K-Patents PR-01-S User Manual

WARNING

INSTRUCTION MANUAL

FOR PROCESS REFRACTOMETER

PR-01-S (-AX/FM/CS)

Protected by one or more of

Protected by one or more of the following U.S. patents:

the following U.S. patents:

Patent No. 4571075

Patent No. 4,571,075 Patent No. 5,563,737

Patent No. 5,563,737 Patent No. 5,009,113

Patent No. 5,009,113 Patent No. 5,617,201

Patent No. 5,617,201 Patent No. 5309288

Patent No. 5,309,288 Patent No. 6,067,151

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 (except with the isolation/retraction valve). For a retractor/isolation valve the line pressure should be within the specifications. For a prism wash system, close a hand valve for the wash medium and disable the power supply. Loosen the clamp or flange bolts cautiously, be prepared to tighten them again. 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 flange for security reasons.

Document/Revision No. INM 1/14 Effective: May 15, 2009

This Product Manual is delivered to end-user with K-Patents Product. Information in this manual is subject to change without notice. The latest manual version is freely available at http//www.kpatents.com/. You can also contact manuals@kpatents.com.

THE PASSWORD FOR PR-01-S IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.

K-PATENTS OY Postal address:

P.O. Box 77 FI-01511 Vantaa, Finland Tel. + 358 207 291 570 Fax +358 207 291 577 info@kpatents.com http://www.kpatents.com/

K-PATENTS OY Street address:

Elannontie 5 FI-01510 Vantaa, Finland

K-PATENTS, INC.

1804 Centre Point Circle, Suite 106, Naperville, IL 60563 Tel. 630-955 1545 Fax 630-955 1585 info@kpatents-usa.com http://www.kpatents.com/

1. TABLE OF CONTENTS

1. TABLE OF CONTENTS ........................................................................................................................1

2. GENERAL INFORMATION .................................................................................................................

2.1. EQUIPMENT....................................................................................................................................

2.2. STANDARD SPECIFICATIONS ....................................................................................................

2.2.1. MODEL CODE .......................................................................................................................

2.3. PRINCIPLE OF MEASUREMENT .................................................................................................

2.4. SENSOR DESCRIPTION.................................................................................................................

2.5. THE INDICATING TRANSMITTER..............................................................................................

2.6. DISPLAY AND KEYBOARD .......................................................................................................

2.7. INFORMATION DISPLAY ...........................................................................................................

2.8. CALIBRATE ..................................................................................................................................

2.9. COMPATIBILITY WITH EARLIER K-PATENTS REFRACTOMETER SYSTEMS................

2.10. IT-R PROGRAM VERSIONS ........................................................................................................

2.10.1. UPGRADING THE PROGRAM VERSION........................................................................

2.11. PASSWORD ...................................................................................................................................

2.12. GENERAL SAFETY CONSIDERATIONS...................................................................................

2.13. WARRANTY..................................................................................................................................

2.14. DISPOSAL......................................................................................................................................

3. MOUNTING .........................................................................................................................................

3.1. SENSOR LOCATION ....................................................................................................................

3.2. MOUNTING EXAMPLES .............................................................................................................

3.3. MOUNTING AND DISMOUNTING ............................................................................................

3.4. WASH NOZZLE FOR STEAM .....................................................................................................

3.5. INDICATING TRANSMITTER ....................................................................................................

3.6. ELECTRICAL CONNECTIONS ...................................................................................................

3.7. SERIAL OUTPUT ..........................................................................................................................

3.8. FUSES.............................................................................................................................................

3 3 4 5 7 8

9 10 12 13 15 16 17 17 18 18 18

19 19 21 24 24 24 25 28 32

4. START UP ............................................................................................................................................

4.1. INITIAL CHECK............................................................................................................................

4.2. CALIBRATION CHECK ...............................................................................................................

4.3. DEMO MODE ................................................................................................................................

5. CALIBRATION....................................................................................................................................

5.1. OUTPUT CURRENT RANGE SELECTION ................................................................................

5.2. CONCENTRATION CALIBRATION FROM KEYBOARD........................................................

5.3. FIELD CALIBRATION..................................................................................................................

5.4. BENCH CALIBRATION ...............................................................................................................

5.5. MECHANICAL ZERO ADJUSTMENT........................................................................................

5.6. SENSOR RANGEABILITY...........................................................................................................

5.7. EPROM PARAMETERS................................................................................................................

5.8. TEMPERATURE CALIBRATION................................................................................................

5.9. INSTRUMENT VERIFICATION ..................................................................................................

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33 33 33 34

35 35 35 36 37 38 38 39 40 40

6. MAINTENANCE..................................................................................................................................

6.1. REGULAR MAINTENANCE........................................................................................................

6.2. DIAGNOSTICS ..............................................................................................................................

6.3. DISPLAY MESSAGES ..................................................................................................................

6.4. INDICATING TRANSMITTER ....................................................................................................

6.5. SENSOR CHECK ...........................................................................................................................

6.6. TEMPERATURE MEASUREMENT.............................................................................................

6.7. PRISM GASKET REPLACEMENT ..............................................................................................

6.8. SENSOR DISASSEMBLY.............................................................................................................

6.9. OPTICAL MODULES TESTING ..................................................................................................

6.10. LED CURRENT ADJUSTMENT ..................................................................................................

43 43 43 46 50 55 61 61 63 64 65

7. PR-01-S PARTS LISTS ........................................................................................................................

7.1. PROBE............................................................................................................................................

7.2. SENSOR..........................................................................................................................................

7.3. INDICATING TRANSMITTER ....................................................................................................

8. PRISM WASH SYSTEMS ...................................................................................................................

8.1. PRISM COATING..........................................................................................................................

8.2. PRISM WASH WITH INTEGRAL STEAM NOZZLE.................................................................

8.3. PRISM WASH WITH INTEGRAL HIGH PRESSURE WATER NOZZLE ................................

8.4. PRISM WASH WITH FLOW THROUGH CELLS.......................................................................

8.5. RECOMMENDED WASH PRESSURES AND TIMES ...............................................................

9. RELAY UNIT .......................................................................................................................................

9.1. CONNECTIONS.............................................................................................................................

9.2. RELAY UNIT CONFIGURATION ...............................................................................................

9.3. COMPATIBILITY..........................................................................................................................

9.4. WASH LOGICS AND SMART WASH.........................................................................................

10. ACCESSORY UNITS.......................................................................................................................

10.1. EXTERNAL OUTPUT UNIT PR-7090 .........................................................................................

10.2. DIVERT CONTROL UNIT DD-01................................................................................................

11. ISOLATION VALVE WITH RETRACTION UNIT (HIMP-2 AND HIMP-3) ..............................

11.1. SYSTEM .........................................................................................................................................

11.2. MOUNTING ...................................................................................................................................

11.3. RETRACTOR WITH ISOLATION VALVE PARTS LIST ..........................................................

12. INTRINSICALLY SAFE REFRACTOMETER PR-01-S-AX/FM/CS ............................................

12.1. EQUIPMENT..................................................................................................................................

12.2. INTRINSICALLY SAFE MOUNTING .........................................................................................

12.3. ZENER BARRIERS......................................................................................................................

12.4. BARRIER POWER UNIT PR-7070 .............................................................................................

12.5. FUNCTIONAL DESCRIPTION ..................................................................................................

67 67 68 70

71 71 72 76 79 82

83 84 84 86 86

89 89 90

91 91 93 94

96 96 98

102 103 103

A INSTALLATION OF THE ISOLATION VALVE HIMP-2/HIMP-3 TO THE PROCESS PIPE .105

B INSERTING THE SENSOR TO THE ISOLATION VALVE HIMP-2/HIMP-3 ..........................113

C RETRACTING THE SENSOR FROM THE ISOLATION VALVE HIMP-2/HIMP-3 ................117

K-PATENTS PROCESS REFRACTOMETER PR-01-S CALIBRATION DATA REPORT...................121

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2. GENERAL INFORMATION

2.1. EQUIPMENT

The K-Patents Process Refractometer consists of three parts (Figure 2.10): the Sensor (A), the Interconnecting Cable (B) and the Indicating transmitter (C). For description of the intrinsically safe K-Patents Process Refractometer, see Chapter 12.

Figure 2.10 Equipment

For intrinsically safe equipment, see Figure 12.10.

The K-Patents Process Refractometer provides a 4 to 20 mA DC output signal proportional to process solution concentration. A serial output is also available as a standard.

Identification: By Serial Number (S/N) label (Figure 2.11) on the Indicating transmitter front panel and by Serial number on sensor label (Figure 2.10, Figure 2.12), e.g. 2003E2C-5604. The sensor type, e.g. 50, is stamped on the probe tip (see Section 2.2.1 for model codes).

PROCESS REFRACTOMETER

IT - RE - GP 100 - 115/220 - 240 V AC, 50/60 Hz, 20V TAG:

Figure 2.11 Identification label,

Indicating transmitter.

S/N:2003E20-5604

Figure 2.12 Identification label, Sensor.

For intrinsically safe sensor label, see Figures 12.11 and 12.12.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.2. STANDARD SPECIFICATIONS

Refractive Index ranges: Low range R.I. 1.320...1.460

High range R.I. 1.380...1.530 Max. span: R.I. 0.08 (See Section 5.6) Accuracy: R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight). Repeatability and

stability correspond to accuracy. Speed of response: 0.8 s undamped Damping time constant: Selectable up to 5 min Process temperature: max. 150°C (300°F) (for higher temp. consult factory) Ambient temperature: Sensor: max. 45°C (113°F), min. -20°C (-4°F), Indicating transmitter: max. 50°C (122°F), min. 0°C (32°F) Process pressure: Flange connections up to 25 bar (350 psi)

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) Wetted parts: AISI 316L stainless steel, prism gaskets Kalrez (prism pads teflon) Sensor weight: Sandvik-clamp 7 kg (15 lbs)/ Flange DIN/ANSI/JIS 10.5 kg (23 lbs) Process connection: NS 80 (3" Sch 10s) (Sandvik clamp/Flange DIN/ANSI/JIS/Sanitary clamp) Current output 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. Serial output: RS485/RS232

Galvanic isolation 500 V DC or AC (peak) Power: 100-115 V/220-240 V, 50/60 Hz, 15 VA Interconnecting cable:

Shielded cable, 2 twisted pairs with individual shields, 0.5 mm

Digital transmission according to RS485. Interconnecting cable length: Standard 10 m (33 ft), max. 100 m (330 ft) Indicating transmitter:

Enclosure IP66 Nema 4X Indicating transmitter weight: 4.5 kg (10 lbs) Alarms: Two built-in signal relays, max 24V, 500 mA Options:

- Long probe version (-LPL). Probe length is 152 mm (6") longer than

standard.

- Wetted parts: Hastelloy C, titanium or palladium doped titanium

- Cable fittings to the Indicating transmitter: European cable glands or

M20x1.5 metric cable glands or US conduit hubs, see Section 7.3.

- Built-on prism wash nozzle, see Section 8.3.

- Intrinsically Safe PR-01-S-AX/FM/CS, see Section 12. ATEX EX II 1 G /

Factory Mutual (FM) approved Class I, Div. 1,

=45 °C); CSA certified for Class I, Groups A-D

amb

Accessories:

Cenelec Eex ia IIC T4;

Groups A, B, C, D T4 (T

- External output unit, Section 10.1

- Digital Divert Control Unit DD-01, Section 10.2

- Retractor and isolation valve, Chapter 11.

- Prism wash nozzles for steam and hot water, Section 3.4.

- Flow cells according to separate drawings available from K-Patents.

Ordering information:

- Desired scale, properties of process solution

- Process temperature and pressure range

- Process flow range and pipe diameter

- Desired process connection

(We reserve right to technical alterations.)

- Length of interconnecting cable

- Supply voltage and frequency

- Options and accessories

- User tag

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

(A)

)

2.2.1. MODEL CODE

Model and Description Model

PR-01-S = Sensor PR-01-S

Refractive Index range limits

50= Low range R.I. 1.320....1.460 (A)

57= High range R.I. 1.380....1.530 (A)

Process connection

-L = Sandvik L-clamp, 80 mm -L

-H = Sanitary 3A-clamp, 4 inch -H

-D = DIN-flange 2656, PN 25, DN 80 -D

-A = ANSI-flange 150 psi, 3 inch -A

-M = ANSI 150 psi, 4 inch -M

-N = ANSI-flange 300 psi, 3 inch -N

-J = JIS-flange , 10K 80 A -J

Sensor wetted parts material

SS = AISI 316 L SS HC = Hastelloy C / ASTM C276 (B)(C XS = SAF 2205 / AISI 316L (L

Electrical classification

-GP = General purpose -GP

-AX = ATEX EX II 1 G / Cenelec Eex ia IIC T4 (I

-FM = FM approved IS CL.1,DIV.1 GRP.A,B,C,D T4 (I)(M

-CS = CSA certified for Class I, Groups A-D (I

Sensor length

-STD = Standard -STD

-LPL = Long probe, insertion length 299mm (B)(E

-LPS = Long probe, insertion length 147mm (B

-LPH = Retractable long probe (F)(G

-LPX = Long probe, insertion lenght xxx mm (B)(E Prism wash

-HPY = Integral nozzle mounting connection (B)(E) -HPY

-HPN = Integral nozzle for water (B)(E

-HPS = Integral nozzle for steam (B)(E

-YPY = Without integral nozzle mounting connection -YPY

Sensor options (H)

-JB = Junction box connection with screw terminals (J)(D

IT-R = Indicating Transmitter IT-R

Cable connection U = 1/2 inch NPT-type conduit hubs (for US) U M = M20x1,5 metric cable glands M

Electrical classification

- GP = General purpose -GP

- CS = CSA approved for use in general purpose (ordinary) locations -CS Transmitter options

-WR = Relay unit, 2 relays -WR

Part Number and Description Part No.

PR-8001 = Interconnecting cable betweenn transmitter and sensor, incl. sensor connector PR-8001 PR-8040 = Interconnecting cable, ( for –JB junction box and for Barrier Unit – IT-R connection) PR-8040

Cable length

-010 = 10 meters (33 feet), standard length -010

- _ _ _ = Specify cable length in meters with 10 meter increments.

Maximum length is 100 meters (330 feet) Example: Sensor: PR-01-S-ASS-GP-STD-HPY Transmitter: IT-RM-GP Cable: PR-8001-020 (A) Leave this section blank, code is specified by the Manufacturer according to the Ordering Information Sheet (B) Not available with Sanitary clamp (C) Not available with Sandvik L-clamp (D) Not available with –FM code (E) AISI 316L material only (F) Available with Sandvik L-clamp only (G) For use with Isolation Valve HIMP- only

-SC = Stainless steel sensor housing (K

(H) Multiple choices can be selected in option section; for a sensor without any options, leave this section blank (I) Specify Barrier Unit and cables (J) Specify PR-8040 Interconnecting cable (K) Available with –JB junction box only (L) Available with –LPH code only (M) Not available with –JB code

HC XS

-AX

-FM

-CS

-LPL

-LPS

-LPH

-LPX

-HPN

-HPS

-JB

-SC

-_ _ _

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Figure 2.20 Indicating transmitter: Dimensions (mm/in) and mounting feet measures.

Figure 2.21 Dimensions: Sensor with Sandvik clamp (mm/in).

Note: For Sanitary clamp, a separate drawing is provided.

Figure 2.22 Dimensions: Sensor with flange. DIN 2656 DN 80 or ANSI B16.5 3" RF 150 PSI

or JIS 1OK 80A (mm/in).

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.3. PRINCIPLE OF MEASUREMENT

The K-Patents Process Refractometer determines the refractive index (R.I) of the process solution by measuring the critical angle of refraction. The light from a light source (L) (Figure 2.30) is directed against the interface between a prism (P) and the process solution (S). The light rays meet this surface at different angles. The reflected rays form an image (ACB), where (C) is the position of the critical angle ray. The rays at (A) are totally reflected at the interface, the rays at (B) are partially reflected and partially refracted into the process solution. In this way the optical image is divided into a light area (A) and a dark area (B). The position of the borderline (C) between the areas shows the value of the critical angle and thus of the refractive index of the process solution. The refractive index normally increases with increasing concentration.

Figure 2.30 Refractometer principle.

Figure 2.31 Optical images.

From this follows that the optical image changes with the process solution concentration as shown in Figure 2.31. The optical image is converted to an electric signal by an image detector.

By this method the concentration of the solution is measured. The color of the solution, gas bubbles or undissolved particles do not interfere with the result.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.4. SENSOR DESCRIPTION

In the K-Patents Process Refractometer Sensor (Figure 2.40) the measurement prism (A) is flush mounted in the oblique surface near the tip. The light source (B) is a light emitting diode.

K-Patents Process Refractometer uses a digital image detector (C). The image detector consists of 256 photocells in a row integrated on one chip.

Figure 2.40 Sensor structure.

The image detector output is a pulse train as shown in Figure 2.41. This number of high pulses corresponds to the position of the shadow edge in the optical image. The number of high pulses is a direct measure of the critical angle. The image digitizer (E) transforms this pulse train to a serial digital signal. This serial signal transmits a package containing a complete description of the optical image and temperature data to the Indicating transmitter.

For automatic temperature compensation, the sensor tip contains a process temperature probe (F).

The digital image sensor (C) is separated from the process heat by fiber optics (D) and the thermal isolation (G). It is housed in the air-cooled sensor head.

CDE

a. Optical image

b. Detector window and the photocells

c. Pulse train from the detector.

TIME

Figure 2.41 Image detector system.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.5. THE INDICATING TRANSMITTER

Figure 2.50 The Indicating transmitter (IT-R).

The Indicating transmitter IT-R (Figure 2.50) receives a serial signal from the Sensor describing the optical image and also giving the process temperature. The microprocessor system displays the optical image (Figure 2.72) and implements an image analyzing algorithm (Figure 2.52), which identifies the exact position of the shadow edge shown in Figure 2.41.

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 signal and a Serial output signal, RS232 or RS485 alternatively.

There are also two built-in signal relays on the power supply card inside the Indicating transmitter. These two signal relays can be configured to any relay function, except to preconditioning or wash control (described in Section 9.2). Configurations are made from the main calibration menu, see Figure 2.61. Note the default setting for the built-in signal relay 1 is No Malfunction and for the relay 2 Internal humidity above 50%. A closed contact on the relay 1 indicates that the instrument works properly. It is recommended to use this relay for alarm purpose in a control system.

The Indicating transmitter also accepts 4 input switch closures for signal HOLD or scale selection. A serial bus connects the Indicating transmitter to the external units such as Relay Unit (See Chapter 9) or External Output Unit (Section 10.1).

Unauthorized access can be prevented: Knockout padlock provisions are included in both cover latches. For password protection, see Section 2.11.

The microprocessor system linearizes the concentration reading, like in the example Figure 2.51, and performs an automatic temperature compensation.

BRIX

1.35 1.40 1.45

R.I.

Raw data

Curvefittedtothedata

Figure 2.51 BRIX diagram.

Figure 2.52 Image analyzing algorithm.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.6. DISPLAY AND KEYBOARD

A built-in Demo program can be used for training, See Section 4.3.

The Normal Display (Figure 2.60) gives the following information:

- Concentration (large size characters) in %, g/l or other units, see Section 2.8.

- Process temperature in °C. Alternatively °F can be displayed, see Section 2.8.

- TEST value: The number of photocells at the light side in the optical image.

- Diagnostic messages like "Normal operation", see Section 6.3.

- Activated alarms

- Soft Keys: The definitions are shown above the corresponding keys A, B, C and D.

For the Normal Display, Figure 2.60, pressing key A starts a prism wash cycle when a Relay Unit (Chapter

9.) is used for prism wash. If a Relay Unit is not used for that purpose, the soft key "Start prism wash" is not visible.

A timeout is set for all displays. The timeout is one hour (60 minutes) for the following displays: Diagnostics Slope, Scaled Image, Raw Sensor Data, Optical Image, Normal Display. The timeout is one minute (60 seconds) for all other displays. During the timeout the display functions the same way as pressed the “Reset” key.

The keys C and D change the Normal Display to a Calibration menu (Figure 2.81) or an Information Display (Figure 2.71) respectively.

Figure 2.60 Normal Display.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Figure 2.61 The selection tree.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

The selection tree:

The display selections are structured like a tree as shown in Figure 2.61. Using the soft keys (A, B, C, D) it is possible to select the next display upwards. In some cases the selection is made from a menu using a numerical key. In Figure 2.61 the Soft Key selection is indicated by letters A-D, menu selection by numbers 1-9. The display itself provides guidance to find the right path step-by-step, which minimizes the need to consult the manual.

The RESET key is used to climb down the tree, for each RESET the next display downwards is selected.

Data entry:

When "New value: _ _ _ _ " is displayed, new parameter values can be entered by the numerical keys. Erroneous numbers are erased by RESET. Press ENTER, when the number is complete. After this ENTER, as well as after any change, there appears on the display:

Press ENTER to change (Otherwise press RESET)

2.7. INFORMATION DISPLAY

The Information Display, Figure 2.71, is selected by the soft key "Display" at the Normal Display (Figure

2.60). This "Display" branch of the selection tree is safe, because here no changes can be made to the system.

Figure 2.71 The Information Display.

The Information Display contains additional data compared to the Normal Display:

- The PROCESS TEMPERATURE in both °C and °F

- The STANDARD RI (25 °C). This shows the Refractive Index of a standard RI liquid applied to the prism, see Section 5.4.

- output current in mA

Optical image (soft key):

Shows the Optical Image, Figure 2.72. The light area (high pulses) is to the left, the dark area (low pulses) is to the right, compare to Figure 2.41. The vertical scale is 0-100 % of highest pulse amplitude, the horizontal scale expresses the numbers of the photocells 0-256. The three leftmost pulses represent additional dark reference cells.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Figure 2.72 The Optical Image.

System configuration (soft key):

- Main program and sensor processor and sensor interface processor versions

- Connection and processor versions of accessory units

- Current output scale: E.g. "4...20 mA = 40.0...60.0 CONC%"

Two soft keys, Relay configuration and Wash times. For details see Section 9.2.

One soft key Switch configuration, see Section 2.8.

Sensor head (soft key):

- Head temperature

- Head humidity. For details see Section 6.1.

2.8. CALIBRATE

The soft key "Calibrate" brings forward two alternative soft keys: "Optical image" and "Parameters".

Figure 2.81 Change parameters menu (calibration menu).

Optical image (soft key):

Displays all raw data from the sensor including the optical image followed by the SCALED IMAGE, SLOPE AND IMAGE DIAGNOSTICS screens, see Section 6.5.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Parameters (soft key):

Displays the CHANGE PARAMETERS menu (Figure 2.81) which contains:

CONC (RI) (soft key):

Further by the soft key "Parameters", the calibration parameters for the concentration are entered, see Section 5.2.

Menu selected functions are:

1. Concentration unit, can be "CONC %", "CONC g/l", "CONC", “OECHSLE” or "BRIX". Also

available is the unit RI (x °C), which is "RI measured in the laboratory at x °C" where typically x = 60 °C, displayed as RI (60 °C). The unit RI (x °C) should not be confused with "Standard RI (25 °C)" even if the x can be chosen as 25.

2. Number of CONC display decimals.

3. Damping time in seconds. This is the time it takes for the concentration measurement to reach

half of its final value at a step change of the concentration

4. Switch selected scales. Provides four additional complete sets of calibration parameters, see

"Switch inputs" below.

1. Prism wash:

Entering of prism wash times for the Relay Unit and a wash check, wash stop and smart wash functions, see Section 9.2.

2. Relays:

Provides relay configuration, see Sections 2.5 and 9.2.

3. Switch inputs:

The microprocessor accepts four switch inputs (A, B, C and D), for connections see Figure 3.63. The function of each switch can be individually defined from one of four alternatives

0. Not defined (which is the factory setting).

1. Remote wash start for Relay Unit wash function and external Hold. The external Hold is used

with a wash timer other than the Relay Unit, or to hold the signal during stops in an intermittent flow (e.g. by contact from the pump control). A wash start is also initiated when the contact opens, if it has been closed longer than one minute.

2. Defined to select alternative process mediums. There are all together four alternative mediums

selectable by closure of the corresponding switch. If no selection switch is closed, the normal medium is selected. Maximum number of mediums is five (Normal, A, B, C, D).

Note. The range will not change. Example: medium 1 = 20 - 40 % Sugar, medium 2 = 20 - 40 % Salt.

3. External wash stop: An input switch can be configurated to an external wash stop to prevent the

prism wash when the corresponding input switch is connected. “External wash stop”-message will show when automatic wash is activated. The input switch can be set to protect the refractometer e.g. if the process is stopped.

4. Calibration stop: An input switch can be configurated for calibration stop. Activating and

connecting the input switch will prevent calibration through software.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

4. Output signals menu:

1. Current output. Sets the zero and span in concentration units that correspond to 4-20 mA

output. The signal range 0-20 mA can also be selected. The 0 will be slightly above 0 mA, typically 0,06 mA. An active HOLD function locks the signal during prism wash by the Relay Unit. When the HOLD function is inactive, the wash results can be seen as a negative peak in the output signal.

2. External current output. Defines the scale for the External Output Unit (Section 10.1) the same

way as above. In addition the source has to be selected from the list Concentration/Standard RI (25 °C)/Temp °C/Temp °F.

3. Serial output. The format is to be defined, see Section 3.7.

5. Temperature menu:

The temperature calibration is made through this menu, see Section 5.8. It is also possible to select the temperature display unit in the normal display as °C/°F. A high temperature limit can be activated and set for a "High process temperature" message, Section 6.3.

6. Standard RI (25 °C):

Gives the calibration parameters for the bench calibration value with standard RI liquids, Section 5.4. The RI (25 °C) can also be added to the normal display.

7. Language

Selection of display language: 1. English 2. German.

8. Divert control

Supports the K-Patents Divert Control Unit DD-01, see separate Instruction Manual for the Digital Black Liquor Divert Control System.

9. Password

A software password can be selected to prohibit unauthorized calibration, see Section 2.11.

2.9. COMPATIBILITY WITH EARLIER K-PATENTS REFRACTOMETER SYSTEMS

The model PR-01-S has been preceded by models PR-01, PR-01-E and PR-01-B.

Sensor

The sensors of all models are using identical mounting parts, so e.g. a PR-01-B refractometer can be replaced by a PR-01-S without any process pipe changes. The critical measure, i.e. the distance between the prism and the process connection, is unchanged.

Interconnecting cable and Indicating transmitter

The PR-01-S cable, and also the transmission, is different from earlier models. Neither Sensor nor Indicating transmitter of the model PR-01-S can be combined with any corresponding unit of the earlier models.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.10. IT-R PROGRAM VERSIONS

The program version number consists of two digits. The first digit is the major version, the latter is the minor version. Programs with the same major versions are compatible. Also earlier major versions can usually be substituted with later major versions.

Version 1.0

Version 2.0: Supports external output unit, Section 10.1. Revised calculation of Standard RI (25 °C), new

style constants. Addition of standard RI to serial output data.

Version 2.1:External output is set inactive by setting the output range span to 0.

Version 3.0: Language selection English/German. Up-date of the optional Standard RI (25 °C) display.

Version 3.1: The measuring task has a higher priority than the keyboard handling task. The default for

relay alarm delay is changed from 0 to 10 s.

Version 4.0: Supports K-Patents Divert Control unit DD-01. Password protection added, Section 2.11. The RI display is shown without the reference temperature, if both temperature coefficient values for RI are zero.

Version 5.0: This version is accompanied by a a sensor modification: The PLUG-IN LIGHT SOURCE, eliminating the light source module adjustments to the optical image. The PLUG-IN LIGHT SOURCE should not be used with any lower program version. Program version 5.0 is compatible with all PR-01-S sensors. The range of the TEST display is now limited to 8...248. An advanced image analyzing algorithm is implemented, Figure 2.52 including IMAGE DIAGNOSTICS screen (Section 6.5). BRIX unit added (Section 2.8). The current output parameters ICAL0 and ICAL1 added to the current output calibration screen. Password limit moved (Figure 2.61): Raw data + Optical image available without password.

Version 6.0: Switch inputs for external wash stop and calibration stop added, Section 2.8. Wash stop when the process temperature is below the limit added, Section 9.2. Limit to divert alarms added (Ref. difference max 2% , Solids alarm min. 58%, Solids warning min 60%). Output unit Oe (Oechsle) added, Section 5.2. Temperature filtering of Intrinsically safe sensor is changed. Support for small relay unit added. Internal Sensor humidity and temperature added.

Version 6.2: A check for Relay accessibility is added to wash check logic. Support to read the display memory is added to the display driver and the display manager modules.

Version 7.0: Support for built-in signal relays on power supply card, Section 2.5. New relay signal sources: internal sensor temperature and internal sensor humidity, Section 9.2. Change of error classifications, Section 6.3. Display timeouts, Section 2.6.

Version 8.1: Support for Sanitary Refractometer PR-03-A. Smart Wash for prism wash, Section 9.4.

Version 8.2: Improved image handling.

Version 8.3: Changes in diagnostics message classification. Change in serial output timing.

Version 8.4: Maximum wash time decreased from 60s to 30s.

Version 8.5: Change in relay configuration. Change in unit marking on main display.

Version 8.6: Support for Sanitary Probe Refractometer PR-03-P

Version 8.7: Support for optical image of Sanitary Probe Refractometer PR-03-P.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.10.1. UPGRADING THE PROGRAM VERSION

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 2.11) 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 2.11 EPROM with program version 8.6

– 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.

– Power off and open the front panel of the IT-R.

– 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.

– Carefully remove the old EPROM from the Processor card

(Figure 2.12) and insert the new EPROM.

– 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.

– Press ENTER button and at the same time switch the power

on. You will now enter the Factory calibration mode.

– Press 1 for Default settings. Make sure that all pre-upgrade

parameters have been written down.

Figure 2.12 EPROM location

on Processor card.

– Press ENTER to load default parameters and press RESET twice to exit from the Factory calibration.

– Switch power off. Switch power back on.

– Enter all the pre-upgrade parameters (wash and relay parameters included) into the transmitter.

2.11. PASSWORD

The "CHANGE PARAMETERS" screen can be optionally locked behind a password function. When the password function is activated, entry to this screen is not allowed without a correct password, see Figure

2.61.

The password function can be activated or inactivated by selecting: "Calibrate/Parameters/9.Password/0. Inactive or 1. Active".

The password for K-Patents PR-01-S (-AX/FM/CS) is printed on the front page of this manual.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

2.12. 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.

2.13. 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.

2.14. 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 aluminum or stainless steel sensor housing can be recycled with other metallic waste of the same type.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

3. MOUNTING

Special precautions have to be taken when an intrinsically safe system is mounted, see Section 12.2.

3.1. SENSOR LOCATION

The sensor is delivered with a mounting guide attached, Figure 3.10.

The sensor is designed for being installed directly in a process line. If the sensor is located out of doors, some basic protection against direct exposure to sunlight and rain should be provided.

Air-cooling

Normally, draught and natural convection provide sufficient air cooling. Criteria for efficient air-cooling:

1. The sensor should be mounted with the main axis horizontal, Figure 3.10.

2. There must be no obstacles for air to flow around the sensor head.

3. The red sensor cover should not be exposed to high temperature radiation.

If the ambient temperature is higher than 45°C (113°F) the air-cooling should be improved by blowing pressurized air against the red sensor cover. This is also recommended when the process temperature is above 110°C (230°F) when the ambient temperature is above 35°C (95°F).

The pressurized air can be supplied by the ventilation system. If no air is available it is possible to wind a copper coil for cooling water around the sensor head cover.

Process flow conditions

The sensor is designed to make the prism self-cleaning. To ensure a representative sample and also prism cleaning action, a good process flow should be directed against the prism surface. A flow velocity above

1.5 m/s (5 ft/s) is recommended. For lower velocities prism wash (Chapter 8) should be considered. Flow

velocity is calculated from v[m/s] = 21.2 * Flow[lit/min]/d²[mm]; v[m/s] = 0.125 * Flow[Gpm]/d²[in].

Accumulation of sediment or of gas bubbles should be prevented.

If the process pipe vibrates, support the pipe.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Figure 3.10 Mounting guide.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Selection of location

To decide "Where to mount" use the following criteria:

1. Process pipe is preferred to process vessel, because favorable flow conditions are difficult to

ensure in a vessel.

2. 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.

3. If the refractometer is used in a feedback control loop, make the time lag small. E.g. when a

dilution valve is controlled, mount the refractometer as near the dilution point as possible.

4. 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.

5. Often the position with the highest pressure (= low point in pipe system + after pump + before

valve) has favorable flow conditions without sedimentation or air trapping risks.

6. The sensor should be conveniently accessible.

3.2. MOUNTING EXAMPLES

For mounting drawing for desired pipe diameter and connection type, contact the representative of K-Patents.

No special mounting parts are needed to mount K-Patents Process Refractometer. For all process pipe diameters just a standard piece of 88.9 x 3.6 steel pipe is used as adapter. For small process pipe diameters the piece of pipe is sealed in the other end to form a flow cell. Examples for different process pipe diameters are given in Figure 3.20 and Figure 3.21.

For flanged mounting, the user has to provide the counter flange. For clamp mounting K-Patents provides a weld-on ring.

Flow cells can be supplied by K-Patents, see Section 8.5.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Large pipe:

Diameter 150 mm (6”) or larger.

Medium size pipe:

Diameter 80 mm (3") or larger, smaller than 150 mm (6")

Pipe bend: Diameter 80 mm (3”) or larger.

Flow cell:

Diameter smaller than 80 mm (3")

Figure 3.20 Sandvik clamp mounting

Note. Separate drawings are provided for Sanitary clamp.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Large pipe:

Diameter 150 mm (6") or larger

Medium size pipe:

Diameter 80 mm (3") or larger

Pipe bend:

Diameter 80 mm (3") or larger, smaller than 150 mm (6")

Flow cell:

Diameter smaller than 80 mm (3")

Figure 3.21 Flange mounting DIN 2635 DN 80. Note: Separate drawings are provided for

ANSI B16.5 3” RF 150 psi and JIS 10K 80A.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

3.3. MOUNTING AND DISMOUNTING

The sensor mounting procedure: (Figure 3.30)

a. Remove the prism protection sticker before the sensor is connected to the process line.

b. Identify the sensor by the serial number. Sensors are interchangeable under special conditions only and

recalibration is normally required, section 3.5.

c. Check flow direction. If the fitting has a fixed flange, the bolt holes should allow proper flow

alignment of probe. If this is not the case, remove the two fixing bolts, (Section 7.1 sensor item 2.2). The sensor flange can then be freely rotated. Save the bolts, they are useful at dismounting.

d. Heat insulate the sensor flange if it can be suspected that a too strong cooling effect can cause prism

coating, Section 8.1.

Note. If the process medium is hot and sticky, it is recommended to heat the probe by using hot water before mounting. A cool prism tends to be rapidly coated.

Figure 3.30 Mounting procedure.

Dismounting

If a flanged sensor sticks in the fitting, pulling force can be generated by the flange fixing bolts.

Proceed as follows:

– remove the fixing bolts (Section 7.1, item 2.2) – lift the sensor flange away from the flange fitting – screw the bolts directly into the threaded holes – tighten the bolts alternately in small steps

3.4. WASH NOZZLE FOR STEAM

For mounting of the prism wash systems, see Chapter 8.

3.5. 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.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

The enclosure is mounted on a wall using four mounting feet, Figure 2.20. Do not drill mounting holes in

the enclosure.

Note: The LCD display has an operating temperature range of 0...50°C and a storage temperature range of

-20...60°C.

Check the serial number from the label, Figure 2.11.

An Indicating transmitter can be exchanged for another of the same model, but the current calibration constants have then to be entered by the keyboard (Section 5.7). For compatibility information, see Section

2.9.

3.6. ELECTRICAL CONNECTIONS

The electric terminals of the Indicating transmitters are all on the Power Supply card, Figure 6.40. This is accessible by opening the enclosure and the front panel. The front panel swings out after the two screws to the right have been loosened (Section 7,3, item 3.14). For intrinsically safe connections, see Section 12.2.

Power:

The power is specified in the DELIVERY DATA SHEET and on the Label (Figure 2.11). The position of the power select switch on the Power Supply card (SW2 in Figure 6.40) should also be checked. The power selection switch has two positions: 220-240 V/50-60 Hz or 100-115 V/50-60 Hz.

The primary AC power is connected to a separate terminal strip 39/40/41 on the Power Supply card marked POWER (Figure 6.40): The terminals are marked 39/L, 40/N and 41/ground symbol.

The power terminals L and N are directly connected to the transformer primary loop, and galvanically separated from the rest of the instrument. The ground terminal (41) is connected to the bottom plate of the Indicating transmitter, to the transformer shield winding and to the outer shield of the interconnecting cable.

Power for +24V DC Indicating Transmitters:

The power is specified in the DELIVERY DATA SHEET and on the Label (Figure 2.11). The position of the power select switch on the Power Supply card (SW2 in Figure 6.40a) should also be checked. The power selector switch must be in 110 position when input voltage is +24 V DC.

The primary DC power is connected to a separate terminal strip 39/40/41 on the Power supply card marked POWER (Figure 6.40a). The terminals are marked 39/+24V, 40/0 and 41/ground symbol.

The power terminals +24V and 0 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.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Terminal strip:

The rest of the connections are made to the terminal strip, Figure 3.61.

SERIAL BUS RS-485 SWITCHES

11 27

12 28

13 17

SENSOR

18293104

Figure 3.61 Terminal strip.

Sensor:

14 18

4-20mA

43 47

45 49

44 48

46 50

25 26

3116

RLY1 RLY2

At the Indicating transmitter end of the interconnecting cable has leads numbered from 1 to 7 to be connected to the terminals with the same numbers. The sensor end of the interconnecting cable is terminated by a plug, Figure 6.22. The interconnecting cable may be shortened or lengthened up to the limit specified, Section 2.2. The interconnecting cable should be installed in a separate metal conduit. For cable specifications, see Section 2.2.

Current output:

The terminal 25 is plus (+) and 26 minus (-) for the 4-20 mA output signal. The signal is specified in Section 2.2.

Recorders, controllers, indicators etc. shall be connected to form a closed current loop, starting from terminal 25 passing each device, in at plus and out at minus, ending at terminal 26. Be careful not to exceed the specified load resistance.

The range of the output signal can be set to 0-20 mA from the keyboard (Section 2.8), select Calibrate/Output signals/Current output/Range.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Serial output RS-232/RS-485:

Terminals 15-18 and Plug connector P3, see Section 3.7.

Serial bus:

Terminals 8-14 provide connection to K-Patents accessory units, like the Relay unit (Chapter 9) and External Output Unit (Section 10.1). The same type of cable is used as for the interconnecting cable to the sensor specified in Section 2.2.

The terminals 8-14 are connected to the same numbers in the external units. Connect the external units in a chain beginning from the Indicating transmitter and ending at the Relay unit (Figure 3.62). For an intermediate unit (e.g. External output unit), the Serial bus input is terminals 8-14 /A and output 8-14/B. If there is no Relay Unit to complete the chain, connect a 120 Ohm resistor over the terminals 8/B and 9/B at the last unit.

Note: The current loop of the Serial bus must always be closed, by a Relay Unit or the 120 Ohm resistor.

Rela

Indicatin transmitter

8-14

External output unit

8-14

unit

8-14

Indicating transmitter

8-14

Indicatin

External output unit

transmitter

8-14

Figure 3.62 Serial bus connections.

8-14

8-9

120

Ohm

Relay unit

8-14

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

Input switches:

Altogether four input switches A, B, C and D (Figure 3.63) can be connected: Terminals 27-A, 28-B, 29-C, 30-D, 31-Common. The switches may be separate, or together in one rotary switch. Input switches can be configured through software, Section 2.8.

A 5V voltage is provided over each switch. The switch terminals are all galvanically isolated from ground and from the rest of the electronics.

SWITCHES SWITCHES

27 2728 2829 2930 3031 31

BCDA

Figure 3.63 Connections to input switches.

Built-in signal relays:

3.7. SERIAL OUTPUT

A remote display unit, a computer, or a terminal can be connected to the PR-01-S serial output terminals. In the Indicating transmitter either RS-232 or RS-485 interface may be used.

The output measurement results are sent in ASCII code (ISO 646, CCITT V.3) using a standard asynchronous interface. The output consists of fixed-length text records. A record is sent for every measurement interval (800 ms).

RS-232: Conforms to the EIA RS-232-C and CCITT V.24 standards. The signals are available at plug terminal P3. Cable diagrams are shown in figure 3.70 (for modems) and figure 3.71 (for computers). Both 25-pin and 9-pin D-shell connector pin numbers are given. If the IT-R is to be connected to a computer, connections 4-5 and 6-8-20 (see figure 3.70) may be omitted in most cases. Note: RS-232-C specifies a maximum cable length of 15 m.

RS-485: The physical interface conforms to the EIA RS-485. The cable should be a shielded twisted pair. The RS-485 signals are available at P3 (DAT- and DAT+ in figure 3.70) or strip terminals 15-18. For a shielded cable connection (recommended), see figure 3.61. K-Patents recommends a cable length not exceeding 200 m.

INSTRUCTION MANUAL FOR K-PATENTS PR-01-S (-AX/FM/CS) DOCUMENT/REVISION No. INM 1/14 Effective: May 15, 2009

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