AW Gear Meters PROSCAN User Manual
PROSCAN
IN-LINE PROCESS SENSOR
OperaƟon & InstallaƟon Manual
Rev. 2
ProScan In-Line Process Sensor
User Manual
Table of Contents
Safety Definitions and Information ............................................................................................................... 3
Unpacking ..................................................................................................................................................... 3
Quick Setup Guide......................................................................................................................................... 4
Choose Location ........................................................................................................................................ 4
Install Electrical Connection ...................................................................................................................... 4
Position Sensor ......................................................................................................................................... 4
Connect ..................................................................................................................................................... 4
Product Description ...................................................................................................................................... 5
Principle of Operation ............................................................................................................................... 5
Features .................................................................................................................................................... 5
Technical Specifications ............................................................................................................................ 6
Mechanical ............................................................................................................................................ 6
Performance/Electrical ......................................................................................................................... 6
Preliminaries ................................................................................................................................................. 6
Standard Shipments .................................................................................................................................. 6
Unpack and Check Contents ..................................................................................................................... 6
Electrical Connections ................................................................................................................................... 7
Operation ...................................................................................................................................................... 9
Applying Power ............................................................................................................................................. 9
Test Output ............................................................................................................................................... 9
Installation .................................................................................................................................................. 10
Deadleg ................................................................................................................................................... 10
Installation Site ....................................................................................................................................... 10
Vertical ................................................................................................................................................ 10
Horizontal ............................................................................................................................................ 10
Straight Sections ................................................................................................................................. 10
Installations Not Recommended ........................................................................................................ 10
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ProScan In-Line Process Sensor
User Manual
Clamp Connection Gasket ....................................................................................................................... 10
Connect ................................................................................................................................................... 11
Calibration Verification or Test with Your Samples .................................................................................... 11
Calibration Procedure ................................................................................................................................. 12
Sensor Offset and Span Calibration ............................................................................................................ 13
Disclaimer.................................................................................................................................................... 23
Limited Warranty ........................................................................................................................................ 24
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ProScan In-Line Process Sensor
Warning!
Caution
Notice
Caution
User Manual
Safety Definitions and Information
Do not attempt to install or use your AW Gear Meters product until you have read the safety
instructions in this section. Save this manual and keep it in an easily accessible place.
Warning means that failure to follow this safety statement may result in extensive product damage,
serious personal injury, or death.
Caution means that failure to follow this safety statement may result in minor or moderate personal
injury, property or equipment damage.
Notice is a statement that informs about installation, operation, maintenance, performance issues, or
general tips which are important but do not create a hazard or safety concern.
Unpacking
1. Separate the ProScan™ device from packaging materials and check for any visual signs of
damage. If you determine there has been damage caused by shipping, file a claim with the
shipping company. If the sensor appears to have been improperly assembled or does not
operate properly, return it for replacement or repair (see Limited Warranty information at the
end of this manual).
2. Carefully remove all items from the shipping package and compare the contents to those listed
on the shipping documents. If there is a discrepancy, contact the manufacturer.
Before connecting or using the ProScan sensor, read this manual.
ProScan™ is a trademark of AW Gear Meters, Franksville, WI 53126
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ProScan In-Line Process Sensor
Caution
Notice
User Manual
Quick Setup Guide
As with any precision-engineered device, always use the ProScan In-Line Process Sensor in accordance
with the manufacturer’s instructions.
Choose Location
The best location to install the ProScan sensor is to a tee or saddle in the process line.
Install Electrical Connection
Attach the five-pin electrical cable to the sensor and tighten the threaded cord grip (see Figure 1, page
8).
Position Sensor
Install the sensor vertically in the process line, preferably with the electrical connection facing the floor
(see Figure 2, page 14).
Connect
Connect the opposite end of the electrical cable to PLC, DCS, or data logger (see Figure 1, page 8).
In the following manual, you will find complete connection, operating, set-up, and maintenance
instructions.
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ProScan In-Line Process Sensor
User Manual
Product Description
ProScan is an in-line optical sensor that
mounts directly to the process line,
providing real-time information about
the process.
ProScan can accurately detect the
point of transition from water to
product, which is the primary
application. Depending on the degree
of solids difference between two
materials, it can also detect a product–to-product transition. And for products such as skim, 1 percent, 2
percent and whole milk, ProScan can act as a monitor of milkfat percentage and an indicator of product
quality.
The most common calibration entered into ProScan includes points for water, skim milk, 1 percent milk,
2 percent milk, whole milk and a maximum response standard equal to 20 mA.
The 3A Certified ProScan also has uses in the brewing, pharmaceutical, and juice processing industries.
The device accurately monitors turbidity and product concentration and can help processors recover as
much product as possible before a cleaning cycle begins. It can also help to ensure equipment adds
costly chemicals at the appropriate time.
The ProScan sensor assists in determining if fluid should be added to recovery tanks or sent to the drain,
and is an excellent monitor of BOD loading on waste lines. Solid construction means the ProScan Sensor
stands up to the high temperatures and temperature fluctuations.
Principle of Operation
Utilizing advanced optical technology, ProScan sends a beam of light into the process and measures the
backscatter, which is proportional to solids concentration. The device’s internal microprocessor then
converts the scatter to a linearized 4-20 mA output, which easily links to a PLC, DCS or data logger.
Features
3A Certification
Real-time process control
Detects phase transitions
Stainless steel construction
Sapphire lens
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ProScan In-Line Process Sensor
User Manual
Sanitary clamp connections
NEMA 6 /IP67 enclosure
Easy to install, set up and maintain
Technical Specifications
Mechanical
Materials: 316-series stainless steel housing and fittings; sapphire and FDA-approved silicone
product contact surface
Dimensions: 3.0" diameter x 3.6" length (approx.)
Weight: 4 lbs. (approx.)
Ratings: NEMA 4X (water-tight, corrosion proof); authorized to carry 3-A symbol
(Standard 46-03)
Optical Lens: uncoated, optical sapphire (aluminum oxide) min. thickness = 2.3mm
Lens Seal: 60 durometer, FDA-approved silicone rubber (meets ZZR-765-E, Class 2 A&B)
Lens Surface Finish: 0.1 microns/inch £
Performance/Electrical
Accuracy: +/-0.2% of span at 4.00 mA (water)
Repeatability: +/-1.0% of span in any target fluid
Process Temp Range: 32° to 250°F (continuous)
Ambient Temp Range: 40° to 120°F
Process Temp Shock: withstands instantaneous changes of up to 125°F (e.g. From 40° to
165°F during CIP, or from 125° to 250°F during SIP)
Temperature Effect: 0.9% of span/10 deg F change (process and/or ambient) maximum
Process Temperature Limits: vacuum to 200 psig at rated temperature
Output: 4-20 mA, 3 or 4 wire
Power: 15-28 VDC, at 35 mA
Connection: 5 pin, water-tight, with quick-disconnect cabling
Preliminaries
Standard Shipments
Unless specified otherwise, ProScan sensors are shipped with a standard calibration covering a span of 4
to 20 mA and representing clean water at 4 mA and a maximum white standard at 20 mA. A calibration
document is included in the shipment to inform you of the calibration date and details.
Unpack and Check Contents
Upon receipt of the shipment, carefully remove all items from the shipping package and compare the
contents to the shipping documents.
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ProScan In-Line Process Sensor
Notice
User Manual
Also check:
The ProScan sensor and other components for any damage that may have occurred during
shipping.
To make sure the sapphire lens is clean and undamaged. (If the lens needs to be cleaned, clean
it gently with a mild soap solution and a soft, clean cloth.)
The sensor’s electrical connector; it should easily mate with the connector pins on the sensor
body.
To make sure the threaded collar allows a snug, secure fit when fully engaged.
Electrical Connections
ProScan has a 5-pin electrical connector. The electrical connection scheme is shown in Figure 9, page 20.
If you purchased the molded, NEMA-6 electrical connector and cable from AW Gear Meters, simply
connect the cable as provided.
If you are using the Hirschmann connector (Part Number 932 878-100 ELST 512 PG9 (www.hirschmann-
usa.com) and need to make a cable connection, please read the following steps.
The most common wiring scheme for ProScan is a 3-wire connection:
Pin 2 is the mA output
Pin 3 is the 12 to 24 VDC power supply
Pin 4 is the ground (negative side of the supply).
A 4-wire connection can also be used to connect ProScan. In this wiring scheme, connect
Pin 1 (the negative side of the mA output)
Pin 2 (positive side of the mA output)
Pin 3 (12 to 24 VDC power supply)
Pin 4 (ground).
Pin 1 is the negative side of the mA output and is connected internally to Pin 4. This makes it more
convenient if you want to make a 4-wire connection as shown in Figure 1, page 8.
Pin 5, located in the center of the connector, is not used.
Once you make the connections inside the electrical connector, tighten the threaded cord grip on the
connector. This helps keep moisture from entering.
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