K-Patents PR-03 User Manual

INSTRUCTION MANUAL

FOR INLINE REFRACTOMETER

PR-03

WARNING

The process medium may be hot or otherwise hazardous.

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

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.

Document/Revision No. INM-3: Rev. 2/4 Effective: February 15th, 2005

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 [e-mail].

THE PASSWORD FOR PR-03 IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.

K-PATENTS OY
Postal address:

P.O. Box 77
FIN-01511 Vantaa, Finland
Tel. + 358-9-825 6640
Fax [phone]
[e-mail]
www.kpatents.com

K-PATENTS OY
Street address:

Elannontie 5
FIN-01510 Vantaa, Finland

K-PATENTS, INC.

1804 Centre Point Circle,
Suite 106,
Naperville, IL 60563
Tel. [phone]
Fax [phone]
[e-mail]
www.kpatents.com

Table of contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 PR-03 refractometer models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 General safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Inline refractometer sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Sensor description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Mounting the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2.1 Choosing sensor mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2.2 Check list for pipe mounting (PR-03-A, PR-03-D, PR-03-M) . . . . . . . . . . . . . . . . . . . . . 7

2.2.3 Check list for mounting in a tank, a vessel or a large pipe (PR-03-P) . . . . . . . . . . . . . . . 8

3 Indicating transmitter (IT-R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Indicating transmitter description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Mounting Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.1 Mounting the Interconnecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2.2.1 Connecting with sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.2.2 AC power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.2.3 +24 V DC power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2.2.4 Current output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2.2.5 Serial bus connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2.2.6 Input switch connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2.3 Serial output connections: connecting a computer with the IT-R . . . . . . . . . . . . . . . . . 14

3.2.4 Demo mode connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 Cable signals between IT-R and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Accessory units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Separate relay units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1.1 Relay unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1.1.1 Relay unit PR-7080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.1.2 Relay unit -WR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.2 Prism wash system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.3 Relay unit mounting and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.3.1 Mounting and connecting Relay unit PR-7080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1.3.2 Mounting and connecting Relay unit -WR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.1.4 Mounting and connecting prism wash systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.1.4.1 Recommended wash pressures and times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.1.4.2 Prism wash nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.1.4.3 Mounting of prism wash systems with steam and water . . . . . . . . . . . . . . . . . . . . . . . 23

4.1.4.4 Mounting of prism wash systems with high pressure water . . . . . . . . . . . . . . . . . . . . 25

4.2 External output unit PR-7090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2.2 External output unit mounting and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5 Startup, configuration and calibration adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2 System check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2.1 Checking accessory units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2.2 Testing prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3 Using Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3.1 Keyboard functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.4 Soft key Display: Getting information on the process

and the settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4.1 Viewing the Optical image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.4.2 Viewing System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.4.3 Checking conditions inside sensor head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.5 Soft key Calibrate: Viewing and changing system settings . . . . . . . . . . . . . . . . . . . 34

5.5.1 Viewing Optical image and raw data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.5.2 Raw data explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.5.3 Viewing Scaled image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.4 Viewing slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.5.5 Viewing Image diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.6 Configuring input switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.7 Configuring relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.8 Configuring external output unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.9 Configuring automatic prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.9.1 Timed wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.9.2 Smart wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.9.3 Preventing automatic wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.9.4 Prism wash check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.10 Adjusting concentration calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.10.1 Checking current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.10.2 Concentration calibration from keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.10.3 Output current range selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.10.4 Temperature calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.10.5 Adjusting damping time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.10.6 Field calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.10.7 Bench calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.1 Checking the sensor moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.2 Checking and replacing prism or prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.3 Disassembling and assembling a standard length sensor . . . . . . . . . . . . . . . . . . . . . . . 48

6.3.1 Disassembling the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.3.2 Replacing the prism and prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.3.3 Assembling the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.4 Disassembling and assembling a probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.4.1 Disassembling the probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.4.2 Replacing the prism and prism gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.4.3 Assembling the probe sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7 Troubleshooting and correcting problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.1 Troubleshooting Indicating transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.2 Troubleshooting sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.2.1 LED value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.2.2 Sensor temperature and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.2.3 Slope value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.2.4 Image diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8 Sensor specifications and

other sensor information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.1 Sensor labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.2 Sensor compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.3 Sanitary refractometer PR-03-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.3.1 PR-03-A sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.3.2 PR-03-A mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.3.3 PR-03-A specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8.3.4 PR-03-A parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.3.5 PR-03-A mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.4 Probe refractometer PR-03-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.4.1 PR-03-P sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.4.2 PR-03-P mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.4.3 PR-03-P specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

8.4.4 PR-03-P parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8.4.5 PR-03-P mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8.4.6 PR-03-P programming specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8.5 Compact process refractometer PR-03-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.5.1 PR-03-D sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.5.2 PR-03-D mounting hardware model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.5.3 PR-03-D specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.5.4 PR-03-D parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8.5.5 PR-03-D mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

8.6 Process refractometer PR-03-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.6.1 PR-03-M sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

8.6.2 PR-03-M specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

8.6.3 PR-03-M parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.6.4 PR-03-M mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.7 Valve body refractometer PR-03-W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.7.1 PR-03-W sensor model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.7.2 PR-03-W specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

8.7.3 PR-03-W parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.7.4 PR-03-W mounting specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

9 Indicating transmitter specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9.1 IT-R label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9.2 IT-R compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9.2.1 Upgrading IT-R program version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9.3 Model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

9.3.1 IT-R model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

9.3.2 Interconnecting cable model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

9.4 IT-R Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

9.4.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

9.4.2 Serial output specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

9.4.3 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

9.5 IT-R Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9.6 Command selection tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

9.7 Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

10 PR-03 process refractometers in potentially explosive atmosphere . . . . . . . . . . . . . 101

10.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

10.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

10.3 PR-03-...-AX parts list: differences to standard sensors . . . . . . . . . . . . . . . . . . . . . . . 103

A Glossary and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

B Information about Delivery data sheet (DDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

C K-Patents inline refractometer calibration data report . . . . . . . . . . . . . . . . . . . . . . . . . 109

D Instrument verification ISO 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1 Introduction 1

C: Indicating Transmitter

ABCD

7

4

1

0

8

5

2

.

9

6

3

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ENTER RESET

K-PATENTS

PROCESSINSTRUMENTS

B: Interconnecting cable

A: Sensor

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.

Figure 1.1 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.

2 PR-03 instruction manual

L

P

MM

S

A C B

BB
C

C

A

A

Low concentration High concentration

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 inter face at different angles.

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.

Figure 1.3 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 3

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 t he 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.

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 t he 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.

6 PR-03 instruction manual

a: optical image

b: detector window and the photocells

c: pulse train from detector

TIME

V

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.

8 PR-03 instruction manual

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

ABCD

7

4

1

0

8

5

2

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9

6

3

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ENTER RESET

K-PATENTS

PROCESSINSTRUMENTS

Raw data

Curve fitted to the data

10

20

30

40

50

60

70

1.35 1.40 1.45

R.I.

BRIX

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.

Figure 3.1 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.

Figure 3.2 Image analyzing algorithm

Figure 3.3 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”).

10 PR-03 instruction manual

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

-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.

◦

C and a storage temperature range of

3 Indicating transmitter (IT-R) 11

11

POWER

SELECTOR

POWER

CONNECTION

SERIAL CABLE

(pc)

SENSOR

CABLE

ACCESSORY UNIT

(serial bus)

SWITCHES

RELAYS

3.2.2 Electrical connections

All the electric terminals of the Indicating transmitter are on the Power supply card (Figure 3.5).

Figure 3.5 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.

12 PR-03 instruction manual

NEUTRAL

LINE

GROUND

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 t hem 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.

Figure 3.7 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.

14 PR-03 instruction manual

27 28 29 30 31

SWITCHES

BCDA

27 28 29 30 31

SWITCHES

D

C

B

A

Figure 3.10 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 Cable plugged into an IT-R

Figure 3.11 Serial (PC) connection

3 Indicating transmitter (IT-R) 15

18293104

11 27

43 47

29

45 49

15

5

12 28

44 48

30

46 50

3116

6

13 17

7

14 18

SENSOR

SERIAL BUS RS-485 SWITCHES

RLY1 RLY2

25 26

4-20mA

+-

The K-Patents communications package contains Windows software for downloading data from the IT-R.
The software has been preset so that it normally star ts 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

Figure 3.12 Making demo connection

4. Close the front panel and turn on the IT-R.

16 PR-03 instruction manual

A

B

C

D

CONC

68.0%

PROCESS TEMPERATURE: 31.2 °C
STANDARD RI(25°C): 1.4194

TEST: 115.7
Normal operation

Calibrate

Display

*

11

44

22

55

33

66

RED

RED

RED

RED

BLUE

BLUE

BLUE

BLUE

SEN+

+24V

SEN-

0V

GND

GND
PGND

1

4

2

5

3

6
7

Indicating transmitter

Plug

WHITE

BLACK

BLUE

BROWN

Cable Image Digitizer

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.

Figure 3.13 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

Figure 3.14 Cable signals

4 Accessory units 17

4 Accessor y 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 4 pcs
European BF11/PG11 cable glands 4 pcs

M20x1.5 cable glands 4 pcs

18 PR-03 instruction manual

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 t he 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

ABCD

44 46 48 5045 47 49 51

Indicating
transmitter

Indicating
transmitter

8-14

8-14

8-14 8-14

8-14

8-14

AB

External output unit

Relay unit

Relay unit

PR-8011

PR-8011

PR-8011

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).

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 t he 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.

Figure 4.3 Connecting Relay unit PR-7080

20 PR-03 instruction manual

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 Wash time Recovery Interval

above process allowed

pressure pressure

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

High pressure water 40 bar (600 psi) 70 bar (1000 psi) 10–15 s 20–30 s 10–20 min

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 Pr ism 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

22 PR-03 instruction manual

Figure 4.5 Process connection of a wash nozzle

Figure 4.6 Example of wash nozzle installed in a flow cell

4 Accessory units 23

8

STEAM

PART SPECIFICATIONSPART SUPPLIED BY

FLOW

6

2

RELAY UNIT PR-7080

TO DRAIN

WIRING SEE WRG-314

1/2"

12

119

7

CABLE PR-8011 BETWEEN INDICATING TRANSMITTER AND RELAY UNIT

SHUT-OFF VALVE&STEAM TRAP PR-3340-230/110

CABLE PR-8300 BETWEEN INDICATING TRANSMITTER AND SENSOR

INDICATING TRANSMITTER IT-R

EFC (ELBOW FLOW CELL)

SENSOR PR-03-A62-HSS

RELAY UNIT PR-7080

7

6

5

412

3

K-PATENTS

K-PATENTS

K-PATENTS

K-PATENTS

K-PATENTS

K-PATENTS

111

111

1

5

AC POWER SUPPLY 230/110 V

SOLENOID CABLE, 3x1 (AWG 17)

STEAM PIPE 1/4"

STRAINER PR-3342

STEAM PIPE 1/2"

CHECK VALVE PR-3302

13

111012

9

8

10

4

13

3

CUSTOMER

CUSTOMER

CUSTOMER

CUSTOMER 2

111

111

13

1

K-PATENTS

K-PATENTS

K-PATENTS

AIR

4.1.4.3 Mounting of prism wash systems with steam and water

Figure 4.7 Mounting of a prism wash system with steam and Relay unit PR-7080

24 PR-03 instruction manual

STEAM

AIR

PART SPECIFICATIONSPART

SUPPLIED BY

SWITCH

POWER

SAFETY

0

I

5

FLOW

TO DRAIN

1/2"

WIRING SEE WRG-313

10

8

6

SHUT-OFF VALVE&STEAM TRAP PR-3340-230/110

CABLE PR-8300 BETWEEN INDICATING TRANSMITTER AND SENSOR

INDICATING TRANSMITTER IT-R

EFC (ELBOW FLOW CELL)

SENSOR PR-03-A62-HSS

WASH RELAY UNIT

654

1

2

3

K-PATENTS

K-PATENTS

K-PATENTS

K-PATENTS

K-PATENTS

1

1

1

1

1

1

AC POWER SUPPLY 230/110 V

SOLENOID CABLE, 3x1 (AWG 17)

STEAM PIPE 1/4"

STRAINER PR-3342

STEAM PIPE 1/2"

CHECK VALVE PR-3302

13

12

10911

8

7

CUSTOMER

CUSTOMER

CUSTOMER

CUSTOMER

2

111

111

9

12

12

4

3

1

13

SAFETY SWITCH 1

7

2

11

K-PATENTS

K-PATENTS

K-PATENTS

CUSTOMER

14 CUSTOMERCABLE 2x1 (AWG 17) 1

14

Figure 4.8 Mounting of a prism wash system with steam and Relay unit -WR