K-Patents PR-03 User Manual

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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 manuals@kpatents.com.

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 +358-9-8256 6461 info@kpatents.com 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. +1-630-955 1545 Fax +1-630-955 1585 Info@kpatents-usa.com 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

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

A C B

BB C

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

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

ENTER RESET

K-PATENTS

PROCESSINSTRUMENTS

Raw data

Curve fitted to the data

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

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

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

45 49

12 28

44 48

46 50

3116

13 17

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

CONC

68.0%

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

TEST: 115.7 Normal operation

Calibrate

Display

RED

BLUE

SEN+

+24V

SEN-

GND

GND PGND

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

8-14

8-14 8-14

8-14

External output unit

Relay unit

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

STEAM

PART SPECIFICATIONSPART SUPPLIED BY

FLOW

RELAY UNIT PR-7080

TO DRAIN

WIRING SEE WRG-314

1/2"

119

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

412

K-PATENTS

111

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

111012

CUSTOMER

CUSTOMER 2

111

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

FLOW

TO DRAIN

1/2"

WIRING SEE WRG-313

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

K-PATENTS

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

10911

CUSTOMER

111

SAFETY SWITCH 1

K-PATENTS

CUSTOMER

14 CUSTOMERCABLE 2x1 (AWG 17) 1

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

4 Accessory units 25

FLOW

PART SPECIFICATIONSPART SUPPLIED BY

TAP WATER, TEMP MAX 60 °C / 140 °F

SWITCH

MAIN

POWER

3/8"

POWER RELAY UNIT

PR-3603-___

2345687

CUSTOMER

AC POWER SUPPLY 230/110 V

CABLE BETWEEN INDICATING TRANSMITTER AND SENSOR PR-8300

INDICATING TRANSMITTER IT-R

EFC (ELBOW FLOW CELL)

WASH RELAY UNIT (WR)

SENSOR PR-03-A62-HSS

CHECK VALVE R 1/4" PR-3302

HIGH PRESSURE HOSE 8M

K-PATENTS

K-P / CUSTOMER

POWER SUPPLY CABLE 3 METERS FOR WATER VALVE

HIGH PRESSURE PUMP PR-3602-110/230/400/550 INCLUDING WATER VALVE

CUSTOMER

11111

POWER RELAY UNIT PR-3603-110/230/400/550 K-PATENTS 1

POWER SUPPLY CABLE 3 METERS FOR HIGH PRESSURE PUMP K-PATENTS 1

K-PATENTS

13 CABLE 2x1 (AWG 17) CUSTOMER 1

4.1.4.4 Mounting of prism wash systems with high pressure water

Warning! In high pressure wash systems, pressure increase can occur in a closed pipe section when the

high pressure pump is operated. K–Patents recommends to mount a pressure relief valve in the pipe section. Relief pressure should be according to pipe pressure rating.

Figure 4.9 Mounting summary of prism wash system for high pressure water with -WR relay unit

26 PR-03 instruction manual

4.2 External output unit PR-7090

The K-Patents inline refractometer can be provided with a separate current output unit to give e.g. a temperature mA signal.

4.2.1 Description

The External output unit PR-7090 has the same dimensions as the four-relay unit PR-7080 (Figure 4.1). The enclosure has IP 65 (Nema 4X) classiﬁcation. To open the enclosure, loosen the screws in the four top corners of the enclosure and lift off cover. This will give access to the output unit’s circuit card.

The cable ﬁttings are delivered as one of the three alternatives:

US 1/2 NPT-TYPE ST-1 conduit hubs 4 pcs European BF11/PG11 cable glands 4 pcs

M20x1.5 cable glands 4 pcs

The mA output range of the Output unit is the same as the built-in mA output of the IT-R, i.e. either 4-20 mA or 0-20 mA. The output range is chosen through the IT-R’s software, see Section 5.8.

Two monitoring LEDs on the output unit’s circuit card indicate its status: Green LED L1 is lit when the output unit is in order. Red LED L2 is lit when correct input dat a are missing. Red light means that either the connection to the IT-R is broken (no interconnecting cable, badly plugged cable or dead cable) or that there’s a problem on either the output unit’s circuit card or the IT-R’s processor card. Under normal operation the green LED should be lighted and the red LED should be dark.

The External output unit is connected with the IT-R with an interconnecting cable PR-8011 . The last three numbers in 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).

4.2.2 External output unit mounting and connections

Note: Seal all unused ﬁttings with blind washers.

The External output unit PR-7090 is mounted on a wall or similar vertical surface using its four mounting feet. Take the length of the interconnecting cable(s) PR-8011 and easy access for service into account when choosing mounting spot for the External output unit.

Open the screws on the External output unit and lift off cover to get access to the circuit card to make the connections. The output mA signal is connected to the terminals 42+ and 43-.

Connect the numbered leads of the interconnecting cable with the same numbers (8-14) on the serial bus A on the circuit card. If you have a Relay unit PR-7080, the Relay unit’s interconnecting cable is connected to the Serial bus B.

Important: If the refractometer system does not include a Relay unit PR-7080, close the circuit with a

120 Ohm closing resistor (Figure 4.10).

4 Accessory units 27

Indicating transmitter

8-14

8-148-14

External output unit

Relay unit

120

Ohm

PR-8011

Indicating transmitter

8-14 8-14

External output unit

120

Ohm

-WR

PR-8011

Important: Before connecting the Output unit with your refractometer system, power off your system. Then

open the IT-R’s enclosure and display panel to access the processor card.

Connect the numbered leads of the free cable end with terminals with the same numbers (8-14) on the serial bus on the Indicating transmitter’s processor card (if there’s an earlier Relay unit connection, move the Relay unit’s interconnecting cable to the Output unit’s circuit card, serial bus B, and then connect the Output unit with the IT-R).

Figure 4.10 Connecting External output unit

28 PR-03 instruction manual

5 Startup, conﬁguration and calibration adjustment 29

POWER

OFF 0 ON

CONC

68.0%

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

TEST: 115.7 Normal operation

Calibrate

Display

CONC

68.0%

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

TEST: 115.7 Normal operation

Start prism wash

Calibrate

Display

5 Startup, conﬁguration and calibration adjustment

5.1 Startup

First check that the serial number of your sensor (Figure 8.1) and your Indicating transmitter (Figure 9.1) match. If you ordered a new sensor to go with an old IT-R, ask K-Patents to send a new label for your IT-R.

Check wiring and supply voltage, Section 3.2.2.

Open the IT-R cover and press the main power switch (Figure 5.1) underneath down to ON position to power up your refractometer system.

Figure 5.1 The power switch

5.2 System check

After the power has been switched on, the IT-R checks the type of the sensor, which should be identiﬁed as PR-03. The sensor code PR-03 is shown on the display for a short time. Then the Normal display (Figure 5.2) appears. The diagnostic message should be Normal operation or, if the process pipe is empty, Low conc/no sample. For any other message see Section 9.7.

Without wash With wash

Figure 5.2 Normal displays

The display also shows the current process temperature.

The TEST value in the display should be in the range of 8-248. The value 248 indicates a clean prism in an empty process pipe. The value 8 means that the prism is coated and no reliable optical image is available.

As the instrument is precalibrated to your process, the concentration reading should be on scale, although it may need some ﬁnal adjustment (see Section 5.10.1). If the concentration reading is off, check your process conditions (see Section 7, “Troubleshooting and correcting problems”).

30 PR-03 instruction manual

CONC

36.7%

TEMPERATURE: 30.2 °C 86.4 °F STANDARD RI(25°C): 1.3960

TEST: 133.6 Normal operation

Optical image

System configuration

Sensor

head

Output signal: 16.7 mA

RI(25ºC

1.4412

PR-03 version 8.5 Sensor interface version 4.0 Sensor processor version 4.0 Relay unit not connected External output unit not connected

Output: 4..20 mA = 1.4260..1.4900 RI(25

Relay

configur-

ation

Switch

configur-

ation

Wash times

RI(25ºC

1.4412

SENSOR HEAD

Head temperature: 20 ºC Head humidity: 32 %

Normal operation

Press the key D (soft key Display) for additional data, e.g. output in mA. Further data is obtained in the Information display by soft keys Optical image (Figure 5.3), System conﬁguration and Sensor head. Return to Normal display by pressing the RESET key as many times as necessary.

Note: Use the keyboard’s keys A, B, C, D for the soft key commands, do not touch the display screen (see

Section 5.3.1).

Information display System conﬁguration display Sensor head display

Figure 5.3 Getting additional information

Measure the output signal. It should agree with the mA display.

If there are problems in the system check, proceed to Chapter 7, “Troubleshooting and correcting problems”.

5.2.1 Checking accessory units

All the accessory units, both relay units -WR and PR-7080 and external output unit, have two indicator LEDs that tell about their status. Open the enclosure cover to see these LEDs. When the refractometer system is on and the IT-R is ﬁnished with the initial check (i.e. the Normal display has appeared, see at page 29), only the green led should be lit. If the red led stays lit, there’s problem in the accessory unit conﬁguration, see Section 5.7 and Section 5.8.

Note: When the refractometer system is powering up, both LEDs light up for a short time during the system

check. After a while the red led should be turned off, in a working system only the green led is lit.

5.2.2 Testing prism wash

Important: Before you test prism wash, check that there is liquid in the pipe in front of the refractometer

and that the steam washing parts are properly installed and connected.

If you are using prism wash controlled by a relay unit check the wash sequence by pressing in the Normal display soft key Start prism wash (Figure 5.2). The TEST value should clearly increase (and the concentration reading decrease) during wash.

Note: The manual wash command cannot override External hold (see Section 5.6).

Note: The Start prism wash soft key appears in the Normal display only when a relay has been con-

ﬁgured as wash relay (Section 5.7). In demo mode it never appears, because the external units have been disconnected.

5 Startup, conﬁguration and calibration adjustment 31

CONC

68.0%

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

TEST: 115.7 Normal operation

Calibrate

Display

CONC

68.0%

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

TEST: 115.7 Normal operation

Start prism wash

Calibrate

Display

5.3 Using Indicating transmitter

5.3.1 Keyboard functions

The keyboard has 10 number keys and four soft keys, marked with letters A-D. The meaning of a soft key changes depending on what has been entered previously, i.e. what display is shown. The meaning of a soft key is always displayed on the screen above the key, for example the Normal display always has soft keys C=Calibrate and D=Display and, if the system has prism wash, also A=Start prism wash (see Figure 5.4).

The ENTER key is used to accept entered numeral values (to "OK" them) and the RESET key is used to cancel input and to move "backwards" in the command structure.

The commands that can be given to the Indicating transmitter have been arranged into a selection tree, i.e. command groups and subgroups (see Figure 9.5). The "root" of the selection tree is the Normal display (Figure 5.4), to which the IT-R always returns if it doesn’t receive any keyboard commands for a predeﬁned reset time (normally 60 seconds).

Figure 5.4 Normal display

Each command in the selection tree can be reached from the Normal display with its own, unique key sequence. For example you can view the relay conﬁguration with the sequence D (Display) - C (System conﬁguration) - A (Relay conﬁguration), i.e. starting from the Normal display, press ﬁrst soft key D, t hen soft key C, then soft key A. After viewing the conﬁguration you can go backwards to the Normal display by pressing the Reset key three times.

Whenever New value: _ _ _ _ is displayed, new parameter values can be entered by the numerical keys. If you accidentally enter a wrong number, you can erase it with RESET. When the number (value) is complete, press ENTER. After this the IT-R will ask for reconﬁrmation with the following text: Press ENTER to change (Otherwise press RESET). Thus, press ENTER if you want the new value to become effective. If you want to discard the new value and return to the old value, press RESET.

32 PR-03 instruction manual

CONC

36.7%

TEMPERATURE: 30.2 °C 86.4 °F STANDARD RI(25°C): 1.3960

TEST: 133.6 Normal operation

Optical image

System configuration

Sensor

head

Output signal: 16.7 mA

Example: You need to change the bias (see Section 5.10.2) to be 25.456 (as in the example in Section 5.10.2). Starting from the Normal display (Section 5.3), you have to perform following steps:

1. Give the right command sequence to get to the value to be changed, in this case

Calibrate/Parameters/CONC (R.I.)/Parameters/Bias

(key sequence C-B-A-A-1).

2. Type the new value.

3. When the new value is ﬁnished, press ENTER.

4. Accept (=reconﬁrm) the new value by pressing ENTER again. The new value now appears on the screen as the current value.

5. Finally, withdraw from the current display by pressing the RESET key as many times as necessary (ﬁve times to get to the Normal display from the Bias setting).

5.4 Soft key Display: Getting information on the process and the settings

Pressing the soft key Display (key D) in the Normal display brings up the Information display , Figure 5.5 below. Through the Information display you can get information about the process, the process parameters and other settings that have been entered to the Indicating transmitter. This branch of the selection tree (Figure 9.5) is safe, because it doesn’t allow you to make changes to the settings, it will only display the existing information.

As you can see in Figure 5.5, the Information display contains additional data compared to the Normal display:

− The process temperature in both◦C and◦F

− The standard RI (25◦C). This shows the Refractive Index of liquid applied to the prism, referenced to

25◦C

− output current in mA

Figure 5.5 The Information display

5 Startup, conﬁguration and calibration adjustment 33

Slope

TEST: 248.0

30.2 ºC Endp: 11 L): 30.5 R(: 5.3 HT: 20 ºC HH: 4 %

SCALED OPTICAL IMAGE

Low concentration / No sample

Slope

TEST: 133.6

30.2 ºC Endp: 11 L): 16.5 R(: 30.3 HT: 20 ºC HH: 4 %

SCALED OPTICAL IMAGE

Normal operation

5.4.1 Viewing the Optical image

You can view the Optical image (Figure 5.6) by pressing the soft key Optical image (key A) in the Information display. The light area (high pulses) is to the left, the dark area (low pulses) is to the right,

compare to Figure 2.2. The vertical scale is 0–100% of highest pulse amplitude, the horizontal scale expresses the numbers of the photocells 0–1024. Figures 5.6 below show some typical optical images appearing at startup.

Empty pipe Normal conditions

Figure 5.6 Typical optical images

Press the RESET key to return to the Information display from the Optical image display.

5.4.2 Viewing System conﬁguration

You can view the System conﬁguration, i.e. information about your refractometer system settings, by pressing the soft key C (= System conﬁguration) in the Information display. The System conﬁguration display contains:

− Main program and sensor processor and sensor interface processor versions

− Connection and processor versions of accessory units

− Current output scale: E.g. 4–20 mA = 40.0–60.0 CONC%

− Three soft keys:

− Relay conﬁguration (key A); for details see Section 5.7, “Conﬁguring relays”.

− Switch conﬁguration (key B); for details see Section 5.6, “Conﬁguring input switches”.

− Wash times (key C); for details see Section 5.9, “Conﬁguring automatic prism wash”.

Press the RESET key to return to the Information display from the System conﬁguration display.

5.4.3 Checking conditions inside sensor head

By pressing the soft key D (= Sensor head) in the Information display you will ﬁnd out what the conditions are inside the sensor head:

− Head temperature

− Head humidity

This is very useful information when suspecting a problem in the sensor head, for details see Section 7.2.2.

34 PR-03 instruction manual

RAW SENSOR DATA

RMN: 2 RMX: 216 LED: 96 Scans: 2 A/D: 314 Sts: 00h HT: 143 HH: 10

Scaled image

Normal operation

5.5 Soft key Calibrate: Viewing and changing system settings

5.5.1 Viewing Optical image and raw data

It is possible to view all raw data from the sensor including the optical image followed by the Scaled Image, Slope and Image Diagnostics displays (see the selection tree, ﬁgure 9.5). Starting from the Normal

display, select Calibrate/Optical image to get the complete optical image. The display (Figure 5.7) contains now all raw data from the Sensor including the signals from each photo cell, i.e. the raw video signal. This differs from the Optical image, Figure 5.6, selected through the Display key.

Figure 5.7 Complete optical image with raw data

For information on the diagnostic messages shown on this screen, see Section 9.7.

5.5.2 Raw data explanations

RMN, RMX Minimum and maximum of the raw video signal. This signal is calculated on the Processor

card from the video signal. The scale is 0-255, corresponding to full scale on display. The light intensity is controlled to keep RMX in the range 170-190.

LED The LED exposure control signal on a light intensity scale 1-255. The ﬂashing red light of

the LED can be seen directly. If the operation is correct, the displayed LED value should be above 20 and below 200.

Scans Number of optical images during one calculation cycle, typically 1 or 2. The scan pulses

(with 5 V amplitude) can be measured at TP 3

A/D This refers to the temperature measurement

Sts Sensor status bits determined by the type of Image Detector card: "04h" indicates a Process

refractometer PR-03. One bit added, "05h", indicates DETECTOR TIMEOUT.

5 Startup, conﬁguration and calibration adjustment 35

SCALED OPTICAL IMAGE

TEST: 115.9

51.2 °C

Endp: 21 L): 9.8 R): 25.9 HT: 20 °C HH: 3%

Slope

Normal operation

HT Sensor head temperature sensor reading. This value is used in calculating the actual Sensor

head internal temperature.

HH Sensor head humidity sensor reading. The actual relative humidity inside the sensor is cal-

culated from HH and HT.

5.5.3 Viewing Scaled image

In t he scaled image (Figure 5.8) the optical image has been modiﬁed mathematically to make a clearer curve.

Figure 5.8 Scaled image display

The Scaled image display provides following information:

TEST: The calculated TEST value, i.e. the number of photocells on the lisght side of the optical image

(to the left fo the vertical line). Range 8–248. Indicated by a dotted vertical line.

(T) Indicates the process temperature. Endp: The vertical intensity value of the rightmost point in % of span. L): A measure of the left side curvature of the optical image. R(: A measure of the right side curvature of the optical image.

A zero curvature indicates a straight line. Both curvature values are deﬁned as positive for an image as Figure 5.5.3.

HT: Sensor head internal temperature in◦C. HH: Sensor head internal relative humidity in %RH.

5.5.4 Viewing slope

The Slope display (Figure 5.9) shows the slope curve of the optical image. Slope is a measure of the sharpness of the optical image.

The SLOPE curve should have a sharp dip at the TEST value. The following additional values are given:

36 PR-03 instruction manual

Diagnostics

SLOPE

TEST: 115.7

31.2 °C

Max: 208 Slope: 2.7 Endp: 21 L): 10.1 R(: 25.8

Normal operation

Figure 5.9 Slope display

Max: The ﬁltered value of the maximum light intensity RMX of the raw data (Figure 5.7). Slope: The absolute value of the slope curve dip at TEST. The value of Slope must be above 1 to be

acceptable.

5.5.5 Viewing Image diagnostics

The Image diagnostics display lists the critical values for TEST acceptance:

Max intensity OK (above 100)? Yes/No Endpoint below 75 %? Yes/No Image below corner? Yes/No Slope OK (above 1)? Yes/No Left curve OK (above 1)? Yes/No Right curve OK (above 1)? Yes/No

For measurement with a normal sample, all answers should be Yes. A message Dip in image may appear if the optical image is irregular.

5.6 Conﬁguring input switches

To reach the input switch conﬁguration settings from the Normal Display, use the command sequence Calibrate/Parameters/Switch inputs.

The microprocessor accepts four switch inputs: A, B, C and D (for connections see 3.10). The function of each switch can be individually deﬁned from one of the following ﬁve alternatives:

0 Not deﬁned (factory setting). 1 Scale select Select parameters for alternative process mediums. There are all to-

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

5 Startup, conﬁguration and calibration adjustment 37

RI(25ºC

1.4412

SWITCH INPUT A (Not defined)

0 Not defined 1 Scale select 2 Ext hold & wash start 3 External wash stop 4 Calibration seal

Switch

Figure 5.10 Switch input display for input A

D).

Note: The range will not change.

Example: medium 1 = 20 - 40 % Sugar, medium 2 = 20 - 40 % Salt.

2 Ext hold & wash start Remote wash start for Relay unit wash function and external Hold.

This switch function is useful for an intermittent process: the prism is washed when the process stops and again when it starts, between the two washes the output signal is on Hold.

Only Sanitary refractometer PR-03-A, Probe refractometer PR-03-P and Process refractometer PR-03-D.

3 External wash stop Only Sanitary refractometer PR-03-A, Probe refractometer PR-03-P

and Process refractometer PR-03-D.

4 Calibration seal An input switch can be conﬁgured for calibration seal. Activating and

connecting the input switch for calibration seal will prevent calibration through software.

5.7 Conﬁguring relays

You can check the existing relay conﬁguration and functions with the Indicating transmitter. Press the key sequence Display/System conﬁguration/Relay conﬁguration to display the current relay settings.

The default setting for built-in signal relay 1 is No malfunction and for signal relay 2 Internal humidity above 50 %. A closed contact on the Relay 1 indicates that the instrument works properly. It is recommended to use this relay for alarm purpose in a control system.

In relay units, Relay B is conﬁgured for wash by default.

You can reprogram the relay functions any time through the IT-R’s calibration menu by performing t he following steps:

38 PR-03 instruction manual

1. Press Calibrate/Parameters/Relays.

2. For built-in relays select either soft key A, Relay1, or soft key B, Relay2.

For a relay unit select key 3, Relay unit and then select the relay to be programmed (in -WR relays A and B, in PR-7080 relays A, B, C, D).

3. Select the relay function

0 Not deﬁned 1 Processor OK The relay is ON if the processor is running 2 Normal operation The relay is ON if the diagnostic message is

Normal operation.

3 No malfunction The relay is ON if the diagnostic message is

Normal operation or Low conc/no sample.

4 Low limit Low alarm relay, relay is ON if value below limit.

First choose an alarm source from the following list:

− CONC %

− Standard RI (25◦C)

− TEMP◦C

− TEMP◦F

− TEST

− Sensor temperature

− Sensor humidity

Then enter a alarm limit. The default value of the limit is zero.

5 High limit High alarm relay, relay is ON if value above limit.

First choose an alarm source from the following list:

− CONC %

− Standard RI (25◦C)

− TEMP◦C

− TEMP◦F

− TEST

− Sensor temperature

− Sensor humidity

Then enter a alarm limit. The default value of the limit is zero.

6 Preconditioning A preconditioning relay. Relay unit only. 7 Wash A wash relay. Relay unit only. 8 In divert control Not used with PR-03.

Important: An alarm relay conﬁguration always requires the following information: high or low limit,

alarm source and alarm limit. The conﬁguration is not complete until all the information is entered to

the IT-R.

Note: If needed, you can adjust alarm delay by pressing the key 4, Alarm delay in the Relays display

(Calibrate / Parameters / Relays). The same delay applis to all relays and is used to prevent oversensitive alarms. The source value has to be out of limits during the whole delay time, given in seconds, to activate the relay. The default value for the alarm delay is ten seconds.

5 Startup, conﬁguration and calibration adjustment 39

RI(25ºC

1.4412

EXTERNAL OUTPUT UNIT (Not connected)

1 Zero (0.0000) 2 Span (0.0000) 3 Hold function (Active) 4 Range (4..20 mA) 5 Source (Not defined)

5.8 Conﬁguring external output unit

To program the External output unit from the keyboard of the Indicating transmitter, start with the sequence Calibrate / Parameters / Output signals / External output to get the External output unit display (Figure 5.11).

1 Zero Measurement value corresponding to 4 mA or 0 mA (depending on your cho-

2 Span Measurement value span corresponding to mA output span 3 Hold function Select either 0 Inactive or 1 Active 4 Range Select either 0 4..20 mA or 1 0..20 mA 5 Source Select from

Example: For source◦C, zero = 20, span = 80, the output signal 4 - 20 mA corresponds to 20-100◦C.

5.9 Conﬁguring automatic prism wash

The relay units -WR and PR-7080 can be conﬁgured to control prism wash. Automatic prism wash can be initiated with regular intervals (Section 5.9.1) or based on cer tain measurement values (Section 5.9.2). It is also possible to conﬁgure these automatic wash functions so that they are not used when the process is stopped or the pipe is empty (Section 5.9.3 and Section 5.9.4).

Figure 5.11 External output unit display

sen range)

0 Not deﬁned 1 RI (25◦C) 2 Standard RI (25◦C) 3 Temp◦C 4 Temp◦F 5 TEST 6 Sensor temperature 7 Sensor humidity

40 PR-03 instruction manual

WASH

RECOVERY

INTERVAL

PRECOND.

5.9.1 Timed wash

When an external relay unit is used as a wash timer, the time settings are entered after the sequence Calibrate / Parameters / Prism wash:

− Preconditioning time s (0)

− Wash time, s (3)

− Recovery time, s (30)

− Wash interval, min (20)

The default values for timed wash are given in parenthesis. The output signal is locked during wash and recovery time.

Figure 5.12 Prism wash sequence

Note: The wash interval timer starts a wash at a preset interval after last wash, independently of how the

last wash was initiated. If the wash interval is set to zero, the timer will not initiate a wash.

Wash type Time Pressure Recovery Interval

Steam wash 3-5 sec. 5-6bar (73-87 psi) 20-30 s 20-30 min

High pressure water wash 10-15 sec. 20-30 bar (290-435 psi) 20-30 s 10-20 min

Table 5.1 Recommended prism wash times for the PR-03 sensors

Important: In steam wash, do not exceed the recommended wash times, because some process media may

burn to the prism surface if steamed for longer time. In case of coating, shorten the wash interval.

5.9.2 Smart wash

Sometimes it is necessary to modify the standard wash routine to ﬁt the application better. The Smart wash feature allows you deﬁne better when wash is needed and when it should not be implemented.

The Smart wash starts the wash when the prism shows signs of being coated. An early indicator of beginning coating is that the Slope decreases. Slope is a measure of the sharpness of the optical image (Section 5.5.4).

The Smart wash settings are made at Calibrate / Parameters / Prism Wash / Smart

wash:

Slope limit A wash is initiated when the Slope value goes below this limit. The Slope limit has to

be set based on observations of slope values both at clean prism and at slight coating. When the slope limit is set to zero, this Smart wash function is inactive.

5 Startup, conﬁguration and calibration adjustment 41

Minimum time This parameter sets a limit to how often the Smart wash is allowed to start a wash, its

range is 0–1440 min. When this parameter is zero, the Smart wash function is inactive.

Maximum test This parameter should normally be set to zero. Then it will not inﬂuence the Smart

wash function. It may be used for ﬁne-tuning: The Smart wash will initiate wash only if the Test value is below Maximum test.

5.9.3 Preventing automatic wash

Note: The preconditioning and wash relays are not activated by automatic wash start under Low conc /

no sample as this indicates a clean prism in an empty process line, i.e. there is no need for washing the prism.

Wash can be prevented when the process temperature is below a limit. The Wash stop function is used to prevent steam wash when the process pipe is empty or when the process is stopped. To activate the wash

stop use the command sequence Calibrate / Parameters / Prism wash / Wash stop / Activate and set the temperature limit. The default value for wash stop is inactive. When

the wash is not accepted the diagnostics message is Wash stop/temp. limit, see Section 9.7.

Wash can also be prevented by an external contact closure, telling e.g. that the process pump has stopped. See Section 5.6.

5.9.4 Prism wash check

The prism wash check is used for making sure that the wash really has an effect on the prism, i.e. that the wash works correctly. A prism wash is accepted if one of the two conditions are satisﬁed:

1. TEST exceeds "TEST limit", i.e. the TEST value reaches the set limit during wash cycle

2. TEST increases more than "TEST difference", i.e. the TEST value increases during wash reaching the value of normal TEST plus the given TEST difference.

The default values of "TEST limit" and "TEST difference" are zero, which makes the Wash check inactive. If one of the conditions are set to zero, the other condition is valid alone.

Example: A typical case is "TEST limit" = 230, "TEST difference" = 0. The wash is accepted, if the Test value exceeds 230 during wash, and the Test difference condition is invalid.

42 PR-03 instruction manual

WASH

STOP ?

EXTERNAL

HOLD ?

Start prism wash

REMOTE WASH

SWITCH

YES

Automatic Wash start

1. Wash interval timer

2. Smart Wash

YES

WASH

RECOVERY

WASH

CHECK

OK?

RETRY

WASH ?

YES

“Prism wash

failure“

Reset “Prism wash failure“

Manual

Figure 5.13 Wash decision logics

5 Startup, conﬁguration and calibration adjustment 43

If the wash is not accepted, the diagnostic message will be Prism wash failure (see Section 9.7 for more information). This message is reset from the keyboard "Reset" or by a successful wash. A Wash

retries parameter deﬁnes how many times wash is tried. The prism wash retries parameter is set with Calibrate / Parameters / Prism wash / Wash check / Wash retries, the default

value (number of retries) is zero.

5.10 Adjusting concentration calibration

A K-Patents inline refractometer system is always delivered precalibrated according to the information given by the user. The refractometer does not need any mechanical adjustments, all adjustments or changes of range are made by keyboard entry only (Sections 5.10.2 and 5.10.3). The ﬁnal calibration to obtain full accuracy is made by collecting data from the actual process and sending that data to K-Patents or local K-Patents representative for calculations and new calibration parameters (Section 5.10.6).

5.10.1 Checking current calibration

Wait until normal process conditions occur. The instrument is precalibrated at delivery, so a correct output should be obtained automatically. If output is badly off-scale, check your process conditions.

If the diagnostic message is Normal operation but the concentration reading is not what could be expected based on laboratory determinations, the deviation can be corrected with a calibration constant bias, see Section 5.10.2 below.

If the concentration reading is correct, but not the output mA, see Section 5.10.3 below for adjusting the concentration reading.

The temperature by the refractometer sensor may not be exactly the same as the temperature given by a separate process temperature sensor. Normally, a constant slight deviation in the temperature by the sensor is not critical. However, it is possible to calibrate the sensor to give the exact process temperature, see Section 5.10.4, “Temperature calibration”.

The damping of the concentration measurement may be increased if necessary e.g. to get a smoother recorder track, see Section 5.10.5.

5.10.2 Concentration calibration from keyboard

The concentration display should be in agreement with laboratory determinations. If t he diagnostic message is Normal operation, deviations can be corrected from keyboard by adding a calibration constant bias value . A change of the calibration constant bias inﬂuences t he Conc% reading the same amount.

Key in Calibrate/Parameters/CONC (R.I.)/Parameters/Bias to read and change the Bias.

Example: If the CONC% display is 26% and the laboratory determination is LAB% = 28%, then a value Bias = 23.456 should be changed to Bias + LAB% - CONC% = 25.456.

Note: The CONC% reading is restricted to positive values even if the mathematical calculation gives a

negative value. For a negative CONC% the display shows "0.0". For BIAS adjustment it is useful to know the real CONC% value. For this reason the calculated negative CONC% reading is shown in the Calibrate branch of the Selection tree, Figure 9.5.

44 PR-03 instruction manual

Warning! Never try to change bias in a day-to-day manner, or week-to-week. Frequent bias changes will

increase the measurement variation, not decrease it.

Ampliﬁcation adjustment: The size of CONC% changes is directly proportional to the calibration constant Gain. The point, where TEST = 128, is not inﬂuenced by Gain. From two measurement points the new Gain can be estimated by the formula New Gain = Old Gain * (LAB%1 - LAB%2) / (CONC%1 - CONC%2). After the change of the Gain, the Bias has to be determined by a new sample.

The constants Square and Cube are linearity corrections that can be provided by K-Patents, see Section 5.10.6.

5.10.3 Output current range selection

It is possible to change t he concentration range of the output current even after the instrument is installed and operating. The change is made through the display Calibrate/Parameters/Output signals/Current output.

Example: To change 4–20 mA = 15–25 CONC% to 4–20 mA = 10–30 CONC%, key in the sequence

Calibrate / Parameters / Output signals / Current output

and then enter Zero = 10 and Span = 20.

5.10.4 Temperature calibration

Normally the process liquid temperature is considerably higher than the ambient. Then the heat loss through the refractometer sensor may cause the temperature display to be somewhat lower than the process temperature. This will not impair the measurement, and the difference can be ignored.

If, however, the temperature has to show an absolutely correct value, then a bias in◦C can be added to the temperature reading by giving the following key sequence Calibrate/Parameters/Temperature/Temp bias and entering the bias in degrees centigrade.

Note: A change of Temperature bias will cause a small change in the concentration output, due to the

temperature compensation. If necessary, this change can be compensated with a Bias change (see Section 5.10.2).

5.10.5 Adjusting damping time

The damping time is the time it takes for the concentration measurement to reach half of its ﬁnal value at a step change of the concentration. For example, if concentration changes from 50 % to 60 % and damping time is 10s, it takes 10 seconds for the IT-R to show concentration 55 %. Figure 5.14 below shows how the damping time affects the measurement curve.

The damping time is set in seconds with the key sequence Calibrate/Parameters/Conc (R.I.)/Damping time. A damping time of 5–15 seconds seems to work best in most cases, the factory setting is 5 sec.

Warning! Avoid overdamping, the signal should not be made insensitive.

5 Startup, conﬁguration and calibration adjustment 45

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Time [s]

CONC%

Undamped

5 s 10 s

30 s

Figure 5.14 Effect of damping time on measurement

5.10.6 Field calibration

The most accurate calibration is made under normal process conditions using your standard laborator y determinations of sample concentration. K-Patents provides a ﬁeld calibration service that optimizes the calibration constants based on the data supplied.

You should systematically record calibrating data on the Calibration data report (page 109, also available at www.kpatents.com and by email at info@kpatents.com). When you have completed the Calibration data report, you have to fax it to either K-Patents headquarters or your local K-Patents representative. A computer analysis of the data will be made at K-Patents and optimal calibration data will be sent to you to be entered in the IT-R.

For a complete report you need 10–15 valid data points (see below). A data point is of use for calibration only when the diagnostic message is Normal operation. If prism wash is employed, do not take samples during the wash. A data point is useful even if the concentration value is outside the range of the output current. Each data point consists of:

LAB% Sample concentration determined by the user. From IT-R display: (see Section 5.3) CONC% Measurement in concentration units TEST Number of photocells on the light side of the optical image (= primary measurement) TEMP Process temperature measurement in centigrades

Accurate calibration is only achieved if the sample is taken correctly and the data points are recorded carefully and only when the message is Normal operation. Pay special attention to following details:

− The sampling valve and the refractometer should be installed close to each other in the process.

− Warning! Wear protective clothing appropriate to your process when operating the sampling

valve and handling t he sample.

− Run the sample before starting to collect data points to avoid sampling old process liquid that has remained in the sampling valve.

− Read the values CONC%, TEST and TEMP in the IT-R’s display at exactly the same time with sampling.

− Use a tight container for the sample to avoid evaporation.

46 PR-03 instruction manual

5.10.7 Bench calibration

The calibration of your refractometer system can be checked ofﬂine using Standard RI liquids. These are available at K-Patents with part number PR-2003. The complete set of 10 bottles covers the RI range 1.310-

1.540. Standard RI liquids are also available directly from: Cargille Laboratories, 55 Commerce Road, Cedar Grove, New Jersey 07009, USA. WWW: http://www.cargille.com/, e-mail: cargillelabs@aol.com, phone: 973-239-6633, fax: 973-239-6096.

The bench calibration should be done at room temperature, but the temperature does not have to be exactly 25◦C as the displayed value is temperature compensated. If the sensor is hot, let it cool down to ambient temperature.

Use a sample holder, Figure 5.15 and "strip" the sensor, i.e. use PR-03-M sensor without the ﬂow cell and PR-03-W sensor without the valve body. Sample holders are available at K-Patents with part number PR1010 for Sanitary refractometer PR-03-A, PR-1012 for Probe refractometer PR-03-P and Compact process refractometer PR-03-D.

Figure 5.15 Sample holder PR-1010

Use the same three R.I. liquids t hat were used for the Delivery Data Sheet of this sensor. See Appendices B,

“Information about Delivery data sheet (DDS)”, and D, “Instrument veriﬁcation ISO 9000”, for more information.

Just a few drops of sample are enough for reliable measurement. However, the sample must be covered to prevent outside light to reach the prism. Sample leakage from holder may give measurement error. Always use repeated measurements for each sample. Note: Clean the prism and the sample holder well with alcohol between the different R.I. samples.

Important: Dispose of used RI liquids. Never put liquids back into the bottle after use!

Important: Ofﬂine calibration using process liquid very seldom gives reliable results, problems are caused

− low ﬂow which makes sample to form an unrepresentative ﬁlm on the prism

− sample evaporation at high temperature or undissolved solids at low temperature giving devia-

tions from laboratory determinations

− an ageing sample which is not representative

− outside light reaching the prism

Thus calibration using the process liquid should always be made inline, see Section 5.10.6, “Field calibration”.

6 Regular maintenance 47

6 Regular maintenance

The need for regular maintenance is minimal, due to the construction with no moving parts, no trimpots and with a solid-state light source. The following rules apply:

• Keep the sensor head and the Indicating transmitter clean and dry.

• Check that the ambient temperature is not above +45◦C (113◦F). The sensor head should not be too hot

to keep a hand on.

• If your refractometer has prism wash, check that it works (in Normal display, press the soft key A,

Prism wash).

6.1 Checking the sensor moisture

The PR-03 sensor has an internal moisture detector. The moisture reading can be checked on the Indicating transmitter display (Display / Sensor Head). Check the moisture reading once in a quarter.

An increasing signal indicates either condensate forming in the sensor head (if the process temperature is below ambient) or prism leakage. If the moisture reading exceeds 30 %, replace the dryer (see below). If the reading exceeds 50 %, check the prism seals.

The dryer (desiccant) is a plastic package inside the sensor head cover. When the dryer is effective, it is yellow. When it turns green, it needs to be replaced. The dryer cannot be reactivated by any means, it

must be replaced. You can order new dryer packages (drying agents/desiccants), spare part number PR- 9107, from K-Patents or your local distributor.

For instructions on how to open the sensor head to replace the dryer, see Section 6.3 for the standard length sensors (Sanitary refractometer PR-03-A, Compact process refractometer PR-03-D, Process refractometer PR-03-M and Valve body refractometer PR-03-W) and Section 6.4 for the Probe sensor PR-03-P.

6.2 Checking and replacing prism or prism gaskets

Once a year check t hat the prism surface is smooth and clean. If the prism is scratched or the gaskets seem to leak, order spare parts from K-Patents or your local distributor and follow the procedure described below to replace them.

48 PR-03 instruction manual

6.3 Disassembling and assembling a standard length sensor

Warning! Always check that the pipeline is empty before removing a sensor from the process line. Never

remove the sensor if there is process liquid in the pipe.

6.3.1 Disassembling the sensor

1. Disconnect the cable. Apply the two connector protection caps. Remove the sensor from the process and rinse it well.

Warning! Wear appropriate protective clothing and be very careful when removing the sensor from the

process line!

2. Fix the sensor by the sensor head (T) in a vertical position, sensor label upwards, Figure 6.1. K-Patents Service stand PR-1002 can be used.

Figure 6.1 Sensor in disassembly position

3. Remove the nut of the Vee-clamp. Move the Vee-clamp one step downwards.

4. Lift the sensor cover and disconnect the cable (A) from the image digitizer card.

6 Regular maintenance 49

5. Disconnect the ribbon cable (B), the LED lead (C), and t he temperature element lead (D).

6. Remove the Image digitizer card kept by four M4 screws (E).

7. Remove the Image detector card kept by three M3 screws (F).

Note: Removing the screws may introduce a slight calibration error.

8. Loosen carefully the six M4 screws (G) of the disc spring holder. Turn in small steps, alternating between the screws.

Warning! Never touch the screws (G) when the instrument is in the process line!

9. Remove the disc spring holder (H), the disc spring (J), and the thermal conductor (K).

6.3.2 Replacing the prism and prism gaskets

1. Lift out the Analyzer module, Figure 6.2. The module does not turn due to the alignment pin (R). Note: The thermal insulator (N) is permanently glued at both ends.

Note: The Heavy-duty process refractometer PR-03-M74 with a sap-

phire prism has a special Analyzer module PR-9101 and a prism support due to the 1 mm higher sapphire prism.

2. To remove the prism, push it gently against the springs in the prism plate (M), as indicated by an arrow in Figure 6.2 (b).

3. Clean the prism. Important: Do not leave any ﬁnger prints on any of the four optical surfaces!

4. Put the prism in place pushing gently against the springs of the prism plate (M). The direction of the force is indicated by an arrow in Figure 6.3 (a). To make sure the prism is in correct position, press the prism in the opposite direction of the arrow.

5. Put the prism in place pushing gently against the springs of the prism plate (M). The direction of the force is indicated by an arrow in Figure 6.3 (a). To make sure the prism is in correct position, press the prism in the opposite direction of the arrow.

6. Cover the prism by a new prism gasket (with the center hole uncut) according to Figure 6.3 (b).

7. Put the prism support (U) upon the gasket. Keep the gasket in place with a ﬁngertip in the middle. Check that the gasket is symmetrical around the middle of the prism surface. Tighten the screws (L) to the bottom, Figure 6.2 (b).

8. Check that the temperature sensor (P) is properly springloaded. In outer position, the sensor tip is level with the prism surface Figure 6.2 (b). It should ﬂex inwards 2-3 mm as indicated by an arrow, but return to the outer position.

(a)

(b)

Figure 6.2 The Analyzer module

50 PR-03 instruction manual

(a) (b)

Figure 6.3 The prism plate, the prism and prism gaskets

9. Now the Analyzer module PR-9001 is assembled. It should be checked before mounting into the sensor head:

1. Clean the window of the CCD-element (V), Figure 6.2. Attach the Image detector card to the

Analyzer module by the two screws (F) with conical heads. Connect electrically all cards, with connectors (A), (B), (C), and (D).

2. Connect the Indicating transmitter, and inspect the optical image at the Raw data display (key se-

quence Calibrate / Optical image).

3. The optical image must form a smooth curve. Dips or separate single points indicate that the optical

surfaces (e.g. the CCD window) are not clean.

Important: The prism must be covered to exclude external light.

4. When the image is OK, switch power off and disconnect all cards. Dismount the Image detector

card from the analyzer module.

10. Now the Analyzer module is ready for sensor assembly.

6.3.3 Assembling the sensor

1. Fit the Analyzer module into the sensor head. Note the alignment pin (R), Figure 6.1.

2. Mount the thermal conductor (K) with the holes aligned to the screw holes. Mount the disk spring (J). Note the position of the disk spring on the detail (J), Figure 6.1.

3. Mount the disk spring holder (H). Faster the six screws (G) in small steps following the pattern of numbers in Figure 6.4. Continue until the holder surface is ﬂush with the surfaces of the three notches (S). No step should be felt with the ﬁnger tip.

Figure 6.4

Tightening the

spring holder screws

4. Mount the Image detector card with the screws (F), Figure 6.1. First tighten the two guiding screws with conical heads, then the third screw. Lock the screws with e.g. nail polish.

5. Mount the Image digitizer card with the screws (E). Connect (B), (C) and (D).

6 Regular maintenance 51

6. Check the dryer color, Figure 6.1. It should be yellow. If it is green, replace the dryer.

7. Connect (A), close the sensor cover and mount the Vee-clamp. The nut and bolt of the clamp should be on the same side as the cable connector.

8. Place the sensor on a table with the prism upwards. Use a sharp knife with a curved edge to cut away the circular piece of the gasket covering the prism. Important: Support the knife on the prism surface only as it will scratch the steel.

9. Now the sensor is ready for process installation. Remember to check calibration (Section 5.10.1, “Checking current calibration” and Appendix D, “Instrument veriﬁcation ISO 9000”).

6.4 Disassembling and assembling a probe sensor

Warning! Always check that the pipeline or the vessel is empty before removing a sensor from the process

line. Never remove the sensor if there is process liquid in the pipe or the vessel.

6.4.1 Disassembling the probe sensor

1. Disconnect the cable. Apply the two connector protection caps. Remove the sensor from the process, and rinse.

Warning! Wear appropriate protective clothing and be very careful when removing the sensor from the

process line!

2. Fix the sensor by the sensor head (T) in a vertical position, sensor label upwards, Figure 6.5. K-Patents Service stand PR-1002 can be used.

3. Remove the nut of the Vee-clamp. Move the Vee-clamp one step downwards.

4. Lift the sensor cover and disconnect the cable (A) from the image digitizer card.

5. Disconnect the ribbon cable (B), the LED lead (C), and the temperature element lead (D).

6. Remove the Image digitizer card kept by four M4 screws (E).

7. Remove the Image detector card kept by three M3 screws (F).

Note: Removing the screws may introduce a

slight calibration error.

Figure 6.5 Probe sensor in disassembly position

52 PR-03 instruction manual

8. Loosen carefully the six M4 screws (G) of the disc spring holder. Turn in small steps, alternating between the screws.

Warning! Never touch the screws (G) when the instrument is in the line!

9. Remove the disc spring holder (H), the disc spring (J), and the thermal conductor (K).

6.4.2 Replacing the prism and prism gaskets

1. Lift out t he Core module, Figure 6.6 (a). The module does not turn due to the alignment pin (R) Remove the Prism support (U) ﬁxed by two M3 screws (L), Figure 6.6 (b). Note: The temperature sensor (P) restricts the movements of the Prism support (U).

2. To remove the prism, push it gently against the springs in the prism plate (M), as indicated by an arrow in 6.3(a).

3. The LED assembly can now be removed by gently pulling the cable (c), Figure 6.5.

4. Remove the connector (D) from the temperature sensor cable, Figure 6.5. Use a pointed tool to press on the small metal springs through the openings at the ﬂat side of the connector.

5. Now pull out the temperature sensor (P). Pull one lead a little fur ther on than the other, to prevent the cable ends from plugging the hole.

6. To remove the lenses, loosen the two M2 screws (Z), Figure 6.7.

Warning! The lenses are springloaded.

7. Remove Prism plate (M) and Lens locking ring (under the Prism plate).

8. Now the lenses, springs and lens spacers are free to be removed, Figure 6.6 (a).

9. Both end pieces of the Core module body are ﬁxed with only one screw each.

10. For assembly of the CORE module, use this procedure in reverse order, then proceed to the sensor assembly instructions below.

Note: When mounting the temperature sensor (P) back again, do

not push it the whole way in. Leave leads visible, so that the Prism support (U) can be mounted.

Note: When inserting the temperature sensor leads in the connector

(D), the middle hole in the connector should be empty.

11. Clean the prism. Important: Do not leave any ﬁnger prints on any of the four optical surfaces!

(a)

(b)

Figure 6.6 The Core module

6 Regular maintenance 53

12. Put the pr ism in place pushing gently against the springs of the prism plate (M). The direction of the force is indicated by an arrow in Figure 6.7 (a). To make sure the prism is in correct position, press the prism in the opposite direction of the arrow.

(a) (b)

Figure 6.7 The prism plate, the prism and prism gaskets

13. Put the prism support (U) upon the gasket. Keep the gasket in place with a ﬁngertip in the middle. Check that the gasket is symmetrical around the middle of the prism surface. Tighten the screws with hemispherical heads (L) to the bottom, Figure 6.6 (b).

14. Push the temperature sensor (P) into its proper position. Mount the LED plate (Y). Check that the temperature sensor (P) is properly springloaded. In outer position, the sensor tip is level with the prism surface, Figure 6.6 (b). It should ﬂex inwards 2-3 mm as indicated by an arrow, but return to the outer position.

15. Now the CORE module is assembled. It should be checked before mounting into the sensor head:

a. Clean the window of the CCD-element (V), Figure 6.71 (a). Attach the Image detector card to the

Analyzer module by the two screws (F) with conical heads. Connect electrically all cards, with connectors (A), (B), (C), and (D).

b. Connect the indicating transmitter, and inspect the optical image on Raw sensor data display, key

sequence Calibrate / Optical image.

c. The optical image must form a smooth curve. Dips or separate single points indicate that the optical

surfaces (e.g. the CCD window) are not clean. Important: The prism must be covered to exclude external light.

d. When the image is OK, switch power off and disconnect all cards. Dismount the Image detector

card from the CORE module.

16. The Core module is now ready for sensor assembly.

54 PR-03 instruction manual

6.4.3 Assembling the probe sensor

1. Fit the core module into the sensor head. Note the alignment pin (R), Figure 6.5.

2. Mount the thermal conductor (K) with the holes aligned to the screw holes. Mount the disk spring (J). Note the position of the disk spring on the detail (J), Figure 6.5.

3. Mount the disk spring holder (H). Fasten the six screws (G) in small steps following the pattern of numbers in Figure 6.8. Continue until the holder surface is ﬂush with the surfaces of the three notches (S). No step should be felt with the ﬁnger tip.

4. Mount the Image detector card with the screws (F), Figure 6.5. First tighten the two guiding screws with conical heads, then the third screw. Lock the screws with e.g. nail polish.

5. Mount the Image digitizer card with the screws (E). Connect (B), (C) and (D).

Figure 6.8

Tightening the

spring holder screws

6. Check the dryer color, Figure 6.1. It should be yellow. If it is green, replace the dryer.

7. Place the sensor on a table with the prism upwards. Use a shar p knife with a curved edge to cut away the circular piece of the gasket covering the prism. Warning! Support the knife on the prism surface

only as it will scratch the steel. Now the sensor is ready for process installation. Remember to check the calibration (Section 5.10.1, “Checking current calibration”, and Appendix D, “Instrument veriﬁcation ISO 9000”).

7 Troubleshooting and correcting problems 55

RAW SENSOR DATA

RMN: 2 RMX: 216 LED: 96 Scans: 2 A/D: 314 Sts: 00h HT: 143 HH: 10

Scaled image

Normal operation

7 Troubleshooting and correcting problems

7.1 Troubleshooting Indicating transmitter

Before investigating the sensor, it is advisable to make sure that the Indicating transmitter is working. The Indicating transmitter can be tested separately from the sensor by the following procedure:

− Power off

− Disconnect cable to sensor

− Power on

Now the diagnostic message should be **No sensor signal**. If this is the case, the IT-R should be in order. Power off, reconnect the cable to sensor, power on and continue to troubleshooting the sensor (Section 7.2).

If the diagnostic message is anything else than **No sensor signal**, check Section 9.7 for the message and required action.

Note: If the original diagnostic message was **Detector timeout**, the 15 V supply to the Image

detector card may be incorrect due to a wrong position of the power selector switch (Figures 3.8 and 3.9) on the IT-R’s processor card. Check that the position of the power selector switch matches your power supply. If the power selector switch is in the correct position, but the error message persists, the problem is in the sensor, not in the IT-R (see below).

7.2 Troubleshooting sensor

The Calibrate branch of the command tree (Figure 9.5 contains a set of consequent displays that can be used to troubleshoot sensor problems. Each display contains some important values than can give you clues to where the problem might be.

7.2.1 LED value

Check the LED value that tells you how well the light passes through the optics. The LED value is given in the Optical image display, available through the commands Calibrate / Optical image.

Figure 7.1 Checking the LED value

56 PR-03 instruction manual

SCALED OPTICAL IMAGE

TEST: 115.9

51.2 °C

Endp: 21 L): 9.8 R): 25.9 HT: 20 °C HH: 3%

Slope

Normal operation

A good LED value is in the range 20-150. The most common reason to a LED value higher than 150 is that prism is coated. It is also possible the prism has been destroyed with an overactive steam wash. Check the wash times and the prism surface (especially if the wash time exceeds the maximum of 3 s). Replace the prism if the surface is damaged (see Chapter 6 for instructions).

If the process is very hot, it is also possible that the light source LED wears out after many years’ constant use and needs replacing. Also leakage into the sensor can destroy LEDs (and everything else inside the sensor housing). However, normally the LEDs last as long as the sensor and high LED values indicate a prism problem.

It is very unusual for the LED value to be lower than 20, but in theory this can be caused by light from outside reaching the prism e.g. because the pipe is translucent.

7.2.2 Sensor temperature and humidity

Checking the conditions inside the sensor head will give you an idea whether there’s is a real physical problem. The Scaled image (Calibrate / Optical image / Scaled image) shows you both the internal sensor temperature and humidity.

Figure 7.2 Scaled image

The HT value gives you the sensor temperature and should be below 60◦C. If the value is over this limit, the measurement may not be accurate and the sensor needs to be cooled more effectively, see Section 2.2.1.

The HH value gives the humidity level inside the sensor and should be lower than 10 %. Most commonly a higher humidity level indicates a leak in the sensor. If the sensor is subjected to big temperature changes, condensate can cause humidity problems. If this is the case, the problem can be solved by replacing the dryer unit inside the sensor, see Section 6.1.

7.2.3 Slope value

The Slope display (Calibrate / Optical image / Scaled image / Slope) shows you the slope image and also gives the Slope value as a number. A good slope value is above 1.5. If the slope value drops near 1.0, something is wrong with the pr ism:

− Prism is coated or

− Prism surface is not good or

− Prism gaskets leak and process liquid gets in by the prism sides

7 Troubleshooting and correcting problems 57

Diagnostics

SLOPE

TEST: 115.7

31.2 °C

Max: 208 Slope: 2.7 Endp: 21 L): 10.1 R(: 25.8

Normal operation

IMAGE DIAGNOSTICS

Max intensity OK (above 100)? Endpoint below 75%? Image below corner? Slope OK (above 1)? Left curve L) OK (above 1)? Right curve R) OK (above 1)?

Yes Yes Yes Yes Yes Yes

SENSOR HEAD

Head temperature: 28 °C

Head humidity: 3%

Normal operation.

IMAGE DIAGNOSTICS

Max intensity OK (above 100)? Endpoint below 75%? Image below corner? Slope OK (above 1)? Left curve L) OK (above 1)? Right curve R) OK (above 1)?

Yes Yes No No Yes No

SENSOR HEAD

Head temperature: 28 °C

Head humidity: 3%

Normal operation.

Figure 7.3 Slope display

Prism coating can be prevented by good process ﬂow, high process temperature (see Section 2.2) or prism wash. If your system already has prism wash, the wash interval can be decreased.

Important: The maximum wash times are given in Table 5.1. Do not exceed the recommended wash time,

instead you can try repeating the wash more often.

If prism surface is damaged, for example something in the process has abraded the pr ism or the wash time has been long, replace the prism and adjust the prism wash or other conditions so that the prism doesn’t get damaged.

If prism gaskets leak, replace them and all the sensor parts that have been damaged by the process liquid inside the sensor (see Chapter 6, “Regular maintenance” for instructions).

7.2.4 Image diagnostics

The last tool in this branch of the selection tree is the Image diagnostics display, available through Calibrate / Optical image / Scaled image / Slope / Diagnostics. If the answer to

all the questions in this screen is Yes (Figure 7.4), the sensor head temperature and humidity are below the limits and the message is Normal operation, your refractometer system should be in working order.

Note: If the system is ofﬂine, some of the image diagnostics questions will get No for an answer even in a

working system (Figure 7.4).

Inline image diagnostics (= process) Ofﬂine image diagnostics (= in air)

Figure 7.4 Image diagnostics display

58 PR-03 instruction manual

IMAGE DIAGNOSTICS

Max intensity OK (above 100)? Endpoint below 75%? Image below corner? Slope OK (above 1)? Left curve L) OK (above 1)? Right curve R) OK (above 1)?

Yes Yes Yes Yes Yes Yes

SENSOR HEAD

Head temperature: 28 °C

Head humidity: 3%

Normal operation.

CONC

68.0%

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

TEST: 115.7 Normal operation

Calibrate

Display

CONC

PROCESS TEMPERATURE: 32.5 °C STANDARD RI(25°C): 1.4190

TEST: 117.2 Normal operation

Optical image

Parameters

68.0%

RAW SENSOR DATA

RMN: 2 RMX: 216 LED: 96 Scans: 2 A/D: 314 Sts: 00h HT: 143 HH: 10

Scaled image

Normal operation

SCALED OPTICAL IMAGE

TEST: 115.9

51.2 °C

Endp: 21 L(: 9.8 R): 25.9 HT: 20 °C HH: 3%

Slope

Normal operation

Diagnostics

SLOPE

TEST: 115.7

31.2 °C

Max: 208 Slope: 2.7 Endp: 21 L): 10.1 R(: 25.8

Normal operation

Good LED value 20-150

Good slope value more than 1.5

Good HT lower than 60 ºC Good HH lower than 10 %

Figure 7.5 Troubleshooting your refractometer system with IT-R

8 Sensor speciﬁcations and other sensor information 59

8 Sensor speciﬁcations and

other sensor information

8.1 Sensor labels

Sanitary refractometer label Process refractometer label

Figure 8.1 Examples of sensor labels

8.2 Sensor compatibility

The K-Patents Inline refractometer models PR-01 and PR-03 are not compatible with each other. The interconnecting cable plug is the same for all the PR-03 models, but it is not compatible with the model PR-01.

8.3 Sanitary refractometer PR-03-A

The 3-A approved Sanitary process refractometer for measuring Brix and concentrations in the pipe line. Easy to install in any pipe size directly or via ﬂow cell. The sanitary refractometer is well suited for all food and beverage processing applications where on-line monitoring and control can help to improve product quality and reduce costs.

60 PR-03 instruction manual

8.3.1 PR-03-A sensor model code

MODEL AND DESCRIPTION MODEL

PR-03 = Sensor PR-03

Sensor classiﬁcation

-A = 3-A approved -A

Refractive Index range limits

62 = R.I. 1.310–1.540 (0-100 Brix) 62

Process connection

-H = Sanitary 3-A clamp, 2 1/2 inch -H

Sensor wetted parts material

SS = AISI 316 L SS

Sensor options

-SC = Stainless steel sensor housing -SC

Example: Sensor: PR-03-A62-HSS

8.3.2 PR-03-A mounting hardware model code

Mounting hardware (without wash nozzles)

MODEL AND DESCRIPTION MODEL

EFC = Elbow ﬂow cell EFC

Sensor connection

-H = Sanitary 3-A clamp, 2 1/2 inch -H

Construction material

SS = AISI 316 SS

Process connection

-H = Sanitary 3-A clamp -H

Pipe section diameter

10 = 25 mm (1 inch) (A) 10 15 = 40 mm (1 1/2 inch) 15 20 = 50 mm (2 inch) 20 25 = 65 mm (2 1/2 inch) (A) 25

Flow cell inlet type

-SI = Straight pipe -SI

-RI = Reduced pipe (cone) -RI

(A) with -SI option only

8 Sensor speciﬁcations and other sensor information 61

Mounting hardware with wash nozzles

MODEL AND DESCRIPTION MODEL

EFC = Elbow ﬂow cell EFC

Sensor connection

-H = Sanitary 3-A clamp, 2 1/2 inch -H

Construction material

SS = AISI 316 SS

Process connection

-H = Sanitary 3-A clamp -H

Pipe section diameter

10 = 25 mm (1 inch) (A) 10 15 = 40 mm (1 1/2 inch) (B) 15 20 = 50 mm (2 inch) 20

Flow cell inlet type

-SI = Straight pipe -SI

-RI = Reduced pipe (cone) -RI

Wash nozzle connection

-NC = Nozzle connection (B) -NC

Wash nozzles

-SN = Steam nozzle, PR-3365 -SN

-WN = Water nozzle, PR-3364 -WN

-WP = Pressurized water nozzle, PR-3366 (C) -WP

-PG = Plug for nozzle connection, PR-3367 -PG

(A) with -SI option only (B) with -RI option only (C) nozzle inlet R 1/2 inch female

Example: Sensor: PR-03-A62-HSS

Flow cell: EFC-HSS-H20-SI

MODEL AND DESCRIPTION MODEL

MFC = Mini ﬂow cell MFC

Sensor connection

-H = Sanitary 3-A clamp, 2 1/2 inch -H

Construction material

SS = AISI 316 SS

Pipe section diameter

05 = 15 mm (1/2 inch) 05

62 PR-03 instruction manual

1.30 1.35 1.40 1.45 1.50 1.55 1.60

R.I.

4001020 30 50

70 80 BRIX

A62

8.3.3 PR-03-A speciﬁcations

General speciﬁcations General system speciﬁcations for a PR-03-A refractometer sensor

Refractive index range R.I. 1.3100–1.5400 (hot water – 100 Brix) Accuracy R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).

Repeatability and stability correspond to accuracy. Speed of response 1.2 s undamped Damping time constant Selectable up to 5 min Process temperature -20◦C–130◦C (-4◦F–266◦F) Temperature compensation Automatic Ambient temperature max. 45◦C (113◦F), min. -20◦C (-4◦F) Humidity 20–100 % Pollution degree Degree 2 Process pressure Sanitary clamp max. 15 bar (200 psi) at 20◦C (70◦F)/

9 bar (125 psi) at 120◦C (250◦F) Recommended ﬂow velocity Above 1.5 m/s (5 ft/s) Quality certiﬁcate ISO 9001

Sensor Meets the requirements of the 3-A Sanitary Standard 46-02

Wetted parts AISI 316L stainless steel, prism gaskets Teﬂon



, prism spinel Sensor weight 2.2 kg (5 lbs) Sensor protection class IP67, Nema 4X Process connection 2 1/2" Sanitary clamp Temperature measurement Built-in Pt-100 Image detector 1024 pixel CCD-element Light source Light emitting diode (LED)

Indicating transmitter See Chapter 9 Options − External output unit, Section 4.2

− Relay units for prism wash/alarm, Section 4.1

− Prism wash nozzles for steam and hot water, Section 8.3.2

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

− Stainless steel sensor housing

Figure 8.2 Sanitary refractometer PR-03-A rangeability

8 Sensor speciﬁcations and other sensor information 63

8.3.4 PR-03-A parts lists

Item Pcs. Part No. Description

1 1 PR-9205 2.5"Sanitary ferrule 2 1 PR-9201 2.5"Sanitary clamp

3 1 PR-9202 2.5"Sanitary gasket EPDM 3 1 PR-9203 2.5"Sanitary gasket NBR 3 1 PR-9204 2.5"Sanitary gasket Teﬂon

4 1 PR-9002 PR-03 Head 5 1 Thermal insulator Teﬂon 6 1 Alignment pin 7 1 PR-03 Base 8 6 Screw M5x10 DIN 7991 A2 9 1 PR-9011 Thermal conductor

* 1 PR-9010 Disc spring set 10 2 Disc spring 11 1 Disc spring holder

12 6 Screw M4x8 DIN 912 A2 13 4 Screw M4x12 DIN 14 1 PR-7133 Image analyzer card 15 4 Screw M4x8 DIN 912 A2 16 1 PR-5012 Vee clamp 11-130



Item Pcs. Part No. Description

17 2 Screw M3x8 DIN 912 18 1 Bushing holder

19 1 Bushing 20 2 Screw M4x8 DIN 912 A2 21 2 Washer M4 DIN 125 22 1 PR-5011 O-ring seal 108x3 23 1 PR-9107 Dryer 24 2 Screw M3x16 DIN 912 A4 25 1 PR-9106 PR-03 Connector complete 26 1 PR-9110 PR-03 Cover 27 1 PR-03 Sensor label 28 4 Screw M3x5 DIN 7380 A4 39 1 PR-9001 CORE-Optics module 44 1 PR-7125 Image detector card

64 PR-03 instruction manual

Item Pcs. Part No. Description

29 2 Screw M3x10 DIN 7380 A2 30 1 Prism support

* 1 PR-9004 H62 prism set 31 1 PR-9003 Prism gasket 32 1 H62 prism

33 2 Screw M2x5 DIN 965A A2 34 1 Prism plate 35 1 Lens locking r ing 36 1 Lens 8/30 37 2 Lens 8/10 38 2 Pressure spring 7.8x6 39 1 PR-9001 CORE optics module 40 1 PR-9250 PR-03 temperature element assembly

Item Pcs. Part No. Description

41 1 PR-9251 PR-03 LED assembly 42 1 LED plate 43 2 Screws M3x4 DIN 912 44 1 PR-7125 Image detector 45 2 Screw M3x10 DIN 7991 A2 46 1 Screw M3x10 DIN 912 A2

8 Sensor speciﬁcations and other sensor information 65

8.3.5 PR-03-A mounting speciﬁcs

K-Patents Sanitary refractometer PR-03 is connected to the process by a 2 1/2" 3-A sanitary clamp. The recommended mounting is in a pipe bend, with a vertical ﬂow upwards before the sensor, and a horizontal pipe after. The beneﬁts of this way of mounting are:

1. Self-cleaning of prism due to the ﬂow directed against its surface.

2. Efﬁcient drainage when the pipe is emptied.

For pipe diameters of 3" or above, a ferrule is welded directly to the pipe wall, Figure 8.3 (a ferrule, length

21.5 mm, is delivered with standard sensor delivery from K-Patents). For smaller pipe diameters, ﬂow cells are available from K-Patents, Figures 8.4, 8.5 and 8.6, see also the tables in Section 8.3.2. The inlet of the ﬂow cells is coned down to obtain a good ﬂow velocity against the prism. The ﬂow cells are exchangeable with standard 90◦bend pieces.

Figure 8.3 Mounting with sanitary ferrule (Pipe diameter 3" (80 mm) or larger)

66 PR-03 instruction manual

Figure 8.4 Flow cell EFC-HSS-H25-SI (Pipe diameter 2 1/2" (65 mm))

Figure 8.5 Flow cell EFC-HSS-H20-RI (Pipe diameter 2" (50 mm))

8 Sensor speciﬁcations and other sensor information 67

Figure 8.6 Flow cell EFC-HSS-H15-RI (Pipe diameter 1 1/2" (40 mm))

If a Sanitary refractometer sensor PR-03-A is to be installed in a sample line, diameter 5-10mm, it is mounted with a mini ﬂow cell, Figure 8.7.

Figure 8.7 PR-03-A mini ﬂow cell

68 PR-03 instruction manual

8.4 Probe refractometer PR-03-P

The K-Patents Probe refractometer PR-03-P-V/P provides an accurate on-line BRIX measurement in cookers, tanks and large pipelines. Some sensor options allow ﬂush mounting in a tank wall and thus make it possible to use a scraper. With certain options the Probe refractometer can also be installed in a cooker through a steam jacket.

8.4.1 PR-03-P sensor model code

MODEL AND DESCRIPTION MODEL

PR-03 = Sensor PR-03

Sensor classiﬁcation

-P = 3-A Sanitary Probe -P

Refractive Index range limits

62 = R.I. 1.310–1.540 (0-100 Brix) 62

Process connection

-T = Sanitary 3-A clamp, 2 1/2 inch, insertion length 139.5 mm -T

-R = Sanitary 3-A clamp, 4 inch, insertion length 139.5 mm -R

-V = Sanitary 3-A clamp, 2 1/2 inch, ﬂush mounted (B) -V

-P = MT4 DN 25/1T APV Tank bottom ﬂange, ﬂush mounted -P

Sensor wetted parts material

SS = AISI 316 L SS

Sensor options (A)

-SC = Stainless steel sensor housing -SC

-PC = Adapted for air purging -PC

(A) For standard sensor, leave this section blank (B) Needs vessel ﬂush mount adaptor VFMA-03-VSS

Table 8.1 PR-03-P model code

8.4.2 PR-03-P mounting hardware model code

MODEL AND DESCRIPTION MODEL

VFMA-03-VSS = vessel ﬂush mount adaptor for PR-03-P62-VSS VFMA-03-VSS VFMA-03-PSS = MT4 DN25/1T APV tank bottom ﬂange for PR-03-P62-PSS VFMA-03-PSS VFBP-03-VSS = Blind plug for vessel ﬂush mount adaptor VFMA-03-VSS VFBP-03-VSS

8 Sensor speciﬁcations and other sensor information 69

8.4.3 PR-03-P speciﬁcations

General speciﬁcations General system speciﬁcations for a PR-03-P refractometer sensor

Refractive Index range R.I. 1.3100–1.5400 (corresponds to hot water–100 Brix) Accuracy R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).

9 bar (125 psi) at 120◦C (250◦F) Recommended ﬂow velocity Above 1.5 m/s (5 ft/s) Quality certiﬁcate ISO 9001

Sensor Meets the requirements of the 3-A Sanitary Standard 46-02

Wetted parts AISI 316L stainless steel, prism gaskets Teﬂon



, prism spinel Sensor weight 2.4 kg (5.3 lbs) Sensor protection class IP67, Nema 4X Process connections 2 1/2" Sanitary clamp

4" Sanitary clamp

MT4 DN 25/1T APV Tank bottom ﬂange Temperature measurement Built-in Pt-100 Image detector 1024 pixel CCD-element Light source Light emitting diode (LED) Indicating transmitter See Chapter 9 Options − External output unit, Section 4.2

− Relay units, Section 4.1

− Stainless steel sensor housing

70 PR-03 instruction manual

8.4.4 PR-03-P parts lists

Item Pcs. Part No. Description

1 1 PR-9205 2.5"sanitary ferrule 1 1 VFMA-03-VSS Vessel ﬂush mount adaptor 1 1 VFMA-03-PSS MT4 DN25/1T APV tank bottom ﬂange 1 1 VFBP Blind plug for tank bottom ﬂange 1 1 PR-4275 4"sanitary ferrule

2 1 PR-9201 2.5"sanitary clamp 2 1 PR-9270 4"sanitary clamp

3 1 PR-9202 2.5"sanitary gasket EPDM 3 1 PR-9203 2.5"sanitary gasket NBR 3 1 PR-9204 2.5"sanitary gasket Teﬂon

3 1 PR-9243 MT4 DN25/1T APV gasket EPDM

3 1 PR-9272 4"3A sanitary gasket EPDM 3 1 PR-9273 4"3A sanitary gasket NBR 3 1 PR-9274 4"3A sanitary gasket Teﬂon

4 1 PR-9310 PR-03-P-TSS head 4 1 PR-9311 PR-03-P-VSS head 4 1 PR-9312 PR-03-P-PSS head 4 1 PR-9313 PR-03-P-RSS head

5 1 Thermal insulator Teﬂon 6 1 Alignment pin 7 1 PR-9005 PR-03 base 8 6 Screw M5x10 DIN 7991 A2 9 1 PR-9011 Thermal conductor



Item Pcs. Part No. Description

* 1 PR-9010 Disc spring set 10 2 Disc spring 11 1 Disc spring holder

12 6 Screw M5x10 DIN912 A2 13 4 Screw M4x12 DIN 14 1 PR-7133 Image digitizer card 15 4 Screw M4x8 DIN 912 A2 16 1 PR-5012 Vee clamp 11-130 17 2 Screw M3x8 DIN 912 18 1 Bushing holder 19 1 Bushing 20 2 Screw M4x8 DIN 912 A2 21 2 Washer M4 DIN 125 22 1 PR-5011 O-ring seal 108x3 23 1 PR-9107 Dryer 24 2 Screw M3x16 DIN 912 A4 25 1 PR-9106 PR-03 connector complete 26 1 PR-9301 PR-03 cover 27 1 PR-03 sensor label 28 4 Screw M3x5 DIN 7380 A4

8 Sensor speciﬁcations and other sensor information 71

Item Pcs. Part No. Description

29 2 Screw M3x20 DIN 7380 A2 30 1 Prism support

* 1 PR-9004 H62 prism set

31 1 PR-9003 Prism gasket

32 1 H62 prism

33 2 Screw M2x5 DIN 965A A2 34 1 Prism plate 35 1 Lens locking r ing 36 1 PR-03-P lens assembly 37 2 Lens 8/10 38 2 Pressure spring 7.8x6 39 1 PR-9301 PR-03-P CORE Optics module 40 1 PR-9255 PR-03-P temperature element assembly

Item Pcs. Part No. Description

41 1 PR-9256 PR-03-P LED assembly 42 1 LED plate 43 2 Screws M3x12 DIN 912 A2 44 1 PR-7125 Image detector 45 2 Screw M3x10 DIN 7991 A2 46 1 Screw M3x10 DIN 912 A2

47 1 Pressure spring 9.8x25 48 1 Lens ring 49 1 Screw M3x12 DIN 912 A2 49 1 Screw M3x12 DIN 912 A2 50 2 Lens 10/50

51 1 Screw M3x10 DIN 7991 A2

72 PR-03 instruction manual

4-20 mA

CHECK CABLE LENGTH

8.4.5 PR-03-P mounting speciﬁcs

The Probe refractometer PR-03-P is primarily designed for mounting in a tank wall. To ensure that the measurement is representative and that the prism stays clean, the probe should be installed close to a stirrer, Figure 8.8.

Figure 8.8 Recommendations for mounting the Probe sensor PR-03-P in a t ank

K-Patents probe refractometer type PR-03-P62-TSS is connected to the process by a 2 1/2" 3-A sanitary clamp, Figure 8.9. The type PR-03-P62-RSS type sensor is connected to process by a 4" 3-A sanitary clamp.

Note: For higher process (or ambient) temperatures, use instead a ﬂush mounted sensor (Figures 8.9, 8.10

and 8.11), where the electronics in the sensor head are further away from the process heat.

Figure 8.9 Insertion of Probe refractometer PR-03-P62-TSS

8 Sensor speciﬁcations and other sensor information 73

Figure 8.10 Flush mounted Probe refractometer PR-03-P62-PSS

The refractometer type PR-03-P62-PSS is ﬂush mounted, using a sanitary APV Tank bottom ﬂange, Figure 8.10. The refractometer can be replaced with a blind plug so that the tank can be used even when the refractometer has been removed for service.

The refractometer type PR-03-P62-VSS is specially designed for vessels with a steam jacket, e.g. a jam cooker. In a jam cooker the blade of the scraper should sweep the prism in direct contact. The PR-03-P62-

VSS is mounted by means of a vessel ﬂush-mount adaptor VFMA-03-VSS, Figure 8.11.

Figure 8.11 Mounting probe refractometer PR-03-P62-VSS

through vessel steam jacket with adaptor VFMA-03-VSS

74 PR-03 instruction manual

Slope

TEST: 248.0

30.2 ºC Endp: 11 L): -7.5 R(: 3.3 HT: 20 ºC HH: 4 %

SCALED OPTICAL IMAGE

Low concentration / No sample

8.4.6 PR-03-P programming speciﬁcs

If the optical image appears inverted when using the probe refractometer PR-03-P (see Figure 8.12), conﬁgure parameter lminv to value 1 by key-in sequence Calibrate / Parameters / Standard RI (25◦C) / Image inversion to turn the picture right way.

Figure 8.12 Inverted optical image

Note: This image inversion correction is only available in program version 8.5 or higher. When an IT-R

is delivered together with a Probe refractometer sensor, the program version is always compatible with the inverted image.

8 Sensor speciﬁcations and other sensor information 75

8.5 Compact process refractometer PR-03-D

The K-Patents Compact process refractometer is a compact general industry model for measuring liquid concentrations in various in-line applications, like chemicals, ﬁbers, plastics, salts and sodium components. Easy to install in smaller pipe lines. Also for applications where special alloys are required.

8.5.1 PR-03-D sensor model code

MODEL AND DESCRIPTION MODEL

PR-03 = Sensor PR-03

Sensor classiﬁcation

-D = General purpose -D

Refractive Index range limits

62 = R.I. 1.310–1.540 (0-100 Brix) 62

Process connection

-L = Sandvik L clamp, 76.1 (A) -L

Sensor wetted parts material

SS = AISI 316 L SS HC = Hastelloy C / ASTM C276 HC TI = Titanium / ASTM B TI NI = Nickel 200 NI

Sensor options (B)

-SC = Stainless steel sensor housing -SC

-PC = Adapted for Exproof by purging (C) -PC

(A) Includes counter ferrule for Sandvik 76.1 (B) For standard sensor without option, leave this section blank (C) Available with -SC code only, including 5 meters sensor cable, PR-8400-005

Example: Sensor: PR-03-D62-LSS

8.5.2 PR-03-D mounting hardware model code

MODEL AND DESCRIPTION MODEL

PFC = Pipe ﬂow cell PFC

Sensor connection

-L = Sandvik L clamp -L

Construction material

SS = AISI 316 SS

Process connection

-A = ANSI 150 psi -A

Pipe section diameter

10 = 25 mm (1 inch) 10

For line sizes 76 mm (2 1/2 inch) or bigger use standard process connections.

76 PR-03 instruction manual

1.30 1.35 1.40 1.45 1.50 1.55 1.60

R.I.

4001020 30 50

70 80 CONC%

D62

8.5.3 PR-03-D speciﬁcations

General speciﬁcations General system speciﬁcations for a PR-03-D refractometer sensor

Refractive Index range R.I. 1.3100–1.5400 (corresponds to hot water–100 Conc% b.w.) Accuracy R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).

9 bar (125 psi) at 120◦C (250◦F) Recommended ﬂow velocity Above 1.5 m/s (5 ft/s) Quality certiﬁcate ISO 9001

Sensor

Wetted parts AISI 316L stainless steel, prism gaskets Teﬂon



, prism spinel Optional wetted parts Hastelloy C/ASTM C276, Titanium/ASTM B 348 GR2, Nickel 200 Sensor weight 2 kg (4.4 lbs) Sensor protection class IP67, Nema 4X Process connection Sandvik L clamp 76.1 mm (2 1/2") Temperature measurement Built-in Pt-100 Image detector 1024 pixel CCD-element Light source Light emitting diode (LED) Indicating transmitter See Chapter 9 Options − External output unit, Section 4.2

− Relay units for prism wash/alarm, Section 4.1

− Stainless steel sensor housing

Figure 8.13 Compact process refractometer PR-03-D rangeability

8 Sensor speciﬁcations and other sensor information 77

8.5.4 PR-03-D parts lists

Item Pcs. Part No. Description

1 1 PR-9280-SS Sandvik ferrule 76.1 AISI 316L 1 1 PR-9280-HC Sandvik ferrule 76.1 Hastelloy 1 1 PR-9280-TI Sandvik ferrule 76.1 Titanium 1 1 PR-9280-NI Sandvik ferrule 76.1 Nickel 2 1 PR-9282 Sandvik clamp FCLC-76.1 AISI 304 3 1 PR-9281 Sandvik O-ring FCLG-T-76.1 Teﬂon 4 1 PR-9009 PR-03 Sandvik 76.1 head 5 1 Thermal insulator Teﬂon 6 1 Alignment pin 7 1 PR-9005 PR-03 base 8 6 Screw M5x10 DIN 7991 A2 9 1 PR-9011 Thermal conductor

* 1 PR-9010 Disc spring set 10 2 Disc spring 11 1 Disc spring holder 12 6 Screw M5x10 DIN 912 A2 13 4 Screw M4x12 DIN 912 14 1 PR-7133 Image digitizer 15 4 Screw M4x8 DIN 912 A2 16 1 PR-9001 CORE optics module 17 1 PR-5012 Vee clamp 11-130



registered

Item Pcs. Part No. Description

18 2 Screw M3x8 DIN 912

19 1 Bushing holder 20 1 Bushing 21 1 PR-7125 Image detector card 22 2 Screw M4x8 DIN 912 A2 23 2 Washer M4 DIN 125 24 1 PR-5011 O-ring seal 108x3 25 1 PR-9107 Dryer 26 2 Screw M3x16 DIN 912 A4 27 1 PR-9106 PR-03 connector complete 28 1 PR-9110 PR-03 sensor cover 29 1 PR-03 sensor label 30 4 Screw M3x5 DIN 7380 A4

78 PR-03 instruction manual

Item Pcs. Part No. Description

29 2 Screw M3x10 DIN 7380 A2 30 1 Prism support 30 1 Prism support H64 31 1 PR-9003 Prism gasket (PTFE) 32 1 PR-9004 H62 prism set (Spinel) 33 2 Screw M2x5 DIN 965A A2 34 1 Prism plate 35 1 Lens locking r ing 36 1 Lens 37 1 Lens 8/10 38 2 Pressure spring 7.8x6 39 1 PR-9001 CORE optics module 40 1 PR-9250 PR-03 temperature element assembly

Item Pcs. Part No. Description

41 1 PR-9251 PR-03 LED assembly 42 1 LED plate 43 2 Screws M3x4 DIN 912 44 1 PR-7125 Image detector card 45 2 Screw M3x10 DIN 7991 A2 46 1 Screw M3x10 DIN 912 A2

8 Sensor speciﬁcations and other sensor information 79

8.5.5 PR-03-D mounting speciﬁcs

In pipes with the nominal size 2.5" (76.1mm) or larger, the Compact process refractometer PR-03-D sensor is mounted with a Sandvik-L 76.1 clamp, Figure 8.14. For smaller pipes, the sensor has to be mounted with the PFC Pipe Flow cell, Figure 8.15.

Figure 8.14 Mounting PR-03-D in pipelines with diameter 2.5" (76.1 mm) or larger

80 PR-03 instruction manual

Figure 8.15 Mounting PR-03-D in pipelines with diameter less than 2.5" (76.1mm)

8 Sensor speciﬁcations and other sensor information 81

8.6 Process refractometer PR-03-M

K-Patents Process refractometer PR-03-M is designed for use in chemically aggressive solutions and ultra-pure ﬁne chemical processes. It has a built-in ﬂow cell designed to keep all metal and other easily corroding parts from coming into contact with the process liquid. All the wetted parts are made of non-metallic materials, either PTFE (Teﬂon PR-03-M sensor withstands corrosion very well.

The ﬂow cell (N) and the sapphire plate (L) are ﬁxed to the stainless steel sensor with four screws. The ﬂow cell (N) is sealed by a Kalrez O-ring (M). The ﬂow cell prevents any leakage reaching the metal parts, because there is a circular leakage chamber behind the O-ring (M). The chamber connects to a check port (O), which has a 1/8" female thread connection.



) or PVDF (Kynar



), and thus the

Figure 8.16 PR-03-M sensor

8.6.1 PR-03-M sensor model code

MODEL AND DESCRIPTION MODEL

PR-03 = Sensor PR-03

Sensor classiﬁcation

-M = Aggressive medium adapter -M

Refractive Index range limits

62 = 1.310–1.540 R.I. (0.100 Conc% b.w.), Spinel prism 62 74 = 1.260–1.500 R.I., sapphire prism 74

Process line connection

-R = Thread (G 1/2 inch) -R

-N = Thread (1/2 inch NPT female) -N

Line size connection diameter

-050 = 1/2 inch (ﬂow volume 2-8 l/min (0.5-2.1 GPM)) -050

Flow cell wetted par ts material

-PV = Kynar

-TF = Teﬂon

Sensor cover

-SC = Stainless Steel sensor housing -SC

(A) including 5 meter sensor cable, PR-8400-005

Example: Sensor: PR-03-M62-R-050-TF-SC



(PVDF=Polyvinylideneﬂuoride) -PV



(PTFE=Polytetraﬂuoroethylene) -TF

Sensor options

-PC = adapted for Exproof by purging (A) -PC

82 PR-03 instruction manual

1.30

1.25

1.35 1.40 1.45 1.50 1.55 1.60

1.65

R.I.

40010 20 30 50

70 80 BRIX

M62

M74

8.6.2 PR-03-M speciﬁcations

General speciﬁcations General system speciﬁcations for a PR-03-M refractometer sensor

Refractive Index range, standard R.I. 1.3100–1.5400 (corresponds to hot water–100 Brix) with

spinel prism Refractive Index range R.I. 1.2600–1.5000 with sapphire prism Refractive Index range R.I. 1.3900–1.6200 with YAG prism Accuracy R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).

Repeatability and stability correspond to accuracy. Speed of response 1.2 s undamped Damping time constant Selectable up to 5 min Process temperature -20◦C–130◦C (-4◦F–212◦F) Temperature compensation Automatic Ambient temperature max. 45◦C (113◦F), min. -20◦C (-4◦F) Humidity 20–100 % Pollution degree Degree 2 Process pressure max 5 bar (72.5 psi) Recommended ﬂow velocity 2–40 l/min (0.5–10.6 GPM) Protected by the following US Patent Patent No. US6067151

Sensor

Wetted parts, standard Teﬂon



or Kynar



PVDF, prism gaskets Teﬂon

O-ring Kalrez, adaptor sapphire Wetted parts, option prism sapphire or YAG Sensor weight 5.5 kg (12.1 lbs) Sensor protection class IP67, Nema 4X Process connection Thread G1/2" (F) Temperature measurement Built-in Pt-100 Image detector 1024 pixel CCD-element Light source Light emitting diode (LED) Sensor housing AISI 316L stainless steel sensor cover Exproof Exproof by purging Indicating transmitter see page See Chapter 9 Options − External output unit, Section 4.2

− Relay units for alarm, Section 4.1



, prism spinel,

Figure 8.17 Process refractometer PR-03-M rangeability

8 Sensor speciﬁcations and other sensor information 83

8.6.3 PR-03-M parts lists

Item Pcs. Part No. Description

1 4 Screw M5x60 DIN 7991 A4 2 1 PR-03-M endplate 3 1 PR-9120 PR-03-M-PV-R05 ﬂow cell (PVDF) 3 1 PR-9121 PR-03-M-TF-R05 ﬂow cell (PTFE) 4 1 PR-9240 O-ring seal 19.2 x 3 Kalrez 4079 5 6 Screw M4 x 20 DIN 7991 A4 6 1 PR-03-M Headring (PVDF) 7 1 PR-9112 O-ring seal 30.3 x 2.4 FPM 8 1 PR-9122 Sapphire plate for PR-03-M

9 1 PR-9113 O-ring seal 37.3 x 3 FPM 10 1 PR-9100 Sensor support 11 1 PR-9102 PR-03-M head 12 1 Thermal insulator (Teﬂon 13 1 Alignment pin 14 1 PR-9005 PR-03 base 15 6 Screw M5x10 DIN 7991 A2 16 1 PR-9001 CORE optics module 16 1 PR-9101 CORE 74 optics module 17 1 PR-9011 Thermal conductor

* 1 PR-9010 Disc spring set 18 2 Disc spring 19 1 Disc spring holder

20 6 Screw M5x10 DIN 912 A2 21 1 PR-7125 Image detector card 22 4 Screw M4x12 DIN 23 1 PR-7133 Image digitizer 24 4 Screw M4x8 DIN 912 A2 25 1 PR-5012 Vee clamp 11-130



)

Item Pcs. Part No. Description

26 2 Screw M3x16 DIN 912 A4 27 1 Bushing holder 28 1 Bushing 29 1 PR-5011 O-ring seal 108x3 30 1 PR-9107 Dryer 31 2 Screw M4x8 DIN 912 A2 32 2 Washer M4 DIN 125 33 2 Screw M3x8 DIN 912 34 1 PR-9106 PR-03 connetor complete 35 1 PR-9110 PR-03 cover 36 1 PR-03 sensor label 37 4 Screw M3x5 DIN A4

84 PR-03 instruction manual

Item Pcs. Part No. Description

38 2 Screw M3x10 DIN 7380 A2 39 1 Prism support 39 1 Prism support H64

* 1 PR-9004 H62 prism set (Spinel) 40 1 PR-9003 Prism gasket (PTFE) 41 1 H62 prism (Spinel)

* 1 PR-9104 H74 prism set (Sapphire) 40 1 PR-9003 Prism gasket (PTFE) 41 1 H74 prism (Sapphire) 42 2 Screw M2x5 DIN 965A A2 43 1 Prism plate 44 1 Lens locking ring 45 1 Lens 46 2 Lens 8/10 47 2 Pressure spring 7.8x6 48 1 PR-9250 PR-03 temperature element assembly

Item Pcs. Part No. Description

49 1 PR-9251 PR-03 LED assembly 50 1 LED plate 51 2 Screws M3x4 DIN 912 21 1 PR-7125 Image detector card 52 2 Screw M3x10 DIN 7991 A2 53 1 Screw M3x10 DIN 912 A2

8 Sensor speciﬁcations and other sensor information 85

PTFE or PVDF wetted parts

Sapphire plate

O-ring (Kalrez)

Prism

Flow cell adapter (AISI 316L)

Graphite cast iron

Saunders valve body flow cell

PR-03-W Sensor

8.6.4 PR-03-M mounting speciﬁcs

K-Patents Process refractometer PR-03-M is connected to the process by a G1/2" female or a 1/2" NPT process connection, Figure 8.18.

Figure 8.18 G1/2" female process connection (mm [in])

8.7 Valve body refractometer PR-03-W

The Valve body refractometer PR-03-W is a heavy-duty instrument designed for chemically aggressive liquids and ultrapure ﬁne chemicals in large-scale pro- duction and in large pipelines. The materials and design of the sensor are similar to the Process refractometer PR-03M, but the valve body makes it possible to ﬁt this refractometer into 50, 80 or 100 mm (2", 3" or 4") pipelines.

The valve body material is graphite cast iron lined with 3 mm PFA (Fluorinated ethylene propylene) ﬂuoroplastic. The cast iron provides a solid mechanical base and the PFA lining ensures the chemical resistance.

The sensor itself is built just like the PR-03-M sensor (see Section 8.6) and it is ﬁxed to the valve body in the same way, with a sapphire plate and a Kalrez O-ring to keep all the metallic parts away from the process liquid.

Figure 8.19 PR-03-W sensor

86 PR-03 instruction manual

8.7.1 PR-03-W sensor model code

MODEL AND DESCRIPTION MODEL

PR-03 = Sensor PR-03

Sensor classiﬁcation

-W = Aggressive medium valve body ﬂow cell -W

Refractive Index range limits

62 = 1.310–1.540 R.I., Spinel prism (0-100 Conc% b.w.) 62 74 = 1.260–1.500 R.I., sapphire prism 74

Sensor wetted parts material

-PV = Kynar

-TF = Teﬂon

Sensor/diaphragm valve body connection

4 = Adapter for 4 inch/DN 100 valve body 4 3 = Adapter for 3 inch/DN 80 valve body 3 2 = Adapter for 2 inch/DN 50 valve body 2

(A) Including 5 meter sensor cable, PR-8400-005



(PVDF=Polyvinylideneﬂuoride) -PV



(PTFE=Polytetraﬂuoroethylene) -TF

Sensor cover

-SC = stainless steel sensor housing -SC

Sensor classiﬁcation

-GP = General purpose, Nema 4X -GP

-PC = Adapted for Exproof by purging(A) -PC

SAUNDERS VALVE BODY FOR SENSOR PR-03-W MODEL

SVB = Saunders valve body SVB

Process line connection

-A040 = ANSI ﬂange 4 inch 150 lbs -A040

-A030 = ANSI ﬂange 3 inch 150 lbs -A030

-A020 = ANSI ﬂange 2 inch 150 lbs -A020

-D100 = DIN ﬂange DN 100 PN 16 -D100

-D080 = DIN ﬂange DN 80 PN 16 -D080

-D050 = DIN ﬂange DN 50 PN 16 -D050

Valve body material

-GC = Graphite cast iron -GC

Valve body lining material

-PFA = PFA (= Fluorinated ethylene propylene) -PFA

8 Sensor speciﬁcations and other sensor information 87

8.7.2 PR-03-W speciﬁcations

General speciﬁcations General system speciﬁcations for a PR-03-W refractometer sensor

Refractive index range, standard R.I. 1.3100–1.5400 (corresponds to hot water–100 Conc% b.w.) with

spinel prism

Refractive index range, option R.I. 1.2600–1.5000 with sapphire prism Accuracy R.I. ± 0.0002 (corresponds typically to ± 0.1% by weight).

Repeatability and stability correspond to accuracy. Speed of response 1.2 s undamped Damping time constant Selectable up to 5 min Process temperature -20◦C–100◦C (-4◦F–212◦F) Temperature compensation Automatic Ambient temperature max. 45◦C (113◦F), min. -20◦C (-4◦F) Humidity 20–100 % Pollution degree Degree 2 Process pressure max. 10 bar (145 psi) Recommended ﬂow velocity 1.5–6 m/s Protected by US Patent No. US6067151, German Patent No. DE19855218

Sensor

Wetted parts, standard Teﬂon



PTFE, prism gasket Teﬂon



PTFE, prism spinel or sapphire,

O-ring Kalrez, adaptor sapphire Sensor weight With 2” Saunders body 15 kg (33 lbs)/3” Saunders body 26 kg

(57 lbs)/4” Saunders body 33 kg (73 lbs) Sensor protection class IP67, Nema 4X Process connection With PFA (Fluorinated ethylene propylene) lined Saunders valve body

2", 3" or 4" Temperature measurement Built-in Pt-100 Image detector 1024 pixel CCD-element Light source Light emitting diode (LED) Sensor housing AISI 316L stainless steel cover Exproof Exproof by purging

Saunders valve body

Valve body material Graphite cast iron Valve body lining material PFA (Fluorinated ethylene propylene) Process connection ANSI ﬂange 4 inch 150 lbs / ANSI ﬂange 3 inch 150 lbs /

ANSI ﬂange 2 inch 150 lbs / DIN ﬂange DN 100 PN 16 /

DIN ﬂange DN 80 PN 16 / DIN ﬂange DN 50 PN 16 Indicating transmitter See Chapter 9 Options − External output unit, Section 4.2

− Relay units for alarm, Section 4.1

88 PR-03 instruction manual

8.7.3 PR-03-W parts lists

Item Pcs. Part No. Description

1 4 Screw M5x60 DIN 7991 A4 3 1 Saunders valve body PFA lining ANSI 2“/DIN 50 3 1 Saunders valve body PFA lining ANSI 3“/DIN 80 3 1 Saunders valve body PFA lining ANSI 4“/DIN 100 4 1 PR-9240 O-ring seal 19.2 x 3 Kalrez 4079 5 6 Screw M4 x 20 DIN 7991 A 4 6 1 Spacer 7 1 PR-9112 O-ring seal 30.3 x 2.4 FPM 8 1 PR-9122 Sapphire plate for PR-03-M

9 1 PR-9113 O-ring seal 37.3 x 3 FPM 10 1 PR-03-M Headring (PVDF) 11 1 PR-9102 PR-03-W head 12 1 Thermal insulator Teﬂon 13 1 Alignment pin 14 1 PR-9005-SC PR-03 base SS 15 6 Screw M5x10 DIN 7991 A2 16 1 PR-9011 Thermal conductor

* 1 PR-9010 Disc spring set 17 2 Disc spring 18 1 Disc spring holder



Item Pcs. Part No. Description

19 6 Screw M5x10 DIN912 A2 20 4 Screw M4x12 DIN 21 1 PR-7133 Image digitizer 22 4 Screw M4x8 DIN 912 A2 23 1 PR-5012 Vee clamp 11-130 24 2 Screw M3x8 DIN 912 25 1 Bushing holder 26 1 Bushing 27 2 Screw M4x8 DIN 125 28 2 Washer M4 DIN 912 A2 29 1 PR-5011 O-ring seal 108x3 30 1 PR-9107 Dryer 31 2 Screw M3x16 DIN 912 A2 32 1 PR-9106 PR-03 connector complete 33 1 PR-9110-SC PR-03 cover 34 1 PR-03 sensor label 35 4 Screw M3x5 DIN 7380 A4 39 1 PR-9001 CORE optics module 39 1 PR-9101 CORE 74 optics module 44 1 PR-7125 Image detector card

8 Sensor speciﬁcations and other sensor information 89

8.7.4 PR-03-W mounting speciﬁcs

PR-03-W Saunders valve body ﬂow cell can be mounted either vertically or horizontally. Special sensor support is not needed as t he valve body (piping) supports the sensor. Either way sensor cover should always be horizontal to avoid sedimentation or gas/air pocket on the prism. Also installation after pump, before valve and low installation point will reduce risk of air/gas pocket. Recommended ﬂow velocity is 1.5–6m/s (6–20ft/s).

90 PR-03 instruction manual

9 Indicating transmitter speciﬁcations 91

PROCESS REFRACTOMETER

IT-RE-GP S/N:00Z25-4129 100 - 115/220 - 240 V AC, 50/60 Hz, 20VA TAG:

9 Indicating transmitter speciﬁcations

9.1 IT-R label

Figure 9.1 Indicating transmitter serial number label

Serial number should match the serial number on sensor head

9.2 IT-R compatibility

An Indicating transmitter can be exchanged for another of the same model, but the current calibration constants have then to be entered by the keyboard (Section 5.10) as your IT-R has been precalibrated for the process it was ordered for.

The models PR-03 and PR-01 use the same Indicating transmitter. When the power is switched on, the microprocessor checks which sensor model is connected, and adapts the software accordingly.

Note: The plug at the sensor end is different for PR-03 and PR-01. All PR-03 models use same electrical

connector and cables.

9.2.1 U pg rading IT-R program version

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

K-Patents improves the IT-R programming all the time. If you need a new (or latest) program version, order the spare part PR-7509. You’ll get a new EPROM (Figure 9.2) with the new program version and you upgrade by removing the old EPROM from the processor card and inserting the new one into its place.

Figure 9.2 An EPROM with program version 8.6

92 PR-03 instruction manual

EPROM

1. Important: Before you upgrade any program versions, write down all current parameters from the calibration screen of the Indicating transmitter. Also remember to take note of the wash and relay parameters.

2. Power of f and open the front panel of the IT-R.

3. Unscrew the cover on the inside of the front panel. Unplug the cable from the Power supply card to the front panel and remove the cover to see the Processor card.

4. Carefully remove the old EPROM (Figure 9.3)and insert the new one.

5. Place the cover over the Processor card, screw it on and reconnect the cable from the Power supply card to the front panel. Close the front panel.

6. Press the ENTER button and at the same time switch on the power. You will now enter the Factory Calibration mode.

7. Press 1 for Default settings. Make sure that all pre-upgrade parameters have been written down.

Figure 9.3 Location

of the EPROM on the Processor card

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

9. Switch power off. Switch power back on.

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

Note: The image inversion needed with the Probe refractometer PR-03-P sensor was ﬁrst implemented in

the main program version 8.6. Program version 8.5 can be updated to manage the image inversion. Versions below 8.5 are not compatible with the Probe refractometer PR-03-P sensor.

9.3 Model code

9.3.1 IT-R model code

MODEL AND DESCRIPTION MODEL

IT-R = Indicating Transmitter IT-R

Cable connection

U = 1/2 inch NPT-type conduit hubs U E = BF11/PG11 cable glands (with -GP option only) E M = M20x1.5 metric cable glands (with -GP option only) M

Electrical classiﬁcation

-GP = General purpose -GP

-CS = CSA appr. for use in general purpose (ordinary) locations -CS

Transmitter options

-WR = Relay unit, 2 relays -WR

9 Indicating transmitter speciﬁcations 93

9.3.2 Interconnecting cable model code

PART NUMBER AND DESCRIPTION PART NO.

PR-8300 = Interconnecting cable between transmitter and sensor PR-8300 PR-8040 = Interconnecting cable (-PC sensor option only) PR-8040

Cable length

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

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

(for connection between transmitter and disconnecting unit)

Maximum length is 100 meters (330 feet)

9.4 IT-R Speciﬁcations

Indicating transmitter

Transmitter protection class: Enclosure IP66, Nema 4X Indicating transmitter weight: 4.5 kg Display: 256 x 128 pixels graphic liquid crystal display (LCD) 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 CD or AC (peak) Power: 100–115 V/220–240 V, 50/60 Hz, 20 VA Alarms: Two built-in signal relays, max 24 V, 500 mA, DC/AC

Approved environmental conditions

Ambient temperature: max. 50◦C (122◦F), min. 0◦C (32◦F) Humidity: 20–100 % Overvoltage category: Category II Pollution degree: Degree 2 Interconnecting cable Shielded cable, 2 twisted pairs with individual shields, 0.5 mm

Digital transmission according RS485 Interconnecting cable length: Standard 10 m (33 ft), max. 100 m (330 ft) Cable ﬁttings options: European cable glands or US conduit hubs

9.4.1 Fuses

The following 250 V fuses according to IEC 60127 are printed on circuit board PR-7030:

Fuse F1, F2 : 5 x 20 mm, T1A (slow) AC Main power protects electronics against

wrong primary voltage Fuse F3 : 5 x 20 mm, T63 mA (slow) 4-20 mA output protection Fuse F4 : 5 x 20 mm, T2A (slow) Secondary main fuse Fuse F5 : 5 x 20 mm, T500 mA (slow) Sensor power protection Fuse F6 : 5 x 20 mm, T500 mA (slow) Serial bus protection Fuse F7 : 5 x 20 mm, T1A (slow) Processor card protection

Important: For a CSA-Certiﬁed instrument use only CSA-Certiﬁed fuses F1, F2, F4-F7.

94 PR-03 instruction manual

Transmit data Receive data Signal ground

INDICATING TRANSMITTER

Request to send Clear to send Data set ready Data carrier detect Data terminal ready

SDRD SGND

SGND DAT- DAT+

DTE

9.4.2 Serial output speciﬁcations

The output measurement results are sent in ASCII code (ISO 646, CCITT V.3) using a standard asynchronous interface. The output consists of ﬁxed-length text records. A record is sent for every measurement interval (1200 ms).

The RS-232 output conforms to the EIA RS-232-C and CCITT V.24 standards. The signals are available at plug terminal P3 on the IT-R’s processor card. A cable diagram for computer connection is shown in Figure 9.4, pin numbers for a 9-pin D-shell connector (standard female COM connector) are given (pin numbers for a 25-pin connector and for a modem connection cable are available at K-Patents on request).

Note: RS-232-C speciﬁes a maximum cable length of 15 m.

Figure 9.4 Connections for a RS-232 cable for COM connection on a PC

The character structure of the data sent via the serial output interface conforms to the ISO 1177 standard. It is compatible with the ’RS-232’ interfaces (COM port and terminal software) of most personal computers.

The character parameters are conﬁguration selectable:

− speed 1200 to 9600 bits/s

− parity odd, even or none

− stop bits 1 or 2

− ﬂow control hardware, XON / XOFF or none.

The factory setting 9600,even,1,none is normally the best option for computer connections.

9.4.3 Password

The Change parameters display can be optionally locked behind a password function. When the password function is activated, entry to this screen is not allowed without a correct password, see Figure 9.5.

The password function can be activated or deactivated by selecting:

Calibrate / Parameters / Password / Active or Calibrate / Parameters / Password / Inactive.

The password for K-Patents PR-03 is printed on the front page of this manual.

K-Patents PR-03 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual