMER
CUSTOMER
CUSTOMER
CUSTOMER
CUSTOMER
CUSTOMER
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
14
3
1
1
2
1
1
1
1
1
1
1
1
1
1
1
WIRING SEE WRG-313
12
1
24
PR-03 instruction manual
7
6
5
FLOW
10
2
Figure 4.9
13
3/8"
TAP WATER, TEMP MAX 60 °C / 140 °F
11
4
CABLE 2x1 (AWG 17)
POWER SUPPLY CABLE 3 METERS FOR HIGH PRESSURE PUMP
POWER SUPPLY CABLE 3 METERS FOR WATER VALVE
HIGH PRESSURE PUMP PR-3602-110/230/400/550 INCLUDING WATER VALVE
POWER RELAY UNIT PR-3603-110/230/400/550
AC POWER SUPPLY 230/110 V
HIGH PRESSURE HOSE 8M
CHECK VALVE R 1/4" PR-3302
EFC (ELBOW FLOW CELL)
CABLE BETWEEN INDICATING TRANSMITTER AND SENSOR PR-8300
WASH RELAY UNIT (WR)
SENSOR PR-03-A62-HSS
INDICATING TRANSMITTER IT-R
8
POWER RELAY UNIT
PR-3603-___
MAIN
SWITCH
I
PART PART SPECIFICATIONS
13
12
11
10
9
8
7
6
5
4
3
2
1
12
POWER
0
9
SUPPLIED BY
CUSTOMER
K-PATENTS
CUSTOMER
K-PATENTS
K-PATENTS
CUSTOMER
K-PATENTS
K-P / CUSTOMER
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
K-PATENTS
3
1
1
1
1
1
2
1
1
1
1
1
1
1
POWER
8
1
4 Accessory units
25
4.1.4.4 Mounting of prism wash systems with high pressure water
! Warning!
In high pressure wash systems, 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.
Mounting summary of prism wash system for high pressure water with -WR relay unit
PR-03 instruction manual
26
4.2 External output unit PR-7090
The K-Patents inline refractometer can be provided with a separate current output unit to give e.g. a temperature mA signal.
4.2.1 Description
The External output unit PR-7090 has the same dimensions as the four-relay unit PR-7080 (Figure 4.1).
The enclosure has IP 65 (Nema 4X) classification. To open the enclosure, loosen the screws in the four top
corners of the enclosure and lift off cover. This will give access to the output unit’s circuit card.
The cable fittings are delivered as one of the three alternatives:
US
1/2 NPT-TYPE ST-1 conduit hubs
European BF11/PG11 cable glands
M20x1.5 cable glands
4 pcs
4 pcs
4 pcs
The mA output range of the Output unit is the same as the built-in mA output of the IT-R, i.e. either
4-20 mA or 0-20 mA. The output range is chosen through the IT-R’s software, see Section 5.8.
Two monitoring LEDs on the output unit’s circuit card indicate its status: Green LED L1 is lit when the
output unit is in order. Red LED L2 is lit when correct input data are missing. Red light means that either the
connection to the IT-R is broken (no interconnecting cable, badly plugged cable or dead cable) or that there’s
a problem on either the output unit’s circuit card or the IT-R’s processor card. Under normal operation the
green LED should be lighted and the red LED should be dark.
The External output unit is connected with the IT-R with an interconnecting cable PR-8011 . The last three
numbers in the cable code indicate the cable length in meters, the shortest available cable is PR-8011-001
(1 meter; 3.3 feet) and the longest possible cable is PR-8011-100 (100 meters; 330 feet).
4.2.2 External output unit mounting and connections
Note: Seal all unused fittings with blind washers.
The External output unit PR-7090 is mounted on a wall or similar vertical surface using its four mounting
feet. Take the length of the interconnecting cable(s) PR-8011 and easy access for service into account when
choosing mounting spot for the External output unit.
Open the screws on the External output unit and lift off cover to get access to the circuit card to make the
connections. The output mA signal is connected to the terminals 42+ and 43-.
Connect the numbered leads of the interconnecting cable with the same numbers (8-14) on the serial bus A
on the circuit card. If you have a Relay unit PR-7080, the Relay unit’s interconnecting cable is connected to
the Serial bus B.
Important: If the refractometer system does not include a Relay unit PR-7080, close the circuit with a
120 Ohm closing resistor (Figure 4.10).
4 Accessory units
27
Indicating
transmitter
A
8-14
8-14
B
8-14
External output unit
A
8-14
8-14
External output unit
A
8-14
8-14
-WR
B
8 9
120
Ohm
PR-8011
Indicating
transmitter
8-14
PR-8011
PR-8011
Indicating
transmitter
Relay unit
External output unit
PR-8011
Figure 4.10
B
8 9
120
Ohm
Connecting External output unit
Important: Before connecting the Output unit with your refractometer system, power off your system. Then
open the IT-R’s enclosure and display panel to access the processor card.
Connect the numbered leads of the free cable end with terminals with the same numbers (8-14) on the
serial bus on the Indicating transmitter’s processor card (if there’s an earlier Relay unit connection, move
the Relay unit’s interconnecting cable to the Output unit’s circuit card, serial bus B, and then connect the
Output unit with the IT-R).
28
PR-03 instruction manual
5 Startup, configuration and calibration adjustment
29
5 Startup, configuration and calibration adjustment
5.1 Startup
First check that the serial number of your sensor (Figure 8.1) and your Indicating transmitter (Figure 9.1)
match. If you ordered a new sensor to go with an old IT-R, ask K-Patents to send a new label for your IT-R.
Check wiring and supply voltage, Section 3.2.2.
Open the IT-R cover and press the main power switch (Figure 5.1) underneath down to ON position to power
up your refractometer system.
POWER
OFF 0
ON I
Figure 5.1
The power switch
5.2 System check
After the power has been switched on, the IT-R checks the type of the sensor, which should be identified
as PR-03. The sensor code PR-03 is shown on the display for a short time. Then the Normal display
(Figure 5.2) appears. The diagnostic message should be Normal operation or, if the process pipe is
empty, Low conc/no sample. For any other message see Section 9.7.
CONC
68.0%
CONC
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
TEST: 115.7
Normal operation
Calibrate
A
B
C
68.0%
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
TEST: 115.7
Normal operation
Start
prism
wash
Display
D
A
Without wash
Figure 5.2
B
Calibrate
C
Display
D
With wash
Normal displays
The display also shows the current process temperature.
The TEST value in the display should be in the range of 8-248. The value 248 indicates a clean prism in an
empty process pipe. The value 8 means that the prism is coated and no reliable optical image is available.
As the instrument is precalibrated to your process, the concentration reading should be on scale, although it
may need some final adjustment (see Section 5.10.1). If the concentration reading is off, check your process
conditions (see Section 7, “Troubleshooting and correcting problems”).
PR-03 instruction manual
30
Press the key D (soft key Display) for additional data, e.g. output in mA. Further data is obtained in the
Information display by soft keys Optical image (Figure 5.3), System configuration and Sensor
head. Return to Normal display by pressing the RESET key as many times as necessary.
Note: Use the keyboard’s keys A, B, C, D for the soft key commands, do not touch the display screen (see
Section 5.3.1).
36.7%
CONC
1.4412
RI(25ºC
RI(25ºC
TEMPERATURE: 30.2 °C 86.4 °F
STANDARD RI(25°C): 1.3960
Output signal: 16.7 mA
PR-03 version 8.5
Sensor interface version 4.0
Sensor processor version 4.0
Relay unit not connected
External output unit not connected
TEST: 133.6
Normal operation
Output: 4..20 mA = 1.4260..1.4900 RI(25
System
Sensor
configur- head
ation
Optical
image
A
B
C
Relay
configuration
Switch
configuration
A
B
D
Information display
Head temperature: 20 ºC
Head humidity: 32 %
Wash
times
Normal operation
C
D
System configuration display
Figure 5.3
1.4412
SENSOR HEAD
A
B
C
D
Sensor head display
Getting additional information
Measure the output signal. It should agree with the mA display.
If there are problems in the system check, proceed to Chapter 7, “Troubleshooting and correcting problems”.
5.2.1 Checking accessory units
All the accessory units, both relay units -WR and PR-7080 and external output unit, have two indicator
LEDs that tell about their status. Open the enclosure cover to see these LEDs. When the refractometer
system is on and the IT-R is finished with the initial check (i.e. the Normal display has appeared, see at
page 29), only the green led should be lit. If the red led stays lit, there’s problem in the accessory unit
configuration, see Section 5.7 and Section 5.8.
Note: When the refractometer system is powering up, both LEDs light up for a short time during the system
check. After a while the red led should be turned off, in a working system only the green led is lit.
5.2.2 Testing prism wash
Important: Before you test prism wash, check that there is liquid in the pipe in front of the refractometer
and that the steam washing parts are properly installed and connected.
If you are using prism wash controlled by a relay unit check the wash sequence by pressing in the Normal display soft key Start prism wash (Figure 5.2). The TEST value should clearly increase (and the
concentration reading decrease) during wash.
Note: The manual wash command cannot override External hold (see Section 5.6).
Note: The Start prism wash soft key appears in the Normal display only when a relay has been configured as wash relay (Section 5.7). In demo mode it never appears, because the external units have been
disconnected.
5 Startup, configuration and calibration adjustment
31
5.3 Using Indicating transmitter
5.3.1 Keyboard functions
The keyboard has 10 number keys and four soft keys, marked with letters A-D. The meaning of a soft key
changes depending on what has been entered previously, i.e. what display is shown. The meaning of a soft
key is always displayed on the screen above the key, for example the Normal display always has soft keys
C=Calibrate and D=Display and, if the system has prism wash, also A=Start prism wash (see
Figure 5.4).
The ENTER key is used to accept entered numeral values (to "OK" them) and the RESET key is used to
cancel input and to move "backwards" in the command structure.
The commands that can be given to the Indicating transmitter have been arranged into a selection tree, i.e.
command groups and subgroups (see Figure 9.5). The "root" of the selection tree is the Normal display
(Figure 5.4), to which the IT-R always returns if it doesn’t receive any keyboard commands for a predefined
reset time (normally 60 seconds).
CONC
68.0%
CONC
68.0%
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
TEST: 115.7
Normal operation
TEST: 115.7
Normal operation
Start
prism
wash
Calibrate
A
B
C
Display
D
Figure 5.4
A
B
Calibrate
C
Display
D
Normal display
Each command in the selection tree can be reached from the Normal display with its own, unique key
sequence. For example you can view the relay configuration with the sequence D (Display) - C (System
configuration) - A (Relay configuration), i.e. starting from the Normal display, press first soft
key D, then soft key C, then soft key A. After viewing the configuration you can go backwards to the Normal
display by pressing the Reset key three times.
Whenever New value: _ _ _ _ is displayed, new parameter values can be entered by the numerical
keys. If you accidentally enter a wrong number, you can erase it with RESET. When the number (value)
is complete, press ENTER. After this the IT-R will ask for reconfirmation with the following text: Press
ENTER to change (Otherwise press RESET). Thus, press ENTER if you want the new value
to become effective. If you want to discard the new value and return to the old value, press RESET.
PR-03 instruction manual
32
Example: You need to change the bias (see Section 5.10.2) to be 25.456 (as in the example in
Section 5.10.2). Starting from the Normal display (Section 5.3), you have to perform following
steps:
1. Give the right command sequence to get to the value to be changed, in this case
Calibrate/Parameters/CONC (R.I.)/Parameters/Bias
(key sequence C-B-A-A-1).
2. Type the new value.
3. When the new value is finished, press ENTER.
4. Accept (=reconfirm) the new value by pressing ENTER again. The new value now appears on
the screen as the current value.
5. Finally, withdraw from the current display by pressing the RESET key as many times as necessary (five times to get to the Normal display from the Bias setting).
5.4 Soft key Display: Getting information on the process
and the settings
Pressing the soft key Display (key D) in the Normal display brings up the Information display , Figure 5.5 below. Through the Information display you can get information about the process, the process
parameters and other settings that have been entered to the Indicating transmitter. This branch of the selection tree (Figure 9.5) is safe, because it doesn’t allow you to make changes to the settings, it will only
display the existing information.
CONC
36.7%
TEMPERATURE: 30.2 °C 86.4 °F
STANDARD RI(25°C): 1.3960
Output signal: 16.7 mA
TEST: 133.6
Normal operation
System
Sensor
configur- head
ation
Optical
image
A
Figure 5.5
B
C
D
The Information display
As you can see in Figure 5.5, the Information display contains additional data compared to the Normal
display:
− The process temperature in both ◦ C and ◦ F
− The standard RI (25 ◦ C). This shows the Refractive Index of liquid applied to the prism, referenced to
25 ◦ C
− output current in mA
5 Startup, configuration and calibration adjustment
33
5.4.1 Viewing the Optical image
You can view the Optical image (Figure 5.6) by pressing the soft key Optical image (key A) in the
Information display. The light area (high pulses) is to the left, the dark area (low pulses) is to the right,
compare to Figure 2.2. The vertical scale is 0–100 % of highest pulse amplitude, the horizontal scale
expresses the numbers of the photocells 0–1024.
Figures 5.6 below show some typical optical images appearing at startup.
SCALED
OPTICAL
IMAGE
TEST: 248.0
30.2 ºC
Endp: 11
L): 30.5
R(: 5.3
HT: 20 ºC
HH: 4 %
Slope
A
SCALED
OPTICAL
IMAGE
TEST: 133.6
30.2 ºC
Endp: 11
L): 16.5
R(: 30.3
HT: 20 ºC
HH: 4 %
Slope
Low concentration / No sample
B
C
D
A
Empty pipe
Figure 5.6
Normal operation
B
C
D
Normal conditions
Typical optical images
Press the RESET key to return to the Information display from the Optical image display.
5.4.2 Viewing System configuration
You can view the System configuration, i.e. information about your refractometer system settings, by pressing the soft key C (= System configuration) in the Information display. The System configuration
display contains:
−
−
−
−
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%
Three soft keys:
− Relay configuration (key A); for details see Section 5.7, “Configuring relays”.
− Switch configuration (key B); for details see Section 5.6, “Configuring input switches”.
− Wash times (key C); for details see Section 5.9, “Configuring automatic prism wash”.
Press the RESET key to return to the Information display from the System configuration display.
5.4.3 Checking conditions inside sensor head
By pressing the soft key D (= Sensor head) in the Information display you will find out what the
conditions are inside the sensor head:
− Head temperature
− Head humidity
This is very useful information when suspecting a problem in the sensor head, for details see Section 7.2.2.
PR-03 instruction manual
34
5.5 Soft key Calibrate: Viewing and changing system settings
5.5.1 Viewing Optical image and raw data
It is possible to view all raw data from the sensor including the optical image followed by the Scaled
Image, Slope and Image Diagnostics displays (see the selection tree, figure 9.5). Starting from the Normal
display, select Calibrate/Optical image to get the complete optical image. The display (Figure 5.7)
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 5.6, selected through the Display key.
RAW
SENSOR
DATA
RMN: 2
RMX: 216
LED: 96
Scans: 2
A/D: 314
Sts: 00h
HT: 143
HH: 10
Scaled
image
A
Figure 5.7
Normal operation
B
C
D
Complete optical image with raw data
For information on the diagnostic messages shown on this screen, see Section 9.7.
5.5.2 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 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. 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
A/D
This refers to the temperature measurement
Sts
Sensor status bits determined by the type of Image Detector card: "04h" indicates a Process
refractometer PR-03. One bit added, "05h", indicates DETECTOR TIMEOUT.
5 Startup, configuration and calibration adjustment
35
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 inside the sensor is calculated from HH and HT.
5.5.3 Viewing Scaled image
In the scaled image (Figure 5.8) the optical image has been modified mathematically to make a clearer
curve.
SCALED
OPTICAL
IMAGE
TEST: 115.9
51.2 °C
Endp: 21
L): 9.8
R): 25.9
HT: 20 °C
HH: 3%
Slope
A
Normal operation
B
Figure 5.8
C
D
Scaled image display
The Scaled image display provides following information:
TEST:
(T)
Endp:
L):
R(:
HT:
HH:
The calculated TEST value, i.e. the number of photocells on the lisght side of the optical image
(to the left fo the vertical line). Range 8–248. Indicated by a dotted vertical line.
Indicates the process temperature.
The vertical intensity value of the rightmost point in % of span.
A measure of the left side curvature of the optical image.
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 5.5.3.
Sensor head internal temperature in ◦ C.
Sensor head internal relative humidity in %RH.
5.5.4 Viewing slope
The Slope display (Figure 5.9) shows the slope curve of the optical image. Slope is a measure of the
sharpness of the optical image.
The SLOPE curve should have a sharp dip at the TEST value. The following additional values are given:
PR-03 instruction manual
36
SLOPE
TEST: 115.7
31.2 °C
Max: 208
Slope: 2.7
Endp: 21
L): 10.1
R(: 25.8
Diagnostics
Normal operation
B
A
Figure 5.9
Max:
Slope:
C
D
Slope display
The filtered value of the maximum light intensity RMX of the raw data (Figure 5.7).
The absolute value of the slope curve dip at TEST. The value of Slope must be above 1 to be
acceptable.
5.5.5 Viewing Image diagnostics
The Image diagnostics display lists the critical values for TEST acceptance:
Max intensity OK (above 100)?
Endpoint below 75 %?
Image below corner?
Slope OK (above 1)?
Left curve OK (above 1)?
Right curve OK (above 1)?
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
For measurement with a normal sample, all answers should be Yes. A message Dip in image may
appear if the optical image is irregular.
5.6 Configuring input switches
To reach the input switch configuration settings from the Normal Display, use the command sequence
Calibrate/Parameters/Switch inputs.
The microprocessor accepts four switch inputs: A, B, C and D (for connections see 3.10). The function of
each switch can be individually defined from one of the following five alternatives:
0
1
Not defined
Scale select
(factory setting).
Select parameters for 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, C,
5 Startup, configuration and calibration adjustment
37
1.4412
RI(25ºC
SWITCH INPUT A (Not defined)
0
1
2
3
4
Not defined
Scale select
Ext hold & wash start
External wash stop
Calibration seal
A
Figure 5.10
Switch
B
Switch
C
Switch
D
B
C
D
Switch input display for input A
D).
Note: The range will not change.
2
Ext hold & wash start
3
External wash stop
4
Calibration seal
Example: medium 1 = 20 - 40 % Sugar, medium 2 = 20 - 40 % Salt.
Remote wash start for Relay unit wash function and external Hold.
This switch function is useful for an intermittent process: the prism
is washed when the process stops and again when it starts, between
the two washes the output signal is on Hold.
Only Sanitary refractometer PR-03-A, Probe refractometer PR-03-P
and Process refractometer PR-03-D.
Only Sanitary refractometer PR-03-A, Probe refractometer PR-03-P
and Process refractometer PR-03-D.
An input switch can be configured for calibration seal. Activating and
connecting the input switch for calibration seal will prevent calibration through software.
5.7 Configuring relays
You can check the existing relay configuration and functions with the Indicating transmitter. Press the
key sequence Display/System configuration/Relay configuration to display the current
relay settings.
The default setting for built-in signal relay 1 is No malfunction and for signal 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.
In relay units, Relay B is configured for wash by default.
You can reprogram the relay functions any time through the IT-R’s calibration menu by performing the
following steps:
PR-03 instruction manual
38
1. Press Calibrate/Parameters/Relays.
2. For built-in relays select either soft key A, Relay1, or soft key B, Relay2.
For a relay unit select key 3, Relay unit and then select the relay to be programmed (in -WR relays
A and B, in PR-7080 relays A, B, C, D).
3. Select the relay function
0
1
2
Not defined
Processor OK
Normal operation
3
No malfunction
4
Low limit
5
High limit
6 Preconditioning
7 Wash
8 In divert control
The relay is ON if the processor is running
The relay is ON if the diagnostic message is
Normal operation.
The relay is ON if the diagnostic message is
Normal operation or Low conc/no sample.
Low alarm relay, relay is ON if value below limit.
First choose an alarm source from the following list:
− CONC %
− Standard RI (25 ◦ C)
− TEMP ◦ C
− TEMP ◦ F
− TEST
− Sensor temperature
− Sensor humidity
Then enter a alarm limit. The default value of the limit is zero.
High alarm relay, relay is ON if value above limit.
First choose an alarm source from the following list:
− CONC %
− Standard RI (25 ◦ C)
− TEMP ◦ C
− TEMP ◦ F
− TEST
− Sensor temperature
− Sensor humidity
Then enter a alarm limit. The default value of the limit is zero.
A preconditioning relay. Relay unit only.
A wash relay. Relay unit only.
Not used with PR-03.
Important: An alarm relay configuration always requires the following information: high or low limit,
alarm source and alarm limit. The configuration is not complete until all the information is entered to
the IT-R.
Note: If needed, you can adjust alarm delay by pressing the key 4, Alarm delay in the Relays display
(Calibrate / Parameters / Relays). The same delay applis to all relays and is used to prevent
oversensitive alarms. The source value has to be out of limits during the whole delay time, given in seconds,
to activate the relay. The default value for the alarm delay is ten seconds.
5 Startup, configuration and calibration adjustment
39
5.8 Configuring external output unit
To program the External output unit from the keyboard of the Indicating transmitter, start with the sequence
Calibrate / Parameters / Output signals / External output to get the External
output unit display (Figure 5.11).
RI(25ºC
1.4412
EXTERNAL OUTPUT UNIT (Not connected)
1
2
3
4
5
Zero (0.0000)
Span (0.0000)
Hold function (Active)
Range (4..20 mA)
Source (Not defined)
A
Figure 5.11
1
Zero
2 Span
3 Hold function
4 Range
5 Source
B
C
D
External output unit display
Measurement value corresponding to 4 mA or 0 mA (depending on your chosen range)
Measurement value span corresponding to mA output span
Select either 0 Inactive or 1 Active
Select either 0 4..20 mA or 1 0..20 mA
Select from
0 Not defined
1 RI (25 ◦ C)
2 Standard RI (25 ◦ C)
3 Temp ◦ C
4 Temp ◦ F
5 TEST
6 Sensor temperature
7 Sensor humidity
Example: For source ◦ C, zero = 20, span = 80, the output signal 4 - 20 mA corresponds to 20-100 ◦ C.
5.9 Configuring automatic prism wash
The relay units -WR and PR-7080 can be configured to control prism wash. Automatic prism wash can be
initiated with regular intervals (Section 5.9.1) or based on certain measurement values (Section 5.9.2). It
is also possible to configure these automatic wash functions so that they are not used when the process is
stopped or the pipe is empty (Section 5.9.3 and Section 5.9.4).
PR-03 instruction manual
40
5.9.1 Timed wash
When an external relay unit is used as a wash timer, the time settings are entered after the sequence Calibrate / Parameters / Prism wash:
−
−
−
−
Preconditioning time s (0)
Wash time, s (3)
Recovery time, s (30)
Wash interval, min (20)
The default values for timed wash are given in parenthesis. The output signal is locked during wash and
recovery time.
PRECOND.
WASH
RECOVERY
INTERVAL
Figure 5.12
Prism wash sequence
Note: The wash interval timer starts a wash at a preset interval after last wash, independently of how the
last wash was initiated. If the wash interval is set to zero, the timer will not initiate a wash.
Wash type
Time
Pressure
Recovery
Interval
Steam wash
High pressure water wash
3-5 sec.
10-15 sec.
5-6 bar (73-87 psi)
20-30 bar (290-435 psi)
20-30 s
20-30 s
20-30 min
10-20 min
Table 5.1
Recommended prism wash times for the PR-03 sensors
Important: In steam wash, do not exceed the recommended wash times, because some process media may
burn to the prism surface if steamed for longer time. In case of coating, shorten the wash interval.
5.9.2 Smart wash
Sometimes it is necessary to modify the standard wash routine to fit the application better. The Smart wash
feature allows you define better when wash is needed and when it should not be implemented.
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 5.5.4).
The Smart wash settings are made at Calibrate / Parameters / Prism Wash / 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.
5 Startup, configuration and calibration adjustment
Minimum time
This parameter sets a limit to how often the Smart wash is allowed to start a wash, its
range is 0–1440 min.
When this parameter is zero, the Smart wash function is inactive.
Maximum test
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 is below Maximum test.
5.9.3 Preventing automatic wash
Note: The preconditioning and wash relays are not activated by automatic wash start under Low conc /
no sample as this indicates a clean prism in an empty process line, i.e. there is no need for washing the
prism.
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 use the command sequence Calibrate / Parameters / Prism wash / Wash stop /
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 9.7.
Wash can also be prevented by an external contact closure, telling e.g. that the process pump has stopped.
See Section 5.6.
5.9.4 Prism wash check
The prism wash check is used for making sure that the wash really has an effect on the prism, i.e. that the
wash works correctly. A prism wash is accepted if one of the two conditions are satisfied:
1. TEST exceeds "TEST limit", i.e. the TEST value reaches the set limit during wash cycle
2. TEST increases more than "TEST difference", i.e. the TEST value increases during wash reaching the value of normal TEST plus the given 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.
Example: 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.
41
PR-03 instruction manual
42
Automatic Wash start
1. Wash interval timer
2. Smart Wash
YES
WASH
STOP ?
Manual
Start
prism
wash
NO
YES
EXTERNAL
HOLD ?
REMOTE WASH
SWITCH
NO
WASH
RECOVERY
YES
NO
WASH
CHECK
OK?
RETRY
WASH ?
YES
NO
Reset “Prism
wash failure“
“Prism wash
failure“
Figure 5.13
Wash decision logics
5 Startup, configuration and calibration adjustment
If the wash is not accepted, the diagnostic message will be Prism wash failure (see Section 9.7
for more information). This message is reset from the keyboard "Reset" or by a successful wash. A Wash
retries parameter defines how many times wash is tried. The prism wash retries parameter is set with
Calibrate / Parameters / Prism wash / Wash check / Wash retries, the default
value (number of retries) is zero.
5.10 Adjusting concentration calibration
A K-Patents inline refractometer system is always delivered precalibrated according to the information given
by the user. The refractometer does not need any mechanical adjustments, all adjustments or changes of
range are made by keyboard entry only (Sections 5.10.2 and 5.10.3). The final calibration to obtain full
accuracy is made by collecting data from the actual process and sending that data to K-Patents or local
K-Patents representative for calculations and new calibration parameters (Section 5.10.6).
5.10.1 Checking current calibration
Wait until normal process conditions occur. The instrument is precalibrated at delivery, so a correct output
should be obtained automatically. If output is badly off-scale, check your process conditions.
If the diagnostic message is Normal operation but the concentration reading is not what could be
expected based on laboratory determinations, the deviation can be corrected with a calibration constant
bias, see Section 5.10.2 below.
If the concentration reading is correct, but not the output mA, see Section 5.10.3 below for adjusting the
concentration reading.
The temperature by the refractometer sensor may not be exactly the same as the temperature given by a
separate process temperature sensor. Normally, a constant slight deviation in the temperature by the sensor
is not critical. However, it is possible to calibrate the sensor to give the exact process temperature, see
Section 5.10.4, “Temperature calibration”.
The damping of the concentration measurement may be increased if necessary e.g. to get a smoother
recorder track, see Section 5.10.5.
5.10.2 Concentration calibration from keyboard
The concentration display should be in agreement with laboratory determinations. If the diagnostic message
is Normal operation, deviations can be corrected from keyboard by adding a calibration constant
bias value . A change of the calibration constant bias influences the Conc% reading the same amount.
Key in Calibrate/Parameters/CONC (R.I.)/Parameters/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 CONC% 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 Calibrate
branch of the Selection tree, Figure 9.5.
43
PR-03 instruction manual
44
! 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 is 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
New Gain = Old 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 5.10.6.
5.10.3 Output current range selection
It is possible to change the concentration range of the output current even after the instrument is installed
and operating. The change is made through the display
Calibrate/Parameters/Output signals/Current output.
Example: To change 4–20 mA = 15–25 CONC% to 4–20 mA = 10–30 CONC%, key in the sequence
Calibrate / Parameters / Output signals / Current output
and then enter Zero = 10 and Span = 20.
5.10.4 Temperature calibration
Normally the process liquid temperature is considerably higher than the ambient. Then the heat loss through
the refractometer 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 ◦ C can be added to the
temperature reading by giving the following key sequence
Calibrate/Parameters/Temperature/Temp bias and entering the bias in degrees centigrade.
Note: A change of Temperature bias will cause a small change in the concentration output, due to the
temperature compensation. If necessary, this change can be compensated with a Bias change (see Section 5.10.2).
5.10.5 Adjusting damping time
The damping time is the time it takes for the concentration measurement to reach half of its final value at
a step change of the concentration. For example, if concentration changes from 50 % to 60 % and damping
time is 10 s, it takes 10 seconds for the IT-R to show concentration 55 %. Figure 5.14 below shows how the
damping time affects the measurement curve.
The damping time is set in seconds with the key sequence
Calibrate/Parameters/Conc (R.I.)/Damping time. A damping time of 5–15 seconds
seems to work best in most cases, the factory setting is 5 sec.
! Warning! Avoid overdamping, the signal should not be made insensitive.
5 Startup, configuration and calibration adjustment
45
60
55
CONC%
Undamped
50
5s
10 s
30 s
45
40
35
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
Time [s]
Figure 5.14
Effect of damping time on measurement
5.10.6 Field calibration
The most accurate calibration is made under normal process conditions using your standard laboratory
determinations of sample concentration. K-Patents provides a field calibration service that optimizes the
calibration constants based on the data supplied.
You should systematically record calibrating data on the Calibration data report (page 109, also available
at www.kpatents.com and by email at [email protected]). When you have completed the Calibration data
report, you have to fax it to either K-Patents headquarters or your local K-Patents representative. A computer
analysis of the data will be made at K-Patents and optimal calibration data will be sent to you to be entered
in the IT-R.
For a complete report you need 10–15 valid data points (see below). A data point is of use for calibration
only when the diagnostic message is Normal operation. If prism wash is employed, do not take
samples during the wash. A data point is useful even if the concentration value is outside the range of the
output current. Each data point consists of:
LAB%
From IT-R display:
CONC%
TEST
TEMP
Sample concentration determined by the user.
(see Section 5.3)
Measurement in concentration units
Number of photocells on the light side of the optical image (= primary measurement)
Process temperature measurement in centigrades
Accurate calibration is only achieved if the sample is taken correctly and the data points are recorded
carefully and only when the message is Normal operation. Pay special attention to following details:
!
− The sampling valve and the refractometer should be installed close to each other in the process.
− Warning! Wear protective clothing appropriate to your process when operating the sampling
valve and handling the sample.
− Run the sample before starting to collect data points to avoid sampling old process liquid that
has remained in the sampling valve.
− Read the values CONC%, TEST and TEMP in the IT-R’s display at exactly the same time with
sampling.
− Use a tight container for the sample to avoid evaporation.
PR-03 instruction manual
46
5.10.7 Bench calibration
The calibration of your refractometer system can be checked offline using Standard RI liquids. These are
available at K-Patents with part number PR-2003. The complete set of 10 bottles covers the RI range 1.3101.540.
Standard RI liquids are also available directly from: Cargille Laboratories, 55 Commerce Road, Cedar
Grove, New Jersey 07009, USA. WWW: http://www.cargille.com/, e-mail: [email protected], phone:
973-239-6633, fax: 973-239-6096.
The bench calibration should be done at room temperature, but the temperature does not have to be exactly
25 ◦ C as the displayed value is temperature compensated. If the sensor is hot, let it cool down to ambient
temperature.
Use a sample holder, Figure 5.15 and "strip" the sensor, i.e. use PR-03-M sensor without the flow cell and
PR-03-W sensor without the valve body. Sample holders are available at K-Patents with part number PR1010 for Sanitary refractometer PR-03-A, PR-1012 for Probe refractometer PR-03-P and Compact process
refractometer PR-03-D.
Figure 5.15
Sample holder PR-1010
Use the same three R.I. liquids that were used for the Delivery Data Sheet of this sensor. See Appendices B,
“Information about Delivery data sheet (DDS)”, and D, “Instrument verification ISO 9000”, for more
information.
Just a few drops of sample are enough for reliable measurement. However, the sample must be covered to
prevent outside light to reach the prism. Sample leakage from holder may give measurement error. Always
use repeated measurements for each sample. Note: Clean the prism and the sample holder well with alcohol
between the different R.I. samples.
Important: Dispose of used RI liquids. Never put liquids back into the bottle after use!
Important: Offline calibration using process liquid very 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
− an ageing sample which is not representative
− outside light reaching the prism
Thus calibration using the process liquid should always be made inline, see Section 5.10.6, “Field calibration”.
6 Regular maintenance
6 Regular maintenance
The need for regular maintenance is minimal, due to the construction with no moving parts, no trimpots and
with a 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.
•
If your refractometer has prism wash, check that it works (in Normal display, press the soft key A,
Prism wash).
6.1 Checking the sensor moisture
The PR-03 sensor has an internal moisture detector. The moisture reading can be checked on the Indicating
transmitter display (Display / Sensor Head). Check the moisture reading once in a quarter.
An increasing signal indicates either condensate forming in the sensor head (if the process temperature is
below ambient) or prism leakage. If the moisture reading exceeds 30 %, replace the dryer (see below). If
the reading exceeds 50 %, check the prism seals.
The dryer (desiccant) is a plastic package inside the sensor head cover. When the dryer is effective, it is
yellow. When it turns green, it needs to be replaced. The dryer cannot be reactivated by any means, it
must be replaced. You can order new dryer packages (drying agents/desiccants), spare part number PR9107, from K-Patents or your local distributor.
For instructions on how to open the sensor head to replace the dryer, see Section 6.3 for the standard length
sensors (Sanitary refractometer PR-03-A, Compact process refractometer PR-03-D, Process refractometer
PR-03-M and Valve body refractometer PR-03-W) and Section 6.4 for the Probe sensor PR-03-P.
6.2 Checking and replacing prism or prism gaskets
Once a year check that the prism surface is smooth and clean. If the prism is scratched or the gaskets seem
to leak, order spare parts from K-Patents or your local distributor and follow the procedure described below
to replace them.
47
PR-03 instruction manual
48
6.3 Disassembling and assembling a standard length sensor
! Warning! Always check that the pipeline is empty before removing a sensor from the process line. Never
remove the sensor if there is process liquid in the pipe.
6.3.1 Disassembling the sensor
!
1. Disconnect the cable. Apply the two connector protection caps. Remove the sensor from the process
and rinse it well.
Warning! Wear appropriate protective clothing and be very careful when removing the sensor from the
process line!
2. Fix the sensor by the sensor head (T) in a vertical position, sensor label upwards, Figure 6.1. K-Patents
Service stand PR-1002 can be used.
Figure 6.1
Sensor in disassembly 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.
6 Regular maintenance
49
5. Disconnect the ribbon cable (B), the LED lead (C), and the temperature element lead (D).
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.
Warning! Never touch the screws (G) when the instrument is in the process line!
9. Remove the disc spring holder (H), the disc spring (J), and the thermal conductor (K).
6.3.2 Replacing the prism and prism gaskets
1. Lift out the Analyzer module, Figure 6.2. The module does not turn
due to the alignment pin (R). Note: The thermal insulator (N) is permanently glued at both ends.
Note: The Heavy-duty process refractometer PR-03-M74 with a sapphire prism has a special Analyzer module PR-9101 and a prism support due to the 1 mm higher sapphire prism.
2. To remove the prism, push it gently against the springs in the prism
plate (M), as indicated by an arrow in Figure 6.2 (b).
3. Clean the prism. Important: Do not leave any finger prints on any of
the four optical surfaces!
(a)
4. 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 6.3 (a). To make sure the prism is in correct position, press the
prism in the opposite direction of the arrow.
5. 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 6.3 (a). To make sure the prism is in correct position, press the
prism in the opposite direction of the arrow.
(b)
Figure 6.2 The
Analyzer module
6. Cover the prism by a new prism gasket (with the center hole uncut)
according to Figure 6.3 (b).
7. Put the prism support (U) upon the 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 6.2 (b).
8. Check that the temperature sensor (P) is properly springloaded. In outer position, the sensor tip is level
with the prism surface Figure 6.2 (b). It should flex inwards 2-3 mm as indicated by an arrow, but return
to the outer position.
PR-03 instruction manual
50
(a)
Figure 6.3
(b)
The prism plate, the prism and prism gaskets
9. Now the Analyzer module PR-9001 is assembled. It should be checked before mounting into the sensor
head:
1. Clean the window of the CCD-element (V), Figure 6.2. 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).
2. Connect the Indicating transmitter, and inspect the optical image at the Raw data display (key sequence Calibrate / Optical image).
3. The optical image must form a smooth curve. Dips or separate single points indicate that the optical
surfaces (e.g. the CCD window) are not clean.
Important: The prism must be covered to exclude external light.
4. When the image is OK, switch power off and disconnect all cards. Dismount the Image detector
card from the analyzer module.
10. Now the Analyzer module is ready for sensor assembly.
6.3.3 Assembling the sensor
1. Fit the Analyzer module into the sensor head. Note the alignment pin (R),
Figure 6.1.
2. Mount the thermal conductor (K) 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 6.1.
3. Mount the disk spring holder (H). Faster the six screws (G) in small steps
following the pattern of numbers in Figure 6.4. Continue until the holder
surface is flush with the surfaces of the three notches (S). No step should be
felt with the finger tip.
Figure 6.4
Tightening the
spring holder screws
4. Mount the Image detector card with the screws (F), Figure 6.1. First tighten the two guiding screws with
conical heads, then the third screw. Lock the screws with e.g. nail polish.
5. Mount the Image digitizer card with the screws (E). Connect (B), (C) and (D).
6 Regular maintenance
51
6. Check the dryer color, Figure 6.1. It should be yellow. If it is green, replace the dryer.
7. Connect (A), close the sensor cover and mount the Vee-clamp. The nut and bolt of the clamp should be
on the same side as the cable connector.
8. Place the sensor on a table with the prism upwards. Use a sharp knife with a curved edge to cut away
the circular piece of the gasket covering the prism. Important: Support the knife on the prism surface
only as it will scratch the steel.
9. Now the sensor is ready for process installation. Remember to check calibration (Section 5.10.1, “Checking current calibration” and Appendix D, “Instrument verification ISO 9000”).
6.4 Disassembling and assembling a probe sensor
! Warning! Always check that the pipeline or the vessel is empty before removing a sensor from the process
line. Never remove the sensor if there is process liquid in the pipe or the vessel.
6.4.1 Disassembling the probe sensor
!
1. Disconnect the cable. Apply the two connector protection caps. Remove the sensor from the process,
and rinse.
Warning! Wear appropriate protective clothing and be very careful when removing the sensor from the
process line!
2. Fix the sensor by the sensor head (T) in a vertical position, sensor label upwards, Figure 6.5.
K-Patents Service stand PR-1002 can be used.
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).
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.
Figure 6.5
Probe sensor in disassembly position
52
PR-03 instruction manual
!
8. Loosen carefully the six M4 screws (G) of the disc spring holder. Turn in small steps, alternating
between the screws.
Warning! 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).
6.4.2 Replacing the prism and prism gaskets
1. Lift out the Core module, Figure 6.6 (a). The module does not turn
due to the alignment pin (R) Remove the Prism support (U) fixed by
two M3 screws (L), Figure 6.6 (b). Note: The temperature sensor (P)
restricts the movements of the Prism support (U).
2. To remove the prism, push it gently against the springs in the prism
plate (M), as indicated by an arrow in 6.3(a).
3. The LED assembly can now be removed by gently pulling the cable
(c), Figure 6.5.
4. Remove the connector (D) from the temperature sensor cable, Figure 6.5. Use a pointed tool to press on the small metal springs through
the openings at the flat side of the connector.
5. Now pull out the temperature sensor (P). Pull one lead a little further
on than the other, to prevent the cable ends from plugging the hole.
!
6. To remove the lenses, loosen the two M2 screws (Z), Figure 6.7.
Warning! The lenses are springloaded.
7. Remove Prism plate (M) and Lens locking ring (under the Prism
plate).
8. Now the lenses, springs and lens spacers are free to be removed, Figure 6.6 (a).
9. Both end pieces of the Core module body are fixed with only one
screw each.
(a)
10. For assembly of the CORE module, use this procedure in reverse
order, then proceed to the sensor assembly instructions below.
Note: When mounting the temperature sensor (P) back again, do
not push it the whole way in. Leave leads visible, so that the Prism
support (U) can be mounted.
Note: When inserting the temperature sensor leads in the connector
(D), the middle hole in the connector should be empty.
11. Clean the prism. Important: Do not leave any finger prints on any of
the four optical surfaces!
(b)
Figure 6.6
The Core module
6 Regular maintenance
53
12. 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 6.7 (a). To make sure the prism is in correct position, press the
prism in the opposite direction of the arrow.
(a)
Figure 6.7
(b)
The prism plate, the prism and prism gaskets
13. Put the prism support (U) upon the 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 with
hemispherical heads (L) to the bottom, Figure 6.6 (b).
14. Push the temperature sensor (P) into its proper position. Mount the LED plate (Y). Check that the
temperature sensor (P) is properly springloaded. In outer position, the sensor tip is level with the prism
surface, Figure 6.6 (b). It should flex inwards 2-3 mm as indicated by an arrow, but return to the outer
position.
15. Now the CORE module is assembled. It should be checked before mounting into the sensor head:
a. 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).
b. Connect the indicating transmitter, and inspect the optical image on Raw sensor data display, key
sequence Calibrate / Optical image.
c. The optical image must form a smooth curve. Dips or separate single points indicate that the optical
surfaces (e.g. the CCD window) are not clean. Important: The prism must be covered to exclude
external light.
d. When the image is OK, switch power off and disconnect all cards. Dismount the Image detector
card from the CORE module.
16. The Core module is now ready for sensor assembly.
PR-03 instruction manual
54
6.4.3 Assembling the probe sensor
1. Fit the core module into the sensor head. Note the alignment pin (R), Figure 6.5.
2. Mount the thermal conductor (K) 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 6.5.
3. Mount the disk spring holder (H). Fasten the six screws (G) in small steps
following the pattern of numbers in Figure 6.8. Continue until the holder
surface is flush with the surfaces of the three notches (S). No step should be
felt with the finger tip.
Figure 6.8
Tightening the
spring holder screws
4. Mount the Image detector card with the screws (F), Figure 6.5. First tighten the two guiding screws with
conical heads, then the third screw. Lock the screws with e.g. nail polish.
5. Mount the Image digitizer card with the screws (E). Connect (B), (C) and (D).
6. Check the dryer color, Figure 6.1. It should be yellow. If it is green, replace the dryer.
!
7. Place the sensor on a table with the prism upwards. Use a sharp knife with a curved edge to cut away
the circular piece of the gasket covering the prism. Warning! Support the knife on the prism surface
only as it will scratch the steel. Now the sensor is ready for process installation. Remember to check the
calibration (Section 5.10.1, “Checking current calibration”, and Appendix D, “Instrument verification
ISO 9000”).
7 Troubleshooting and correcting problems
55
7 Troubleshooting and correcting problems
7.1 Troubleshooting Indicating transmitter
Before investigating the sensor, it is advisable to make sure that the Indicating transmitter is working. The
Indicating transmitter can be tested separately from the sensor by the following procedure:
− Power off
− Disconnect cable to sensor
− Power on
Now the diagnostic message should be **No sensor signal**. If this is the case, the IT-R should
be in order. Power off, reconnect the cable to sensor, power on and continue to troubleshooting the sensor
(Section 7.2).
If the diagnostic message is anything else than **No sensor signal**, check Section 9.7 for the
message and required action.
Note: If the original diagnostic message was **Detector timeout**, the 15 V supply to the Image
detector card may be incorrect due to a wrong position of the power selector switch (Figures 3.8 and 3.9) on
the IT-R’s processor card. Check that the position of the power selector switch matches your power supply.
If the power selector switch is in the correct position, but the error message persists, the problem is in the
sensor, not in the IT-R (see below).
7.2 Troubleshooting sensor
The Calibrate branch of the command tree (Figure 9.5 contains a set of consequent displays that can be
used to troubleshoot sensor problems. Each display contains some important values than can give you clues
to where the problem might be.
7.2.1 LED value
Check the LED value that tells you how well the light passes through the optics. The LED value is given in
the Optical image display, available through the commands Calibrate / Optical image.
RAW
SENSOR
DATA
RMN: 2
RMX: 216
LED: 96
Scans: 2
A/D: 314
Sts: 00h
HT: 143
HH: 10
Scaled
image
A
Figure 7.1
Normal operation
B
C
D
Checking the LED value
PR-03 instruction manual
56
A good LED value is in the range 20-150. The most common reason to a LED value higher than 150 is
that prism is coated. It is also possible the prism has been destroyed with an overactive steam wash. Check
the wash times and the prism surface (especially if the wash time exceeds the maximum of 3 s). Replace
the prism if the surface is damaged (see Chapter 6 for instructions).
If the process is very hot, it is also possible that the light source LED wears out after many years’ constant
use and needs replacing. Also leakage into the sensor can destroy LEDs (and everything else inside the
sensor housing). However, normally the LEDs last as long as the sensor and high LED values indicate a
prism problem.
It is very unusual for the LED value to be lower than 20, but in theory this can be caused by light from
outside reaching the prism e.g. because the pipe is translucent.
7.2.2 Sensor temperature and humidity
Checking the conditions inside the sensor head will give you an idea whether there’s is a real physical
problem. The Scaled image (Calibrate / Optical image / Scaled image) shows you both
the internal sensor temperature and humidity.
SCALED
OPTICAL
IMAGE
TEST: 115.9
51.2 °C
Endp: 21
L): 9.8
R): 25.9
HT: 20 °C
HH: 3%
Slope
A
Normal operation
B
Figure 7.2
C
D
Scaled image
The HT value gives you the sensor temperature and should be below 60 ◦ C. If the value is over this limit,
the measurement may not be accurate and the sensor needs to be cooled more effectively, see Section 2.2.1.
The HH value gives the humidity level inside the sensor and should be lower than 10 %. Most commonly
a higher humidity level indicates a leak in the sensor. If the sensor is subjected to big temperature changes,
condensate can cause humidity problems. If this is the case, the problem can be solved by replacing the
dryer unit inside the sensor, see Section 6.1.
7.2.3 Slope value
The Slope display (Calibrate / Optical image / Scaled image / Slope) shows you
the slope image and also gives the Slope value as a number. A good slope value is above 1.5. If the slope
value drops near 1.0, something is wrong with the prism:
− Prism is coated or
− Prism surface is not good or
− Prism gaskets leak and process liquid gets in by the prism sides
7 Troubleshooting and correcting problems
57
SLOPE
TEST: 115.7
31.2 °C
Max: 208
Slope: 2.7
Endp: 21
L): 10.1
R(: 25.8
Diagnostics
Normal operation
B
A
Figure 7.3
D
C
Slope display
Prism coating can be prevented by good process flow, high process temperature (see Section 2.2) or prism
wash. If your system already has prism wash, the wash interval can be decreased.
Important: The maximum wash times are given in Table 5.1. Do not exceed the recommended wash time,
instead you can try repeating the wash more often.
If prism surface is damaged, for example something in the process has abraded the prism or the wash time
has been long, replace the prism and adjust the prism wash or other conditions so that the prism doesn’t get
damaged.
If prism gaskets leak, replace them and all the sensor parts that have been damaged by the process liquid
inside the sensor (see Chapter 6, “Regular maintenance” for instructions).
7.2.4 Image diagnostics
The last tool in this branch of the selection tree is the Image diagnostics display, available through Calibrate / Optical image / Scaled image / Slope / Diagnostics. If the answer to
all the questions in this screen is Yes (Figure 7.4), the sensor head temperature and humidity are below the
limits and the message is Normal operation, your refractometer system should be in working order.
Note: If the system is offline, some of the image diagnostics questions will get No for an answer even in a
working system (Figure 7.4).
IMAGE DIAGNOSTICS
IMAGE DIAGNOSTICS
Max intensity OK (above 100)?
Endpoint below 75%?
Image below corner?
Slope OK (above 1)?
Left curve L) OK (above 1)?
Right curve R) OK (above 1)?
Max intensity OK (above 100)?
Endpoint below 75%?
Image below corner?
Slope OK (above 1)?
Left curve L) OK (above 1)?
Right curve R) OK (above 1)?
Yes
Yes
Yes
Yes
Yes
Yes
SENSOR HEAD
Head temperature: 28 °C
Head humidity: 3%
SENSOR HEAD
Head temperature: 28 °C
Head humidity: 3%
Normal operation.
A
B
Yes
Yes
No
No
Yes
No
Normal operation.
C
D
A
Inline image diagnostics (= process)
Figure 7.4
B
C
D
Offline image diagnostics (= in air)
Image diagnostics display
PR-03 instruction manual
58
CONC
SCALED
OPTICAL
IMAGE
68.0%
TEST: 115.9
51.2 °C
Endp: 21
L(: 9.8
R): 25.9
HT: 20 °C
HH: 3%
PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194
TEST: 115.7
Normal operation
Calibrate
Display
Good HT lower than 60 ºC
Good HH lower than 10 %
Slope
Normal operation
A
CONC
B
C
D
68.0%
A
B
C
D
SLOPE
TEST: 115.7
31.2 °C
Max: 208
Slope: 2.7
Endp: 21
L): 10.1
R(: 25.8
PROCESS TEMPERATURE: 32.5 °C
STANDARD RI(25°C): 1.4190
Good slope value
more than 1.5
TEST: 117.2
Normal operation
Optical
image
A
Diagnostics
Parameters
B
C
D
RAW
SENSOR
DATA
RMN: 2
RMX: 216
LED: 96
Scans: 2
A/D: 314
Sts: 00h
HT: 143
HH: 10
Scaled
image
A
A
Normal operation
B
C
D
IMAGE DIAGNOSTICS
Good LED value 20-150
Max intensity OK (above 100)?
Endpoint below 75%?
Image below corner?
Slope OK (above 1)?
Left curve L) OK (above 1)?
Right curve R) OK (above 1)?
Yes
Yes
Yes
Yes
Yes
Yes
SENSOR HEAD
Head temperature: 28 °C
Head humidity: 3%
Normal operation.
Normal operation
B
C
Figure 7.5
D
A
B
C
Troubleshooting your refractometer system with IT-R
D
8 Sensor specifications and other sensor information
59
8 Sensor specifications and
other sensor information
8.1 Sensor labels
Sanitary refractometer label
Figure 8.1
Process refractometer label
Examples of sensor labels
8.2 Sensor compatibility
The K-Patents Inline refractometer models PR-01 and PR-03 are not compatible with each other. The
interconnecting cable plug is the same for all the PR-03 models, but it is not compatible with the model
PR-01.
8.3 Sanitary refractometer PR-03-A
The 3-A approved Sanitary process refractometer for measuring Brix and concentrations in the pipe line.
Easy to install in any pipe size directly or via flow cell. The sanitary refractometer is well suited for all food
and beverage processing applications where on-line monitoring and control can help to improve product
quality and reduce costs.
PR-03 instruction manual
60
8.3.1 PR-03-A sensor model code
MODEL AND DESCRIPTION
MODEL
PR-03 = Sensor
PR-03
Sensor classification
-A = 3-A approved
-A
Refractive Index range limits
62 = R.I. 1.310–1.540 (0-100 Brix)
Process connection
-H = Sanitary 3-A clamp, 2 1/2 inch
Sensor wetted parts material
SS = AISI 316 L
Sensor options
-SC = Stainless steel sensor housing
Example:
Sensor:
62
-H
SS
-SC
PR-03-A62-HSS
8.3.2 PR-03-A mounting hardware model code
Mounting hardware (without wash nozzles)
MODEL AND DESCRIPTION
MODEL
EFC = Elbow flow cell
EFC
Sensor connection
-H = Sanitary 3-A clamp, 2 1/2 inch
Construction material
SS = AISI 316
Process connection
-H = Sanitary 3-A clamp
Pipe section diameter
10 = 25 mm (1 inch) (A)
15 = 40 mm (1 1/2 inch)
20 = 50 mm (2 inch)
25 = 65 mm (2 1/2 inch) (A)
Flow cell inlet type
-SI = Straight pipe
-RI = Reduced pipe (cone)
(A) with -SI option only
-H
SS
-H
10
15
20
25
-SI
-RI
8 Sensor specifications and other sensor information
61
Mounting hardware with wash nozzles
MODEL AND DESCRIPTION
MODEL
EFC = Elbow flow cell
EFC
Sensor connection
-H = Sanitary 3-A clamp, 2 1/2 inch
Construction material
SS = AISI 316
-H
SS
Process connection
-H = Sanitary 3-A clamp
-H
Pipe section diameter
10 = 25 mm (1 inch) (A)
15 = 40 mm (1 1/2 inch) (B)
20 = 50 mm (2 inch)
Flow cell inlet type
-SI = Straight pipe
-RI = Reduced pipe (cone)
Wash nozzle connection
-NC = Nozzle connection (B)
Wash nozzles
-SN = Steam nozzle, PR-3365
-WN = Water nozzle, PR-3364
-WP = Pressurized water nozzle, PR-3366 (C)
-PG = Plug for nozzle connection, PR-3367
10
15
20
-SI
-RI
-NC
-SN
-WN
-WP
-PG
(A) with -SI option only
(B) with -RI option only
(C) nozzle inlet R 1/2 inch female
Example:
Sensor:
PR-03-A62-HSS
Flow cell:
EFC-HSS-H20-SI
MODEL AND DESCRIPTION
MODEL
MFC = Mini flow cell
MFC
Sensor connection
-H = Sanitary 3-A clamp, 2 1/2 inch
Construction material
SS = AISI 316
Pipe section diameter
05 = 15 mm (1/2 inch)
-H
SS
05
PR-03 instruction manual
62
8.3.3 PR-03-A specifications
General specifications
Refractive index range
Accuracy
General system specifications for a PR-03-A refractometer sensor
R.I. 1.3100–1.5400 (hot water – 100 Brix)
R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).
Repeatability and stability correspond to accuracy.
Speed of response
1.2 s undamped
Damping time constant
Selectable up to 5 min
Process temperature
-20 ◦ C–130 ◦ C (-4 ◦ F–266 ◦ F)
Temperature compensation
Automatic
Ambient temperature
max. 45 ◦ C (113 ◦ F), min. -20 ◦ C (-4 ◦ F)
Humidity
20–100 %
Pollution degree
Degree 2
Process pressure
Sanitary clamp max. 15 bar (200 psi) at 20 ◦ C (70 ◦ F)/
9 bar (125 psi) at 120 ◦ C (250 ◦ F)
Recommended flow velocity Above 1.5 m/s (5 ft/s)
Quality certificate
ISO 9001
Sensor
Wetted parts
Sensor weight
Sensor protection class
Process connection
Temperature measurement
Image detector
Light source
Indicating transmitter
Options
Meets the requirements of the 3-A Sanitary Standard 46-02
R
AISI 316L stainless steel, prism gaskets Teflon , prism spinel
2.2 kg (5 lbs)
IP67, Nema 4X
2 1/2" Sanitary clamp
Built-in Pt-100
1024 pixel CCD-element
Light emitting diode (LED)
See Chapter 9
− External output unit, Section 4.2
− Relay units for prism wash/alarm, Section 4.1
− Prism wash nozzles for steam and hot water, Section 8.3.2
− Flow cells according to separate drawings available from K-Patents
− Stainless steel sensor housing
A62
R.I.
1.30
1.35
0
10
1.40
20
Figure 8.2
30
40
1.45
50
60
1.50
70
80
1.55
BRIX
Sanitary refractometer PR-03-A rangeability
1.60
8 Sensor specifications and other sensor information
63
8.3.4 PR-03-A parts lists
Item
Pcs.
Part No.
Description
1
2
1
1
PR-9205
PR-9201
2.5"Sanitary ferrule
2.5"Sanitary clamp
3
3
3
1
1
1
PR-9202
PR-9203
PR-9204
2.5"Sanitary gasket EPDM
2.5"Sanitary gasket NBR
R
2.5"Sanitary gasket Teflon 4
5
6
7
8
9
1
1
1
1
6
1
PR-9002
PR-03 Head
R
Thermal insulator Teflon Alignment pin
PR-03 Base
Screw M5x10 DIN 7991 A2
Thermal conductor
*
10
11
1
2
1
12
13
14
15
16
6
4
1
4
1
PR-9011
PR-9010
PR-7133
PR-5012
Disc spring set
Disc spring
Disc spring holder
Screw M4x8 DIN 912 A2
Screw M4x12 DIN
Image analyzer card
Screw M4x8 DIN 912 A2
Vee clamp 11-130
Item
Pcs.
17
18
19
20
21
22
23
24
25
26
27
28
39
44
2
1
1
2
2
1
1
2
1
1
1
4
1
1
Part No.
PR-5011
PR-9107
PR-9106
PR-9110
PR-9001
PR-7125
Description
Screw M3x8 DIN 912
Bushing holder
Bushing
Screw M4x8 DIN 912 A2
Washer M4 DIN 125
O-ring seal 108x3
Dryer
Screw M3x16 DIN 912 A4
PR-03 Connector complete
PR-03 Cover
PR-03 Sensor label
Screw M3x5 DIN 7380 A4
CORE-Optics module
Image detector card
PR-03 instruction manual
64
Item
Pcs.
29
30
2
1
*
31
32
1
1
1
33
34
35
36
37
38
39
40
2
1
1
1
2
2
1
1
Part No.
Description
Screw M3x10 DIN 7380 A2
Prism support
PR-9004
PR-9003
PR-9001
PR-9250
H62 prism set
Prism gasket
H62 prism
Screw M2x5 DIN 965A A2
Prism plate
Lens locking ring
Lens 8/30
Lens 8/10
Pressure spring 7.8x6
CORE optics module
PR-03 temperature element assembly
Item
Pcs.
Part No.
Description
41
42
43
44
45
46
1
1
2
1
2
1
PR-9251
PR-03 LED assembly
LED plate
Screws M3x4 DIN 912
Image detector
Screw M3x10 DIN 7991 A2
Screw M3x10 DIN 912 A2
PR-7125
8 Sensor specifications and other sensor information
8.3.5 PR-03-A mounting specifics
K-Patents Sanitary refractometer PR-03 is connected to the process by a 2 1/2" 3-A sanitary clamp. The
recommended mounting is in a pipe bend, with a vertical flow upwards before the sensor, and a horizontal
pipe after. The benefits of this way of mounting are:
1. Self-cleaning of prism due to the flow directed against its surface.
2. Efficient drainage when the pipe is emptied.
For pipe diameters of 3" or above, a ferrule is welded directly to the pipe wall, Figure 8.3 (a ferrule, length
21.5 mm, is delivered with standard sensor delivery from K-Patents). For smaller pipe diameters, flow cells
are available from K-Patents, Figures 8.4, 8.5 and 8.6, see also the tables in Section 8.3.2. 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.
Figure 8.3
Mounting with sanitary ferrule (Pipe diameter 3" (80 mm) or larger)
65
PR-03 instruction manual
66
Figure 8.4
Figure 8.5
Flow cell EFC-HSS-H25-SI (Pipe diameter 2 1/2" (65 mm))
Flow cell EFC-HSS-H20-RI (Pipe diameter 2" (50 mm))
8 Sensor specifications and other sensor information
Figure 8.6
Flow cell EFC-HSS-H15-RI (Pipe diameter 1 1/2" (40 mm))
If a Sanitary refractometer sensor PR-03-A is to be installed in a sample line, diameter 5-10 mm, it is
mounted with a mini flow cell, Figure 8.7.
Figure 8.7
PR-03-A mini flow cell
67
PR-03 instruction manual
68
8.4 Probe refractometer PR-03-P
The K-Patents Probe refractometer PR-03-P-V/P provides an accurate on-line BRIX measurement in cookers, tanks and large pipelines. Some sensor options allow flush mounting in a tank wall and thus make it
possible to use a scraper. With certain options the Probe refractometer can also be installed in a cooker
through a steam jacket.
8.4.1 PR-03-P sensor model code
MODEL AND DESCRIPTION
MODEL
PR-03 = Sensor
PR-03
Sensor classification
-P = 3-A Sanitary Probe
-P
Refractive Index range limits
62 = R.I. 1.310–1.540 (0-100 Brix)
62
Process connection
-T = Sanitary 3-A clamp, 2 1/2 inch, insertion length 139.5 mm
-R = Sanitary 3-A clamp, 4 inch, insertion length 139.5 mm
-V = Sanitary 3-A clamp, 2 1/2 inch, flush mounted (B)
-P = MT4 DN 25/1T APV Tank bottom flange, flush mounted
Sensor wetted parts material
SS = AISI 316 L
-T
-R
-V
-P
SS
Sensor options (A)
-SC = Stainless steel sensor housing
-PC = Adapted for air purging
-SC
-PC
(A) For standard sensor, leave this section blank
(B) Needs vessel flush mount adaptor VFMA-03-VSS
Table 8.1
PR-03-P model code
8.4.2 PR-03-P mounting hardware model code
MODEL AND DESCRIPTION
MODEL
VFMA-03-VSS = vessel flush mount adaptor for PR-03-P62-VSS
VFMA-03-PSS = MT4 DN25/1T APV tank bottom flange for PR-03-P62-PSS
VFBP-03-VSS = Blind plug for vessel flush mount adaptor VFMA-03-VSS
VFMA-03-VSS
VFMA-03-PSS
VFBP-03-VSS
8 Sensor specifications and other sensor information
8.4.3 PR-03-P specifications
General specifications
Refractive Index range
Accuracy
General system specifications for a PR-03-P refractometer sensor
R.I. 1.3100–1.5400 (corresponds to hot water–100 Brix)
R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).
Repeatability and stability correspond to accuracy.
Speed of response
1.2 s undamped
Damping time constant
Selectable up to 5 min
Process temperature
-20 ◦ C–130 ◦ C (-4 ◦ F–266 ◦ F)
Temperature compensation
Automatic
Ambient temperature
max. 45 ◦ C (113 ◦ F), min. -20 ◦ C (-4 ◦ F)
Humidity
20–100 %
Pollution degree
Degree 2
Process pressure
Sanitary clamp max. 15 bar (200 psi) at 20 ◦ C (70 ◦ F)/
9 bar (125 psi) at 120 ◦ C (250 ◦ F)
Recommended flow velocity Above 1.5 m/s (5 ft/s)
Quality certificate
ISO 9001
Sensor
Wetted parts
Sensor weight
Sensor protection class
Process connections
Temperature measurement
Image detector
Light source
Indicating transmitter
Options
Meets the requirements of the 3-A Sanitary Standard 46-02
R
AISI 316L stainless steel, prism gaskets Teflon , prism spinel
2.4 kg (5.3 lbs)
IP67, Nema 4X
2 1/2" Sanitary clamp
4" Sanitary clamp
MT4 DN 25/1T APV Tank bottom flange
Built-in Pt-100
1024 pixel CCD-element
Light emitting diode (LED)
See Chapter 9
− External output unit, Section 4.2
− Relay units, Section 4.1
− Stainless steel sensor housing
69
PR-03 instruction manual
70
8.4.4 PR-03-P parts lists
Item
Pcs.
Part No.
Description
1
1
1
1
1
1
1
1
1
1
PR-9205
VFMA-03-VSS
VFMA-03-PSS
VFBP
PR-4275
2.5"sanitary ferrule
Vessel flush mount adaptor
MT4 DN25/1T APV tank bottom flange
Blind plug for tank bottom flange
4"sanitary ferrule
2
2
1
1
PR-9201
PR-9270
2.5"sanitary clamp
4"sanitary clamp
3
3
3
1
1
1
PR-9202
PR-9203
PR-9204
2.5"sanitary gasket EPDM
2.5"sanitary gasket NBR
R
2.5"sanitary gasket Teflon 3
1
PR-9243
MT4 DN25/1T APV gasket EPDM
3
3
3
1
1
1
PR-9272
PR-9273
PR-9274
4"3A sanitary gasket EPDM
4"3A sanitary gasket NBR
R
4"3A sanitary gasket Teflon 4
4
4
4
1
1
1
1
PR-9310
PR-9311
PR-9312
PR-9313
PR-03-P-TSS head
PR-03-P-VSS head
PR-03-P-PSS head
PR-03-P-RSS head
5
6
7
8
9
1
1
1
6
1
R
Thermal insulator Teflon PR-9005
PR-9011
Alignment pin
PR-03 base
Screw M5x10 DIN 7991 A2
Thermal conductor
Item
Pcs.
Part No.
Description
*
10
11
1
2
1
PR-9010
Disc spring set
Disc spring
Disc spring holder
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
6
4
1
4
1
2
1
1
2
2
1
1
2
1
1
1
4
PR-7133
PR-5012
PR-5011
PR-9107
PR-9106
PR-9301
Screw M5x10 DIN912 A2
Screw M4x12 DIN
Image digitizer card
Screw M4x8 DIN 912 A2
Vee clamp 11-130
Screw M3x8 DIN 912
Bushing holder
Bushing
Screw M4x8 DIN 912 A2
Washer M4 DIN 125
O-ring seal 108x3
Dryer
Screw M3x16 DIN 912 A4
PR-03 connector complete
PR-03 cover
PR-03 sensor label
Screw M3x5 DIN 7380 A4
8 Sensor specifications and other sensor information
Item
Pcs.
29
30
2
1
*
31
32
1
1
1
33
34
35
36
37
38
39
40
2
1
1
1
2
2
1
1
Part No.
Description
Screw M3x20 DIN 7380 A2
Prism support
PR-9004
PR-9003
PR-9301
PR-9255
71
H62 prism set
Prism gasket
H62 prism
Screw M2x5 DIN 965A A2
Prism plate
Lens locking ring
PR-03-P lens assembly
Lens 8/10
Pressure spring 7.8x6
PR-03-P CORE Optics module
PR-03-P temperature element assembly
Item
Pcs.
Part No.
Description
41
42
43
44
45
46
47
48
49
49
50
51
1
1
2
1
2
1
1
1
1
1
2
1
PR-9256
PR-03-P LED assembly
LED plate
Screws M3x12 DIN 912 A2
Image detector
Screw M3x10 DIN 7991 A2
Screw M3x10 DIN 912 A2
Pressure spring 9.8x25
Lens ring
Screw M3x12 DIN 912 A2
Screw M3x12 DIN 912 A2
Lens 10/50
Screw M3x10 DIN 7991 A2
PR-7125
PR-03 instruction manual
72
8.4.5 PR-03-P mounting specifics
The Probe refractometer PR-03-P is primarily designed for mounting in a tank wall. To ensure that the
measurement is representative and that the prism stays clean, the probe should be installed close to a stirrer,
Figure 8.8.
CHECK CABLE LENGTH
~
4-20 mA
Figure 8.8
Recommendations for mounting the Probe sensor PR-03-P in a tank
K-Patents probe refractometer type PR-03-P62-TSS is connected to the process by a 2 1/2" 3-A sanitary
clamp, Figure 8.9. The type PR-03-P62-RSS type sensor is connected to process by a 4" 3-A sanitary
clamp.
Note: For higher process (or ambient) temperatures, use instead a flush mounted sensor (Figures 8.9, 8.10
and 8.11), where the electronics in the sensor head are further away from the process heat.
Figure 8.9
Insertion of Probe refractometer PR-03-P62-TSS
8 Sensor specifications and other sensor information
Figure 8.10
Flush mounted Probe refractometer PR-03-P62-PSS
The refractometer type PR-03-P62-PSS is flush mounted, using a sanitary APV Tank bottom flange, Figure 8.10. The refractometer can be replaced with a blind plug so that the tank can be used even when the
refractometer has been removed for service.
The refractometer type PR-03-P62-VSS is specially designed for vessels with a steam jacket, e.g. a jam
cooker. In a jam cooker the blade of the scraper should sweep the prism in direct contact. The PR-03-P62VSS is mounted by means of a vessel flush-mount adaptor VFMA-03-VSS, Figure 8.11.
Figure 8.11 Mounting probe refractometer PR-03-P62-VSS
through vessel steam jacket with adaptor VFMA-03-VSS
73
PR-03 instruction manual
74
8.4.6 PR-03-P programming specifics
If the optical image appears inverted when using the probe refractometer PR-03-P (see Figure 8.12), configure parameter lminv to value 1 by key-in sequence Calibrate / Parameters / Standard RI
(25◦ C) / Image inversion to turn the picture right way.
SCALED
OPTICAL
IMAGE
TEST: 248.0
30.2 ºC
Endp: 11
L): -7.5
R(: 3.3
HT: 20 ºC
HH: 4 %
Slope
A
Low concentration / No sample
B
Figure 8.12
C
D
Inverted optical image
Note: This image inversion correction is only available in program version 8.5 or higher. When an IT-R
is delivered together with a Probe refractometer sensor, the program version is always compatible with the
inverted image.
8 Sensor specifications and other sensor information
75
8.5 Compact process refractometer PR-03-D
The K-Patents Compact process refractometer is a compact general industry model for measuring liquid
concentrations in various in-line applications, like chemicals, fibers, plastics, salts and sodium components.
Easy to install in smaller pipe lines. Also for applications where special alloys are required.
8.5.1 PR-03-D sensor model code
MODEL AND DESCRIPTION
MODEL
PR-03 = Sensor
PR-03
Sensor classification
-D = General purpose
-D
Refractive Index range limits
62 = R.I. 1.310–1.540 (0-100 Brix)
62
Process connection
-L = Sandvik L clamp, 76.1 (A)
-L
Sensor wetted parts material
SS = AISI 316 L
HC = Hastelloy C / ASTM C276
TI = Titanium / ASTM B
NI = Nickel 200
Sensor options (B)
-SC = Stainless steel sensor housing
-PC = Adapted for Exproof by purging (C)
SS
HC
TI
NI
-SC
-PC
(A) Includes counter ferrule for Sandvik 76.1
(B) For standard sensor without option, leave this section blank
(C) Available with -SC code only, including 5 meters sensor cable, PR-8400-005
Example:
Sensor:
PR-03-D62-LSS
8.5.2 PR-03-D mounting hardware model code
MODEL AND DESCRIPTION
MODEL
PFC = Pipe flow cell
PFC
Sensor connection
-L = Sandvik L clamp
Construction material
SS = AISI 316
Process connection
-A = ANSI 150 psi
Pipe section diameter
10 = 25 mm (1 inch)
For line sizes 76 mm (2 1/2 inch) or bigger use standard process connections.
-L
SS
-A
10
PR-03 instruction manual
76
8.5.3 PR-03-D specifications
General specifications
Refractive Index range
Accuracy
General system specifications for a PR-03-D refractometer sensor
R.I. 1.3100–1.5400 (corresponds to hot water–100 Conc% b.w.)
R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).
Repeatability and stability correspond to accuracy.
Speed of response
1.2 s undamped
Damping time constant
Selectable up to 5 min
Process temperature
-20 ◦ C–130 ◦ C (-4 ◦ F–266 ◦ F)
Temperature compensation
Automatic
Ambient temperature
max. 45 ◦ C (113 ◦ F), min. -20 ◦ C (-4 ◦ F)
Humidity
20–100 %
Pollution degree
Degree 2
Process pressure
max. 15 bar (200 psi) at 20 ◦ C (70 ◦ F)/
9 bar (125 psi) at 120 ◦ C (250 ◦ F)
Recommended flow velocity Above 1.5 m/s (5 ft/s)
Quality certificate
ISO 9001
Sensor
Wetted parts
Optional wetted parts
Sensor weight
Sensor protection class
Process connection
Temperature measurement
Image detector
Light source
Indicating transmitter
Options
R
AISI 316L stainless steel, prism gaskets Teflon , prism spinel
Hastelloy C/ASTM C276, Titanium/ASTM B 348 GR2, Nickel 200
2 kg (4.4 lbs)
IP67, Nema 4X
Sandvik L clamp 76.1 mm (2 1/2")
Built-in Pt-100
1024 pixel CCD-element
Light emitting diode (LED)
See Chapter 9
− External output unit, Section 4.2
− Relay units for prism wash/alarm, Section 4.1
− Stainless steel sensor housing
D62
R.I.
1.30
1.35
0
10
Figure 8.13
1.40
20
30
40
1.45
50
60
1.50
70
1.55
1.60
80 CONC%
Compact process refractometer PR-03-D rangeability
8 Sensor specifications and other sensor information
77
8.5.4 PR-03-D parts lists
Item
1
1
1
1
2
3
4
5
6
7
8
9
*
10
11
12
13
14
15
16
17
Pcs.
1
1
1
1
1
1
1
1
1
1
6
1
1
2
1
6
4
1
4
1
1
Part No.
PR-9280-SS
PR-9280-HC
PR-9280-TI
PR-9280-NI
PR-9282
PR-9281
PR-9009
PR-9005
PR-9011
PR-9010
PR-7133
PR-9001
PR-5012
Description
Sandvik ferrule 76.1 AISI 316L
Sandvik ferrule 76.1 Hastelloy
Sandvik ferrule 76.1 Titanium
Sandvik ferrule 76.1 Nickel
Sandvik clamp FCLC-76.1 AISI 304
Sandvik O-ring FCLG-T-76.1 Teflon registered
PR-03 Sandvik 76.1 head
R
Thermal insulator Teflon Alignment pin
PR-03 base
Screw M5x10 DIN 7991 A2
Thermal conductor
Disc spring set
Disc spring
Disc spring holder
Screw M5x10 DIN 912 A2
Screw M4x12 DIN 912
Image digitizer
Screw M4x8 DIN 912 A2
CORE optics module
Vee clamp 11-130
Item
Pcs.
18
19
20
21
22
23
24
25
26
27
28
29
30
2
1
1
1
2
2
1
1
2
1
1
1
4
Part No.
PR-7125
PR-5011
PR-9107
PR-9106
PR-9110
Description
Screw M3x8 DIN 912
Bushing holder
Bushing
Image detector card
Screw M4x8 DIN 912 A2
Washer M4 DIN 125
O-ring seal 108x3
Dryer
Screw M3x16 DIN 912 A4
PR-03 connector complete
PR-03 sensor cover
PR-03 sensor label
Screw M3x5 DIN 7380 A4
PR-03 instruction manual
78
Item
Pcs.
29
30
30
31
32
33
34
35
36
37
38
39
40
2
1
1
1
1
2
1
1
1
1
2
1
1
Part No.
PR-9003
PR-9004
PR-9001
PR-9250
Description
Screw M3x10 DIN 7380 A2
Prism support
Prism support H64
Prism gasket (PTFE)
H62 prism set (Spinel)
Screw M2x5 DIN 965A A2
Prism plate
Lens locking ring
Lens
Lens 8/10
Pressure spring 7.8x6
CORE optics module
PR-03 temperature element assembly
Item
Pcs.
Part No.
Description
41
42
43
44
45
46
1
1
2
1
2
1
PR-9251
PR-03 LED assembly
LED plate
Screws M3x4 DIN 912
Image detector card
Screw M3x10 DIN 7991 A2
Screw M3x10 DIN 912 A2
PR-7125
8 Sensor specifications and other sensor information
8.5.5 PR-03-D mounting specifics
In pipes with the nominal size 2.5" (76.1 mm) or larger, the Compact process refractometer PR-03-D sensor
is mounted with a Sandvik-L 76.1 clamp, Figure 8.14. For smaller pipes, the sensor has to be mounted with
the PFC Pipe Flow cell, Figure 8.15.
Figure 8.14
Mounting PR-03-D in pipelines with diameter 2.5" (76.1 mm) or larger
79
PR-03 instruction manual
80
Figure 8.15
Mounting PR-03-D in pipelines with diameter less than 2.5" (76.1 mm)
8 Sensor specifications and other sensor information
81
8.6 Process refractometer PR-03-M
K-Patents Process refractometer PR-03-M is designed for use in chemically aggressive solutions
and ultra-pure fine chemical processes. It has a
built-in flow cell designed to keep all metal and
other easily corroding parts from coming into contact with the process liquid. All the wetted parts
are made of non-metallic materials, either PTFE
R
R
(Teflon ) or PVDF (Kynar ), and thus the
PR-03-M sensor withstands corrosion very well.
The flow cell (N) and the sapphire plate (L) are
fixed to the stainless steel sensor with four screws.
The flow cell (N) is sealed by a Kalrez O-ring
(M). The flow cell prevents any leakage reaching
the metal parts, because there is a circular leakage
chamber behind the O-ring (M). The chamber connects to a check port (O), which has a 1/8" female
thread connection.
Figure 8.16
PR-03-M sensor
8.6.1 PR-03-M sensor model code
MODEL AND DESCRIPTION
MODEL
PR-03 = Sensor
PR-03
Sensor classification
-M = Aggressive medium adapter
Refractive Index range limits
62 = 1.310–1.540 R.I. (0.100 Conc% b.w.), Spinel prism
74 = 1.260–1.500 R.I., sapphire prism
Process line connection
-R = Thread (G 1/2 inch)
-N = Thread (1/2 inch NPT female)
-M
62
74
-R
-N
Line size connection diameter
-050 = 1/2 inch (flow volume 2-8 l/min (0.5-2.1 GPM))
-050
Flow cell wetted parts material
R
-PV = Kynar (PVDF=Polyvinylidenefluoride)
R
-TF = Teflon (PTFE=Polytetrafluoroethylene)
-PV
-TF
Sensor cover
-SC = Stainless Steel sensor housing
Sensor options
-PC = adapted for Exproof by purging (A)
(A) including 5 meter sensor cable, PR-8400-005
Example:
Sensor:
PR-03-M62-R-050-TF-SC
-SC
-PC
PR-03 instruction manual
82
8.6.2 PR-03-M specifications
General specifications
Refractive Index range, standard
General system specifications for a PR-03-M refractometer sensor
R.I. 1.3100–1.5400 (corresponds to hot water–100 Brix) with
spinel prism
Refractive Index range
R.I. 1.2600–1.5000 with sapphire prism
Refractive Index range
R.I. 1.3900–1.6200 with YAG prism
Accuracy
R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).
Repeatability and stability correspond to accuracy.
Speed of response
1.2 s undamped
Damping time constant
Selectable up to 5 min
Process temperature
-20 ◦ C–130 ◦ C (-4 ◦ F–212 ◦ F)
Temperature compensation
Automatic
Ambient temperature
max. 45 ◦ C (113 ◦ F), min. -20 ◦ C (-4 ◦ F)
Humidity
20–100 %
Pollution degree
Degree 2
Process pressure
max 5 bar (72.5 psi)
Recommended flow velocity
2–40 l/min (0.5–10.6 GPM)
Protected by the following US Patent Patent No. US6067151
Sensor
Wetted parts, standard
R
R
R
Teflon or Kynar PVDF, prism gaskets Teflon , prism spinel,
O-ring Kalrez, adaptor sapphire
prism sapphire or YAG
5.5 kg (12.1 lbs)
IP67, Nema 4X
Thread G1/2" (F)
Built-in Pt-100
1024 pixel CCD-element
Light emitting diode (LED)
AISI 316L stainless steel sensor cover
Exproof by purging
see page See Chapter 9
− External output unit, Section 4.2
− Relay units for alarm, Section 4.1
Wetted parts, option
Sensor weight
Sensor protection class
Process connection
Temperature measurement
Image detector
Light source
Sensor housing
Exproof
Indicating transmitter
Options
M74
M62
1.25
R.I.
1.30
1.35
0
10
1.40
20
Figure 8.17
30
40
1.45
50
60
1.50
70
80
1.55
1.60
BRIX
Process refractometer PR-03-M rangeability
1.65
8 Sensor specifications and other sensor information
83
8.6.3 PR-03-M parts lists
Item
Pcs.
1
2
3
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
17
4
1
1
1
1
6
1
1
1
1
1
1
1
1
1
6
1
1
1
*
18
19
20
21
22
23
24
25
1
2
1
6
1
4
1
4
1
Part No.
PR-9120
PR-9121
PR-9240
PR-9112
PR-9122
PR-9113
PR-9100
PR-9102
PR-9005
PR-9001
PR-9101
PR-9011
PR-9010
PR-7125
PR-7133
PR-5012
Description
Screw M5x60 DIN 7991 A4
PR-03-M endplate
PR-03-M-PV-R05 flow cell (PVDF)
PR-03-M-TF-R05 flow cell (PTFE)
O-ring seal 19.2 x 3 Kalrez 4079
Screw M4 x 20 DIN 7991 A4
PR-03-M Headring (PVDF)
O-ring seal 30.3 x 2.4 FPM
Sapphire plate for PR-03-M
O-ring seal 37.3 x 3 FPM
Sensor support
PR-03-M head
R
Thermal insulator (Teflon )
Alignment pin
PR-03 base
Screw M5x10 DIN 7991 A2
CORE optics module
CORE 74 optics module
Thermal conductor
Disc spring set
Disc spring
Disc spring holder
Screw M5x10 DIN 912 A2
Image detector card
Screw M4x12 DIN
Image digitizer
Screw M4x8 DIN 912 A2
Vee clamp 11-130
Item
Pcs.
26
27
28
29
30
31
32
33
34
35
36
37
2
1
1
1
1
2
2
2
1
1
1
4
Part No.
PR-5011
PR-9107
PR-9106
PR-9110
Description
Screw M3x16 DIN 912 A4
Bushing holder
Bushing
O-ring seal 108x3
Dryer
Screw M4x8 DIN 912 A2
Washer M4 DIN 125
Screw M3x8 DIN 912
PR-03 connetor complete
PR-03 cover
PR-03 sensor label
Screw M3x5 DIN A4
PR-03 instruction manual
84
Item
Pcs.
38
39
39
*
40
41
*
40
41
42
43
44
45
46
47
48
2
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
Part No.
PR-9004
PR-9003
PR-9104
PR-9003
PR-9250
Description
Screw M3x10 DIN 7380 A2
Prism support
Prism support H64
H62 prism set (Spinel)
Prism gasket (PTFE)
H62 prism (Spinel)
H74 prism set (Sapphire)
Prism gasket (PTFE)
H74 prism (Sapphire)
Screw M2x5 DIN 965A A2
Prism plate
Lens locking ring
Lens
Lens 8/10
Pressure spring 7.8x6
PR-03 temperature element assembly
Item
Pcs.
Part No.
Description
49
50
51
21
52
53
1
1
2
1
2
1
PR-9251
PR-03 LED assembly
LED plate
Screws M3x4 DIN 912
Image detector card
Screw M3x10 DIN 7991 A2
Screw M3x10 DIN 912 A2
PR-7125
8 Sensor specifications and other sensor information
85
8.6.4 PR-03-M mounting specifics
K-Patents Process refractometer PR-03-M is connected to the process by a G1/2" female or a 1/2" NPT
process connection, Figure 8.18.
Figure 8.18
G1/2" female process connection (mm [in])
8.7 Valve body refractometer PR-03-W
The Valve body refractometer PR-03-W
is a heavy-duty instrument designed for
chemically aggressive liquids and ultrapure fine chemicals in large-scale production and in large pipelines. The materials and design of the sensor are similar to the Process refractometer PR-03M, but the valve body makes it possible to fit this refractometer into 50, 80
or 100 mm (2", 3" or 4") pipelines.
Saunders valve body flow cell
3
PR-03-W Sensor
Flow cell adapter
(AISI 316L)
Prism
Graphite cast iron
FLOW
The valve body material is graphite cast
iron lined with 3 mm PFA (Fluorinated
Sapphire plate
ethylene propylene) fluoroplastic. The
O-ring (Kalrez)
cast iron provides a solid mechanical
PTFE or PVDF wetted parts
base and the PFA lining ensures the
chemical resistance.
Figure 3. Process Refractometer PR-03-W
sensor
and Saunders
bodysensor
valve flow cell (3” pipe): Dimensions.
Figure
8.19
PR-03-W
For automatic temperature compensation, the sensor
DESCRIPTION
The sensor itself is built just TECHNICAL
like the PR-03-M
sensor (see Section 8.6) and
it is fixed
to the
valve
body inprobe. The
tip contains
a Pt-100
process
temperature
1
K-Patents
Process
Refractometer
PR-03-W
is metallic
response
time away
is very fast
(τ( the
/2) = process
6 s), which is
the same way, with a sapphireThe
plate
and
a
Kalrez
O-ring
to
keep
all
the
parts
from
delivered with a Saunders valve body flow cell. The
necessary for a real-time concentration
liquid.
flow cell can be mounted either in a vertical or
measurement. The microprocessor system
horizontal pipe.
The valve body material is graphite cast iron lined
with 3mm PFA (Fluorinated ethylene propylene)
fluoroplastic. The Cast iron provides a solid
mechanical base and the PFA-lining ensures the
chemical resistance.
The sensor wetted parts materials are Spinel or
sapphire (prism), PTFE or PELD (prism gasket),
sapphire plate, PVDF or PTFE®Teflon and PFA
(flow cell lining material). The K-Patents PR-03-W
has a stainless steel sensor cover.
The measurement surface, the prism, is flush
mounted into the surface of the sensor probe tip.
The prism is integral part of the CORE-optics
(Compact Optical Rigid Element) module, which is
linearizes the concentration reading, and performs
automatic temperature compensation. Exact
precision is achieved due to the fact that the
compensation is calculated mathematically and not
using a conversion table.
The measurement is completely digital, as a serial
signal is used to send the raw measurement data
(optical image data and temperature) from the
sensor to the Indicating Transmitter. The
microprocessor system displays the optical image
and implements an image analyzing algorithm.
The Indicating Transmitter contains a power supply,
a microprocessor system and a front panel with a
Liquid Crystal Display (LCD) and a Keyboard.
The output signals are a 4-20 mA concentration
PR-03 instruction manual
86
8.7.1 PR-03-W sensor model code
MODEL AND DESCRIPTION
MODEL
PR-03 = Sensor
PR-03
Sensor classification
-W = Aggressive medium valve body flow cell
Refractive Index range limits
62 = 1.310–1.540 R.I., Spinel prism (0-100 Conc% b.w.)
74 = 1.260–1.500 R.I., sapphire prism
Sensor wetted parts material
R
-PV = Kynar (PVDF=Polyvinylidenefluoride)
R
-TF = Teflon (PTFE=Polytetrafluoroethylene)
Sensor/diaphragm valve body connection
4 = Adapter for 4 inch/DN 100 valve body
3 = Adapter for 3 inch/DN 80 valve body
2 = Adapter for 2 inch/DN 50 valve body
Sensor cover
-SC = stainless steel sensor housing
Sensor classification
-GP = General purpose, Nema 4X
-PC = Adapted for Exproof by purging(A)
-W
62
74
-PV
-TF
4
3
2
-SC
-GP
-PC
(A) Including 5 meter sensor cable, PR-8400-005
SAUNDERS VALVE BODY FOR SENSOR PR-03-W
MODEL
SVB = Saunders valve body
SVB
Process line connection
-A040 = ANSI flange 4 inch 150 lbs
-A030 = ANSI flange 3 inch 150 lbs
-A020 = ANSI flange 2 inch 150 lbs
-D100 = DIN flange DN 100 PN 16
-D080 = DIN flange DN 80 PN 16
-D050 = DIN flange DN 50 PN 16
Valve body material
-GC = Graphite cast iron
Valve body lining material
-PFA = PFA (= Fluorinated ethylene propylene)
-A040
-A030
-A020
-D100
-D080
-D050
-GC
-PFA
8 Sensor specifications and other sensor information
8.7.2 PR-03-W specifications
General specifications
General system specifications for a PR-03-W refractometer sensor
Refractive index range, standard R.I. 1.3100–1.5400 (corresponds to hot water–100 Conc% b.w.) with
spinel prism
Refractive index range, option
R.I. 1.2600–1.5000 with sapphire prism
Accuracy
R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).
Repeatability and stability correspond to accuracy.
Speed of response
1.2 s undamped
Damping time constant
Selectable up to 5 min
Process temperature
-20 ◦ C–100 ◦ C (-4 ◦ F–212 ◦ F)
Temperature compensation
Automatic
Ambient temperature
max. 45 ◦ C (113 ◦ F), min. -20 ◦ C (-4 ◦ F)
Humidity
20–100 %
Pollution degree
Degree 2
Process pressure
max. 10 bar (145 psi)
Recommended flow velocity
1.5–6 m/s
Protected by
US Patent No. US6067151, German Patent No. DE19855218
Sensor
Wetted parts, standard
Sensor weight
Sensor protection class
Process connection
Temperature measurement
Image detector
Light source
Sensor housing
Exproof
Saunders valve body
Valve body material
Valve body lining material
Process connection
Indicating transmitter
Options
R
R
Teflon PTFE, prism gasket Teflon PTFE, prism spinel or sapphire,
O-ring Kalrez, adaptor sapphire
With 2” Saunders body 15 kg (33 lbs)/3” Saunders body 26 kg
(57 lbs)/4” Saunders body 33 kg (73 lbs)
IP67, Nema 4X
With PFA (Fluorinated ethylene propylene) lined Saunders valve body
2", 3" or 4"
Built-in Pt-100
1024 pixel CCD-element
Light emitting diode (LED)
AISI 316L stainless steel cover
Exproof by purging
Graphite cast iron
PFA (Fluorinated ethylene propylene)
ANSI flange 4 inch 150 lbs / ANSI flange 3 inch 150 lbs /
ANSI flange 2 inch 150 lbs / DIN flange DN 100 PN 16 /
DIN flange DN 80 PN 16 / DIN flange DN 50 PN 16
See Chapter 9
− External output unit, Section 4.2
− Relay units for alarm, Section 4.1
87
PR-03 instruction manual
88
8.7.3 PR-03-W parts lists
Item
Pcs.
1
3
3
3
4
5
6
7
8
9
10
11
12
13
14
15
16
4
1
1
1
1
6
1
1
1
1
1
1
1
1
1
6
1
*
17
18
1
2
1
Part No.
PR-9240
PR-9112
PR-9122
PR-9113
PR-9102
PR-9005-SC
PR-9011
PR-9010
Description
Screw M5x60 DIN 7991 A4
Saunders valve body PFA lining ANSI 2“/DIN 50
Saunders valve body PFA lining ANSI 3“/DIN 80
Saunders valve body PFA lining ANSI 4“/DIN 100
O-ring seal 19.2 x 3 Kalrez 4079
Screw M4 x 20 DIN 7991 A 4
Spacer
O-ring seal 30.3 x 2.4 FPM
Sapphire plate for PR-03-M
O-ring seal 37.3 x 3 FPM
PR-03-M Headring (PVDF)
PR-03-W head
R
Thermal insulator Teflon Alignment pin
PR-03 base SS
Screw M5x10 DIN 7991 A2
Thermal conductor
Disc spring set
Disc spring
Disc spring holder
Item
Pcs.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
39
39
44
6
4
1
4
1
2
1
1
2
2
1
1
2
1
1
1
4
1
1
1
Part No.
PR-7133
PR-5012
PR-5011
PR-9107
PR-9106
PR-9110-SC
PR-9001
PR-9101
PR-7125
Description
Screw M5x10 DIN912 A2
Screw M4x12 DIN
Image digitizer
Screw M4x8 DIN 912 A2
Vee clamp 11-130
Screw M3x8 DIN 912
Bushing holder
Bushing
Screw M4x8 DIN 125
Washer M4 DIN 912 A2
O-ring seal 108x3
Dryer
Screw M3x16 DIN 912 A2
PR-03 connector complete
PR-03 cover
PR-03 sensor label
Screw M3x5 DIN 7380 A4
CORE optics module
CORE 74 optics module
Image detector card
8 Sensor specifications and other sensor information
8.7.4 PR-03-W mounting specifics
PR-03-W Saunders valve body flow cell can be mounted either vertically or horizontally. Special sensor
support is not needed as the valve body (piping) supports the sensor. Either way sensor cover should always
be horizontal to avoid sedimentation or gas/air pocket on the prism. Also installation after pump, before
valve and low installation point will reduce risk of air/gas pocket. Recommended flow velocity is 1.5–6m/s
(6–20ft/s).
89
90
PR-03 instruction manual
9 Indicating transmitter specifications
9 Indicating transmitter specifications
9.1 IT-R label
PROCESS REFRACTOMETER
IT-RE-GP
S/N:00Z25-4129
100 - 115/220 - 240 V AC, 50/60 Hz, 20VA
TAG:
Figure 9.1 Indicating transmitter serial number label
Serial number should match the serial number on sensor head
9.2 IT-R compatibility
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 5.10) as your IT-R has been precalibrated for the
process it was ordered for.
The models PR-03 and PR-01 use the same Indicating transmitter. When the power is switched on, the
microprocessor checks which sensor model is connected, and adapts the software accordingly.
Note: The plug at the sensor end is different for PR-03 and PR-01. All PR-03 models use same electrical
connector and cables.
9.2.1 Upgrading IT-R program version
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 (i.e the same first number) are compatible. Also
earlier major versions can usually be substituted with later major versions.
K-Patents improves the IT-R programming all the time. If you need a new (or latest) program version,
order the spare part PR-7509. You’ll get a new EPROM (Figure 9.2) with the new program version and you
upgrade by removing the old EPROM from the processor card and inserting the new one into its place.
Figure 9.2
An EPROM with program version 8.6
91
PR-03 instruction manual
92
1. Important: Before you upgrade any program versions, write down all
current parameters from the calibration screen of the Indicating transmitter. Also remember to take note of the wash and relay parameters.
2. Power off and open the front panel of the IT-R.
3. Unscrew the cover on the inside of the front panel. Unplug the cable
from the Power supply card to the front panel and remove the cover to
see the Processor card.
4. Carefully remove the old EPROM (Figure 9.3)and insert the new one.
EPROM
5. Place the cover over the Processor card, screw it on and reconnect the
cable from the Power supply card to the front panel. Close the front
panel.
6. Press the ENTER button and at the same time switch on the power. You
will now enter the Factory Calibration mode.
7. Press 1 for Default settings. Make sure that all pre-upgrade parameters
have been written down.
Figure 9.3 Location
of the EPROM on
the Processor card
8. Press ENTER to load default parameters and press RESET twice to exit from the Factory calibration.
9. Switch power off. Switch power back on.
10. Enter all the pre-upgrade parameters (wash and relay parameters included) into the transmitter.
Note: The image inversion needed with the Probe refractometer PR-03-P sensor was first implemented in
the main program version 8.6. Program version 8.5 can be updated to manage the image inversion. Versions
below 8.5 are not compatible with the Probe refractometer PR-03-P sensor.
9.3 Model code
9.3.1 IT-R model code
MODEL AND DESCRIPTION
MODEL
IT-R = Indicating Transmitter
IT-R
Cable connection
U = 1/2 inch NPT-type conduit hubs
E = BF11/PG11 cable glands (with -GP option only)
M = M20x1.5 metric cable glands (with -GP option only)
Electrical classification
-GP = General purpose
-CS = CSA appr. for use in general purpose (ordinary) locations
Transmitter options
-WR = Relay unit, 2 relays
U
E
M
-GP
-CS
-WR
9 Indicating transmitter specifications
93
9.3.2 Interconnecting cable model code
PART NUMBER AND DESCRIPTION
PART NO.
PR-8300 =
PR-8040 =
PR-8300
PR-8040
Interconnecting cable between transmitter and sensor
Interconnecting cable (-PC sensor option only)
(for connection between transmitter and disconnecting unit)
Cable length
-010 =
10 meters (33 feet), standard length
-_ _ _ =
Specify cable length in meters with 10 meter increments.
Maximum length is 100 meters (330 feet)
-010
-_ _ _
9.4 IT-R Specifications
Indicating transmitter
Transmitter protection class:
Indicating transmitter weight:
Display:
Current output:
Enclosure IP66, Nema 4X
4.5 kg
256 x 128 pixels graphic liquid crystal display (LCD)
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, galvanic isolation 500 V CD or AC (peak)
100–115 V/220–240 V, 50/60 Hz, 20 VA
Two built-in signal relays, max 24 V, 500 mA, DC/AC
Serial output:
Power:
Alarms:
Approved environmental conditions
Ambient temperature:
max. 50 ◦ C (122 ◦ F), min. 0 ◦ C (32 ◦ F)
Humidity:
20–100 %
Overvoltage category:
Category II
Pollution degree:
Degree 2
Interconnecting cable
Shielded cable, 2 twisted pairs with individual shields, 0.5 mm 2
Digital transmission according RS485
Interconnecting cable length:
Standard 10 m (33 ft), max. 100 m (330 ft)
Cable fittings options:
European cable glands or US conduit hubs
9.4.1 Fuses
The following 250 V fuses according to IEC 60127 are printed on circuit board PR-7030:
Fuse F1, F2 : 5 x 20 mm, T1A (slow)
Fuse F3
Fuse F4
Fuse F5
Fuse F6
Fuse F7
:
:
:
:
:
AC Main power protects electronics against
wrong primary voltage
5 x 20 mm, T63 mA (slow) 4-20 mA output protection
5 x 20 mm, T2A (slow)
Secondary main fuse
5 x 20 mm, T500 mA (slow) Sensor power protection
5 x 20 mm, T500 mA (slow) Serial bus protection
5 x 20 mm, T1A (slow)
Processor card protection
Important: For a CSA-Certified instrument use only CSA-Certified fuses F1, F2, F4-F7.
PR-03 instruction manual
94
9.4.2 Serial output specifications
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. A record is sent for every measurement
interval (1200 ms).
The RS-232 output conforms to the EIA RS-232-C and CCITT V.24 standards. The signals are available
at plug terminal P3 on the IT-R’s processor card. A cable diagram for computer connection is shown in
Figure 9.4, pin numbers for a 9-pin D-shell connector (standard female COM connector) are given (pin
numbers for a 25-pin connector and for a modem connection cable are available at K-Patents on request).
Note: RS-232-C specifies a maximum cable length of 15 m.
INDICATING TRANSMITTER
DTE
D9
RD
SD
SGND DAT-
Figure 9.4
SGND
DAT+
3
2
5
7
8
6
1
4
Transmit data
Receive data
Signal ground
Request to send
Clear to send
Data set ready
Data carrier detect
Data terminal ready
Connections for a RS-232 cable for COM connection on a PC
The character structure of the data sent via the serial output interface conforms to the ISO 1177 standard. It
is compatible with the ’RS-232’ interfaces (COM port and terminal software) of most 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 or none.
The factory setting 9600,even,1,none is normally the best option for computer connections.
9.4.3 Password
The Change parameters display 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 9.5.
The password function can be activated or deactivated by selecting:
Calibrate / Parameters / Password / Active or
Calibrate / Parameters / Password / Inactive.
The password for K-Patents PR-03 is printed on the front page of this manual.
9 Indicating transmitter specifications
95
9.5 IT-R Parts list
Item
Pcs.
1
1.1
1.2
1.3
1.4
1.5
1.5
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
1
4
4
4
4
4
4
1
1
1
1
1
1
4
4
4
1
1
1
Part No.
PR-7301
PR-7030
PR-7028
PR-7029
Description
Item
Pcs.
Enclosure
Mounting feet
Screws 10-32 pan head
Screws 10-32 pan head
Cable glands PG 11 (European)
Conduit hubs 1/2" NPT-Type ST-1 (US)
Conduit hubs M20x1.5 (European)
Frame plate
Screw DIN 912 M5 x 50 Zn
Washer DIN 9021 5.2 x 18 Zn
Washer DIN 9021 5.2 x 18 Zn
Nut DIN M5 Nyloc N
Transformer
Nuts DIN 934 M4
Stand-off M4 x 15
Screws DIN 912 M4 x 8
Power supply card
Switch actuator
Ribbon cable
Fuse set
(10 Fuses: 4 x 1A, 1 x 63 mA, 2.2A, 3 x 0.5 A)
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
1
2
4
1
6
2
2
4
4
2
2
2
2
2
2
2
1
1
1
1
1
1
4
1
Part No.
PR-7315
PR-7305
PR-7019
PR-7020
PR-7010
PR-7009
PR-8000-...
Description
Front panel
Hinge
Screws DIN 912 M3 x 10
Keyboard
Screws DIN 799/DIN 965 M3 x 12
Ferrule 3.0 x 8 x 3
Stand-off M3 x 10
Stand-off M3 x 15
DIN 912 M3 x 8
Nut DIN 934 M3
Stand-off M3 x 15
Nut DIN 934 M3
Ferrule 5 x 8 x 3
Screw DIN 912 M3 x 10
Locking screw
Locking washer
Display
Display cable
Display controller card
Processor card
Program memory
Cover
Sensor cable
NORMAL
DISPLAY
Figure 9.5
The IT-R selection tree
SYSTEM CONFIGURATION
SENSOR HEAD
D
OPTICAL IMAGE
PASSWORD LIMIT
PARAMETERS
C
A
B
OPTICAL IMAGE
DIVERT CONTROL
PASSWORD
CONC (R.I.)
8
9
A
WASH TIMES
SWITCH CONFIGURATION
RELAY CONFIGURATION
LANGUAGE
7
A
B
C
STANDARD RI (25°C)
TEMPERATURE
OUTPUT SIGNALS
SWITCH INPUTS
6
5
4
3
RELAYS
PRISM WASH
1
2
SCALED IMAGE
A
PRECONDITION TIME
1
2
3
4
DIVERT CONTROL
R1 CUBE
R1 SQUARE
R1 GAIN
R1 BIAS
REMOVE FROM DISPLAY
HIGH TEMP LIMIT
TEMPC1
TEMPC0
DISPLAYED TEMP UNIT
DISABLE HIGH TEMP LIMIT
TEMP BIAS
SERIAL OUTPUT
EXTERNAL OUTPUT
CURRENT OUTPUT
SWITCHES
A
1
2
3
4
SWITCH SELECTED SCALES
DAMPING TIME
DISPLAY DECIMALS
UNIT
PARAMETERS
SET PASSWORD
1
A
1
2
3
4
A
B
1
2
3
4
1
2
3
A-D
A-B RELAY 1 OR RELAY 2
3 RELAY UNIT
4 RELAY ALARM DELAY
WASH INTERVAL
RECOVERY TIME
WASH TIME
SLOPE
A
Note! Relay 1, Relay 2 refer to built-in signal relays (Chapter 3), whereas relay unit refers to external relay unit (Chapter 4).
DISPLAY
CALIBRATE
C
D
START PRISM WASH
A
A
1
2
3
4
5
6
7
8
9
0
1
9
1
2
3
4
5
6
WASH CHECK
A
B
C
SQUARE TEMP CO
CONC TC ADJUST
TEMP TC ADJUST
TEMP COEFF
TNM
CUBE
SQUARE
GAIN
BIAS
ACTIVE
INACTIVE
IMAGE INVERSION
ICAL1
ICAL0
RANGE
HOLD FUNCTION
SPAN
ZERO
SMART WASH
WASH STOP
DIAGNOSTICS
A
96
PR-03 instruction manual
9.6 Command selection tree
9 Indicating transmitter specifications
97
9.7 Display messages
Message
Cause and action
NORMAL OPERATION
No faults.
DIVERT CONTROL
Not used with PR-03.
If this message occurs, deactivate with the command
Calibrate / Parameters / Divert control /
Divert Control.
REMOVED FROM DIVERT CONTROL
Not used with PR-03
RETRYING WASH
The prism wash failed the wash check (Section 5.9.4). The
prism wash will be attempted as many times as is set by the
Wash retry parameter (Section 5.9.4).
(Sanitary refractometer PR-03-A
and probe refractometer PR-03-P)
WASH STOP/TEMP LIMIT
(Sanitary refractometer PR-03-A
and Probe refractometer PR-03-P)
The process temperature is below the temperature limit set for
wash stop (Section 5.9.3). The message is shown until wash
succeeds or the RESET key is pushed.
LOW CONCENTRATION/NO SAMPLE
Normally caused by empty process pipe or exceptionally low
concentration.
If pipe is full and sample indicates normal concentration,
check the optical image (Section 7.2).
HIGH PROCESS TEMPERATURE
Process temperature is above the set limit (Section 5.7). Common causes are abnormal process conditions or a leaking
prism wash steam valve.
LOW LIGHT INTENSITY
Most common cause is onset of prism coating.
DIP IN IMAGE
Indicates irregular optical image. Can be caused by a speck of
dust on the CCD window.
HIGH CONC/PRISM COATED
Is most commonly caused by prism coating, but may also indicate exceptionally high concentration. If sample is normal and
the message persists after the prism surface is cleaned, check
the optical image (Section 7.2).
** WASH STOP/EXT. STOP **
Caused by closing an input switch that has been activated for
external wash stop (Section 3.2.2.6 and Section 5.6).
(Sanitary refractometer PR-03-A
and probe refractometer PR-03-P)
PR-03 instruction manual
98
PRISM WASH FAILURE
(Sanitary refractometer PR-03-A
and Probe refractometer PR-03-P)
The prism wash works, but during the wash the TEST value
did not exceed the set TEST limit or did not increase more
than the set TEST difference (Section 5.9.4).
** EXTERNAL OUTPUT FAULT **
There was no response from the External output unit, maybe
because the unit is disconnected from the IT-R. Other possible
causes are a failure in Serial bus on the IT-R or in the Output
unit.
To prevent this message when the Output unit is disconnected,
key in Calibrate / Parameters / Output signals
/ External output / Source and select the option Not
defined (Section 5.8).
** RELAY UNIT FAULT **
There was no response from the Relay unit, maybe because the
unit is disconnected from the IT-R. Other possible causes are a
failure in Serial bus on the IT-R or in the Relay unit.
To prevent this message when the Relay unit is disconnected,
key in Calibrate / Parameters / Relays /
Relay unit and select Not defined for each relay (Section 5.7).
** TEMP MEASUREMENT FAULT **
The temperature value reported by the sensor corresponds to
a value below -50 ◦ C or above +250 ◦ C by a margin of 10 %.
Normally means that the temperature sensor has failed and
needs to be changed.
** PRISM COATED/LED FAULT **
The light intensity of the LED is too low, normally due to
coating. Clean the prism surface. If the message persists,
check optical image (Section 7.2). If the process temperature
is very high or if process liquid has leaked into the sensor at
some point, the message may be caused by LED failure and
the LED needs to be replaced.
HIGH INTERNAL HUMIDITY
Humidity inside the sensor is higher than 50 %. Normally indicates leakage in the sensor. Remove the sensor from the process line and check it according to Section 6.1.
** DETECTOR TIMEOUT **
Normally a detector card failure. If the power selector switch
in the IT-R is in the wrong position, the detector’s supply may
be incorrect. If the power selector is in correct position and
the message persists, change the Image detector card (see Section 6.3, “Disassembling and assembling a standard length sensor” and Section 6.4, “Disassembling and assembling a probe
sensor”).
9 Indicating transmitter specifications
99
** 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 **
The IT-R doesn’t get any signal from the sensor during the
1200 ms measurement interval. This message is normal when
the interconnecting cable is disconnected from either end. In
other cases check the connections and the cable.
** WRONG CONCENTRATION
Makes R.I. outside range.
PARAMETERS **
** CONSTANTS ERROR **
Wrong EPROM parameters. Check parameters. If problem
persists, consult authorized service.
** SENSOR INTERFACE FAULT **
Indicates a fault on the processor card of the IT-R, probably a
failure of the sensor interface processor.
Action: Replace the processor card.
EPROM WRITE ERROR
Indicates a fault on the processor card of the IT-R, probably
component failure.
Action: Replace the processor card.
PRECONDITIONING
A system status message shown every time the preconditioning
valve is activated by a Relay unit (Section 5.7).
(Sanitary refractometer PR-03-A
and probe refractometer PR-03-P)
WASH
(Sanitary refractometer PR-03-A
and Probe refractometer PR-03-P)
RECOVERY
(Sanitary refractometer PR-03-A
and Probe refractometer PR-03-P)
HOLD
(Sanitary refractometer PR-03-A
and Probe refractometer PR-03-P)
A system status message shown every time when the prism
wash valve is activated by a relay unit (Section 5.7). If Hold
function is active, the concentration output signal is locked
(Section 5.8) when the message shows.
A system status message shown after wash during the delay
time when the concentration output signal is still locked (if
Hold function is active, Section 5.8).
A system status message indicating that an input switch configured as a Hold switch is closed (Section 5.8).
100
PR-03 instruction manual
10 PR-03 process refractometers in potentially explosive atmosphere
10 PR-03 process refractometers in potentially explosive
atmosphere
The PR-03 refractometer series can be used in locations with potentially explosive atmosphere with following modifications, made by K-Patents Oy. The refractometer sensor’s compliance with the Essential Health
and Safety Requirements are assured by complying with standard EN 50 021:1999.
The PR-03-...-AX refractometers have been certified by KEMA Quality B.V. under European ATEX directive 94/9/EC for ATEX EX II 3 G/Cenelec Eex nA IIC T4. The EX-Type Certificate Number is KEMA
04ATEX 1088X. The report number is KEMa No. 207 1534.
10.1 Equipment
The K-Patents refractometer system (Figure 10.1) for potentially explosive atmosphere locations consists of
a modified refractometer sensor PR-03-...-AX, a standard Indicating transmitter IT-R and a standard cable
PR-8300-...
Hazardous area
(up to Zone 2)
Figure 10.1
Safe Area
Refractometer system PR-03-...-AX
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The ATEX approved sensor PR-03-...-AX is identified by the sensor label, see Figure 10.2. The Indicating transmitter is a standard IT-RE-GP.
The approvals are valid for sensors PR-03-A, PR-03-P, PR-03-D, PR-03M and PR-03-W.
VANTAA FINLAND
Figure 10.2 PR-03-...-AX
sensor label.
10.2 Installation
Sensor wiring must follow drawing WRG-302, see Figure 10.3.
Figure 10.3
Safe sensor wiring according to WRG-302.
Important: Tampering and replacement with other than K-Patents original components is not allowed
because this may affect adversely the safe use of the system.
! Warning! Insertion or withdrawal of modules or replacement of fuses is to be accomplished only when the
area is known to be free of flammable vapors.
Note: Sensor connector may not be connected or disconnected when the circuits are energized. Switch OFF
the power from Indicating transmitter main power switch before disconnecting sensor cable from sensor.
After connecting sensor cable back to the sensor you can switch power ON from main switch of Indicating
transmitter.
10 PR-03 process refractometers in potentially explosive atmosphere
10.3 PR-03-...-AX parts list: differences to standard sensors
Item
Pcs.
14
1
Part No.
Description
PR-7133-EX
Image digitizer for AX sensor
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104
Item
Pcs.
40
41
41
1
1
1
Part No.
Description
PR-9250-EX
PR-9251-EX
PR-9256-EX
PR-03 temperature element assembly
PR-03-A emitter assembly
PR-03-P LED assembly
A Glossary and Abbreviations
A Glossary and Abbreviations
•
BIAS = Bias value, a calibration constant bias value. Change of Bias influences CONC% reading the
same amount. See Section 5.10.2 (“Concentration calibration from keyboard”).
•
CORE = Compact Optical Rigid Element
•
CORE-optics = CORE-optics module, inside a sensor, contains all the optical parts of a sensor.
See Sections 2 (“Inline refractometer sensor”), 6 (“Regular maintenance”) and 8 (“Sensor specifications
and other sensor information”).
•
DDS = Delivery Data Sheet
See Appendix B (“Information about Delivery data sheet (DDS)”).
•
display = each different screen shown on the Indicating transmitter’s screen is called a display. See
Section 5.3 for more information about the different displays.
•
IT-R = Indicating transmitter processes and displays data sent by a sensor in a K-Patents inline refractometer system.
See Sections 3 (“Indicating transmitter (IT-R)”), 5 (“Startup, configuration and calibration adjustment”)
and 9 (“Indicating transmitter specifications”).
•
(K-Patents) PR-03 inline refractometers = all PR-03 models = Sanitary refractometers + Process refractometers
•
Process refractometers = (in this manual) Compact process refractometer PR-03-D, Process refractometer PR-03-M, Valve body refractometer PR-03-W
•
R.I. = Refractive Index (of a liquid)
See Section 1 (“Introduction”).
•
Sanitary refractometers = (in this manual) Sanitary refractometer PR-03-A + Probe refractometer
PR-03-P
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PR-03 instruction manual
B Information about Delivery data sheet (DDS)
B Information about Delivery data sheet (DDS)
The Delivery Data Sheet (DDS) is included in your refractometer system delivery. It records all the information on your system as delivered.
The Instrument data contains the hardware information, among others sensor model code and connection.
The Process part of the DDS specifies the process, medium and curve the delivered refractometer system is
fitted for.
The Programs list contains the program versions of the different processors in your refractometer system. Most important is the version number of the main program, i.e. the program on your EPROM (see
Section 9.2).
The Parameters listed in the DDS were entered in your IT-R before delivery. The Final test values were
achieved the given parameters. See Section 5.10, “Adjusting concentration calibration” for more information on these parameters.
Figure B.1
A Delivery Data Sheet.
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PR-03 instruction manual
C K-Patents inline refractometer calibration data report
71
K-PATENTS PROCESS REFRACTOMETER CALIBRATION DATA
C11.
K-Patents
inline refractometer calibration data report
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
NO.
SAMPLE
CONC. LAB%
CONC%
TEST
TEMP. °C
SAMPLE DATE
AND TIME
SIGN
Note: See Section 5.10.6 for more information on how to fill in the calibration data report.
INSTRUCTION MANUAL FOR K-PATENTS PROCESS REFRACTOMETER PR-03-D
Document/Revision No. INM-3D: Rev. 1/2
Effective: December 15h, 2002
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PR-03 instruction manual
D Instrument verification ISO 9000
D Instrument verification ISO 9000
A company that maintains a quality system according to ISO 9000 quality standard must have defined
procedures for controlling and calibrating its measuring equipment. This is required for demonstrating the
conformance of the final end product to the specified requirements. The company should:
− identify the required accuracy 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. When no such standard exists, the basis used for calibration
should be documented.
This text provides a valid method for meeting the above requirements with a K-Patents inline refractometer
system. K-Patents quality system is certified against the ISO 9001 by Det Norske Veritas. K-Patents verifies
the calibration of all delivered instruments according to a similar procedure as described in this section.
Definitions
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 polynomial, used for refractive index measurement with a
reference temperature of 25 ◦ C.
The Refractive Index (R.I.) calibration can be traced to national standard NIST 1823, whenever certified
standard R.I. liquids are used in the calibration.
Accuracy of R.I. calibration
Maximum deviation accepted in R.I. calibration:
The total acceptable deviation for PR-03 is R.I. 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. 00002).
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.
Verification of Refractive Index (R.I.) calibration
The R.I. calibration can be verified with three certified standard R.I. liquids as follows:
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PR-03 instruction manual
112
1. Take the sensor from the process and place it on a table.
Note: Keep the PR-03-M with the flow cell and place it on a table with the flow cell (medium adaptor)
up. Use the flow cell as a sample holder.
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 without any traces of the process liquid. Use a cleaning solvent appropriate
for the process medium.
4. Use the certified standard R.I. liquids, which correspond to the values indicated in the Final test section
of the latest Delivery Data Sheet or Standard calibration sheet of your PR-03 sensor. The three R.I.
values are selected by K-Patents calibration software to represent the used R.I. range.
5. Check the R.I. calibration with the three R.I. liquids. The use of K-Patents PR-03 sample holder (see
Figure 5.15) or of the flow cell (medium adaptor) 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
from Normal display
Value to be checked
Acceptable value
Information display
D
Standard RI (25◦ C)
Sample R.I. ± 0.0006
Corrective action if the verification fails
If the verification does not meet the acceptance criteria defined above, 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 for more details of prism mounting and dismounting.
2. The following values and diagnostics should be checked from the Indicating transmitter displays with
the standard R.I. liquid on the prism.
Display
Key-in sequence
from Normal Display
Raw sensor data
C-A
Image diagnostics C-A-A-A-A
Value to be checked
Acceptable value
LED
below 200
Max intensity OK
Yes
Endpoint below 75% Yes
Image below corner Yes
Slope OK
Yes
Left curve OK
Yes
Right curve OK
Yes
D Instrument verification ISO 9000
If the above checks 1 and 2 fail, please contact K-Patents or your local K-Patents 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:
1. Mount the sensor on the service bench.
2. Use 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.
3. Record R.I. value and corresponding TEST and temperature values from the Normal display of PR-03.
4. Send the table of values to K-Patents or to K-Patents local representative.
5. K-Patents calculates new calibration parameters for R.I. measurement.
6. Key in the new parameters (soft keys C-B-6-1/2/3/4) and then repeat the verification check as described
above.
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1 Index
115
Index
** CONSTANTS ERROR **
** DETECTOR TIMEOUT **
** EXTERNAL OUTPUT FAULT **
98
99
** NO SENSOR SIGNAL **
** PRISM COATED/LED FAULT **
** RELAY UNIT FAULT **
CUBE 44
current output
connection 13
99
98
98
98
** SENSOR INTERFACE FAULT **
99
** SENSOR TRANSMISSION ERROR **
** TEMP MEASUREMENT FAULT **
** WASH STOP/EXT. STOP **
99
98
97
** WRONG CONCENTRATION PARAMETERS **
-WR
see Relay unit -WR
3A Sanitary Standard 1
99
d
damping 44
DDS
see Delivery Data Sheet
Delivery Data Sheet 107
DIP IN IMAGE 97
dip in image 36
e
ENTER
key
31
EPROM WRITE ERROR
a
A/D
34
b
bench calibration 46
BIAS
see calibration constant bias
built-in signal relays
see signal relays
c
calibration
bench
see bench calibration
field
see field calibration
temperature
see temperature calibration
calibration constant bias 43
chemically aggressive process 85
chemically aggressive solutions 81
Compact Optical Rigid Element
see CORE
computer
see PC
connecting
computer to IT-R
see PC
99
f
field calibration 45
flow velocity 18
g
GAIN
h
HH
44
35
HIGH CONC/PRISM COATED
HIGH INTERNAL HUMIDITY
97
98
high pressure wash 18, 25
HIGH PROCESS TEMPERATURE
HOLD
99
HT 35
humidity
inside sensor
see sensor humidity
i
image
optical
see optical image
scaled
see scaled image
image detector
output 5
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image diagnostics 57
Information display 32
input switch 10
input switches
configuration 36
connecting 13
interconnecting cable PR-8011 18, 26
inverted optical image 74
k
keyboard
layout 31
l
LED 34
LED value
55
LOW CONCENTRATION/NO SAMPLE
LOW LIGHT INTENSITY
97
97
m
mounting
Compact process refractometer PR-03-D 79
pipe diameter 7
Probe refractometer PR-03-P 72
process pressure 7
Process refractometer PR-03-M 85
process temperature 7
Sanitary refractometer PR-03-A 65
Valve body refractometer PR-03-W 89
n
NORMAL OPERATION
97
o
optical image 2, 34
inverted
see inverted optical image
typical 33
viewing 33
output signals 9
p
parameters
see Delivery Data Sheet
PC
connecting with IT-R 14
power selector switch 12
PR-7080
see Relay unit PR-7080
see External output unit PR-7090
PR-8011
see Interconnecting cable PR-8011
PRECONDITIONING 99
prism coating 18, 57
prism gaskets
replacing 47, 49
prism wash
nozzles 20
pressure 20
time 20
PRISM WASH FAILURE 98
process parameters
information on 32
program versions 91
r
R.I.
see refractive index
raw data 34
RECOVERY 99
refractive index 2
refractometer
model 1
relay
see signal relays
relay configuration 37
Relay unit -WR 18
Relay unit PR-7080 18
RESET key 31
RETRYING WASH 97
RI
see refractive index
RMN 34
RMX 34
s
safety 25
scaled image 35, 56
Scans 34
selection tree 96
sensor
cooling 6
1 Index
structure 5
sensor humidity 56
sensor temperature 56
separate relay unit
2 relays 18
4 relays 18
cable fittings 17, 26
signal relays
built-in 9
slope 35, 56
smart wash 40
soft key 31
SQUARE 44
steam wash 18, 23, 24
Sts 34
system configuration
viewing 33
t
temperature
inside sensor
see sensor temperature
temperature calibration 44
temperature parameters
see temperature calibration
117
TEST value 5
wash 30
timed wash 40
training
see demo
u
ultra-pure fine chemical processes 81
ultra-pure process 85
v
valve body
85
w
warranty 3
WASH 99
wash
smart
see smart wash
timed
see timed wash
WASH STOP/TEMP LIMIT
wash time 40
water wash 18
water temperature
20
97
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