K-Patents PR-23-SD User Manual

Safe-Drive™ Process Refractometer PR-23-SD Generation 1

Best Practices for PR-23-SD with steam wash system

Contents

Section 1 About This Document .......................................................................................................... 3

Section 2 Before Installation ................................................................................................................ 3

2.1 Installation Location Checklist ....................................................................................... 3

2.2 Component Checklist ..................................................................................................... 4

Section 3 Safety Requirements ............................................................................................................ 7

Section 4 Installation Process .............................................................................................................8

4.1 Spool piece assembly .................................................................................................... 8

4.2 Cutting Installation Opening for SDI Valve .................................................................... 9

4.3 Disassembling SDI Valve for Welding ......................................................................... 10

4.4 Welding SDI Valve in Place ..........................................................................................11

4.5 Reassembling SDI Valve ............................................................................................. 12

4.6 Installing Steam Prism Wash System .......................................................................... 14

4.7 Before Installing and Removing PR-23-SD Sensor .................................................... 17

4.8 Installing Sensor .......................................................................................................... 17

4.9 Box Flushing ................................................................................................................ 19

4.10 Removing Sensor ........................................................................................................ 21

4.11 Removing Wash Nozzle ............................................................................................... 23

4.12 Installing Wash Nozzle ................................................................................................ 25

4.13 Installing DTR Transmitter ........................................................................................... 26

Section 5 Commissioning SD Sensor System ................................................................................. 29

5.1 Prism Wash Test .......................................................................................................... 30

5.2 Calibration Check ........................................................................................................ 31

Section 6 Operating and Monitoring SD Sensor System ................................................................ 32

6.1 Preventive Maintenance Plan (PMP) ........................................................................... 32

6.2 Check Valve Maintenance ........................................................................................... 33

6.3 Resetting SD Sensor System ...................................................................................... 33

Section 7 Appendices .........................................................................................................................34

Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013

Safe-Drive™ Process Refractometer PR-23-SD Generation 1 Best Practices

1 About This Document

This document is intended for individuals installing, commissioning, operating, and/ or servicing the Safe-Drive™ Process Refractometer PR-23-SD generation 1 model that has been manufactured in years 2006–2013. The purpose of this document is to provide a quick guide for the abovementioned tasks in the form of K-Patents recommended best practices.

This document in intended for PR-23-SD applications that have a steam wash system (typical application for black liquor).

NOTE: These instructions are for quick reference only. For more thorough guidance, please refer to K-Patents user manual and documentation.

2 Before Installation

2.1 Installation Location Checklist

Before the SD sensor system is installed, it is important to inspect the installation location carefully for the following conditions:

●

Install the SD sensor system onto either vertical or horizontal pipeline. The

recommended ow rate is 0.4 m/s – 2 m/s (1.5 ft/s – 6 ft/s).

●

Mount the system at waist level. This is the natural and safe height for the system and enables you to use the tools more ergonomically.

●

Leave a 1 m (approximately 3 ft) space around the installation for operating around the SD sensor system. For the same reason, the steam connections should be installed on the sides or back of the sensor system.

●

Recommended maximum ambient temperature of installation location is 45°C (120°F).

●

Avoid locations that are blocked by other piping and/or equipment, or require additional tools, such as a ladder, to access the sensor. The installation location must be level, rm, and free of clutter to provide safe and easy access to the system.

●

Use suitable type of steam for cleaning the prism. Dry saturated steam and 10-12 bar (150-180 psi) are recommended.

●

Access to steam. The distance between the steam supply and the SD sensor system should be considered for the length of steam piping.

●

Access to drain for steam trap condensate outlet.

●

Emergency shower and eye wash should be easily accessible. Water can also be used for cleaning SDI valve lip seals and sensor after sensor removal.

●

Shut-off valve needs pressurized instrumentation air (5-10 bars / 70-150 psi).

●

Ensure connection to the power supply (110-230V AC).

If these conditions do not apply, please reconsider the intended location for your installation or contact K-Patents.

2.2 Component Checklist

Before starting installation, make sure you have all the tools and components listed below.

NOTE: Components 4–6 are connected by union nipple or piping not included in the delivery.

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1 2 3

4 5 6

7 8 9

- 0 .

BACK

ENTER

System components included in K-Patents delivery

Figure 1 System components included in K-Patents delivery

3a 3b 3c

PR-23-SD sensor

SDI valve

Retractor tool

Prism wash nozzle assembly Wash nozzle installation bolts M5x8 DIN912 A4-70

Compressed air operated solenoid shut-off valve with steam trap

Steam connection hose

Pressure regulator with lter and gauge

Sensor connection cable

DTR transmitter

NOTE: If any of tools or components are missing, contact your supplier before starting installation

Installation Equipment

PROCESS

REFRACTOMETER

PR-23

Figure 2 Installation equipment

Retractor inner casing Supplied by K- Patents

Retractor outer casing Supplied by K- Patents

Adjustable wrench

Combination wrench, 19 mm / 3/4 in

Flat head screwdriver

Allen key 8 mm / 5/16 in

Thread seak tape

Sensor insertion / removal instruction card Supplied by K- Patents

Product user manual Supplied by K- Patents

NOTE: The material of the SDI valve body that is welded onto a process pipe is Duplex steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and ller accordingly.

K-Patents recommends complying with the applicable EN / ASTM standards.

3 Safety Requirements

These safety requirements must be followed at all times when installing, operating, or servicing PR-23-SD sensor. These are the minimum safety requirements – your company may require additional PPE (personal protective equipment).

For more information on safety issues, please see K-Patents Safety Instructions.

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Figure 3 Safety symbols

WARNING: Watch out for hot steam and process pipes. Wear protective clothing as

instructed below to work safely.

●

Only authorized personnel can perform the tasks instructed in this document.

●

Long-sleeved safety clothing.

●

Safety glasses and/or goggles.

●

Hard hat or helmet.

●

Protective gloves.

●

Locate the nearest emergency shower and eye wash before starting the work.

●

Never operate the Safe-Drive™ Retractor alone.

●

Hard-cap safety boots.

4 Installation Process

For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video (www.kpatents.com, PR-23-SD SafeDrive™ Operation Guide Video).

Installation of the SD sensor system consists of

●

Cutting pipe opening for SDI isolation valve.

●

Welding and assembling the SDI valve onto the processing piping.

●

Installing the steam prism wash system.

●

Installing the PR-23-SD sensor.

●

Installing the DTR transmitter.

4.1 Spool piece assembly

If the SDI valve was supplied pre-welded and assembled onto a pipe spool piece for integration in existing piping on site, please skip ahead to installing prism wash.

Figure 4 Vertical and horizontal spool piece assemblies

4.2 Cutting Installation Opening for SDI Valve

Use the installation guide sticker provided by K-Patents to determine the installation opening shape and size suitable for your process pipe. If you do not have the guide sticker at hand, please follow the instructions in the images below:

Figure 5 Installation guide sticker

NOTE: For larger pipes, use the same dimensions as for 24” (610 mm) pipes.

To cut the installation opening

1. Cut the installation guide sticker to match the pipe size.

2. Clean the surface of the pipe around the installation area and attach the sticker onto the pipe.

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NOTE: Make sure that the FLOW marker is parallel to the pipe and points to the correct

ow direction. On a horizontal pipe the nozzle points downwards and on a vertical pipe

it points to right. The SD sensor system must always be installed in horizontal position and on the side of the pipe.

3. Drill two holes – 50 mm (2”) and 25 mm (1”) – as guided by the sticker.

4. Remove the bridge between the holes so that the opening is exactly the shape of the sticker.

Process pipe

Cutout

Safe Drive

mounting flange

Process pipe

Weld

Safe Drive

mounting flange

Figure 6 Installation on vertical and horizontal pipes

4.3 Disassembling SDI Valve for Welding

To avoid thermal damage to the isolation valve sealing, you must separate the valve body from the valve assembly before it is welded onto the pipe.

NOTE: Be very careful not to drop or lose any parts that come loose when separating the

body from the assembly.

To disassemble the SDI valve, open the four (4) M10 allen key bolts with an 8 mm (5/16”) allen key (1).

Figure 7 Disassembling valve

4.4 Welding SDI Valve in Place

After you have disassembled the SDI valve, the valve body is welded onto the process pipe.

●

The material of the SDI valve body is Duplex steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and ller accordingly.

●

See the attached drawings 2149 (MTG) and MTG472 for more detailed welding instructions.

●

Follow all local requirements for welding.

●

K-Patents recommends complying with the applicable EN / ASTM standards.

●

Consider the materials and shapes of the welded objects when performing welding pre-processing (tools, cleaning, preheating).

●

Consider the materials and shapes of the welded objects when performing welding post-processing (postheating, fluxing).

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90°

NOTE!

Weld

The material of the welded parts is Duplex steel SAF2205

Process

pipe

Figure 8 Welding on vertical and horizontal pipes

4.5 Reassembling SDI Valve

After the SDI valve body has been welded in place, reassemble the valve in reverse order.

Weld

90°

Process

pipe

NOTE: Make sure that the seals of the ball valve are propely aligned.

Widest bayonet lug always positioned at top

Valve handle always positioned at top

Widest bayonet lug always positioned at top

Figure 9 Reassembling valve on vertical and horizontal pipes

●

Make sure that the SDI valve handle and the largest bayonet connection are on top.

Valve handle always positioned at top

Otherwise, you will not be able to insert the sensor in its place.

●

Tighten the bolts to a torque of 36 N-m (26 lb-ft) with an 8 mm (5/16”) allen key.

WARNING: Always shut the main steam valve before performing any work on the wash nozzle.

To reinstall the wash nozzle assembly

1. Insert the wash nozzle assembly to its place (1)..

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2. Tighten the large nozzle nut (1).

NOTE: Make sure the valve orientation is correct.

3. Attach the safety cover over the nozzle nut (2).

4. Tighten the safety cover M5 Allen screw (3).

5. Attach the nozzle guide plate (4).

6. Tighten the guide plate with two (2) M5x10

screws to the welding body (5).

7. Tighten the M5x8 screw to nozzle (6)..

OPEN

4.6 Installing Steam Prism Wash System

In black liquor service material deposit, scaling or coating may occur on the prism surface. To avoid this, you need to install an integral prism wash with steam that uses the retractable nozzle included in the SDI valve.

Important Steam Prism Wash Considerations

●

The distance from the steam nozzle on the SDI valve to the steam shut-off valve should be kept as short as possible to avoid condensate. The recommended length of the distance is 0.6 m (2 ft) or less.

●

Separate or isolate the power to the solenoid from the power to the transmitter by installing a safety switch. This enables the steam wash to be serviced without having to power down the whole SD sensor system.

●

Pipe the steam trap properly to drain so that the trap is not blowing hot steam.

●

Steam piping upstream of shut-off valve is ½” or larger.

8. Attach the steam line (1).

9. Open the steam connection (2).

●

In addition to the SDI valve steam ttings, the following components must be included

in the steam wash installation:

●

steam shut-off valve

●

air-operated solenoid valve

●

steam trap

●

switch or terminal for power isolation

For K-Patents recommendations, please see K-Patents Steam Instructions.

●

OPTIONAL, in case of contaminants: To remove any contaminants within the steam source, installing a steam strainer is recommended. See K-Patents list of recommended accessories.

●

OPTIONAL, in case of excessive pressure: If the steam pressure exceeds to maximum pressure differential, a pressure reducing valve (PRV) needs to be installed to reduce the steam pressure to optimal design. See K-Patents list of recommended accessories.

Figure 10 Mounting steam wash system

For more detailed information on steam-realted issues, please see K-Patents Steam Instructions.

To install the wash system

1. Dene the wash setting values for the wash system:

●

steam source minimum and maximum pressures

●

wash time – the time one wash will last (seconds)

●

recovery time – the time after the wash has nished, before the measurement is

live data again (seconds)

●

interval – the time between washes (minutes)

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Recommended steam prism wash settings

Minimum above

process pressure

Steam (SN) 5 bar (75 psi) 8 bar (115 psi) 3-5 s 20-30 s 20-30 min

Maximum above

process pressure

Wash time Recovery Interval

NOTE: Damage caused to prism by excessive pressure or washing is not covered by the

product warranty.

Choose the correct steam source pressure by comparing it to the process pressure. The steam source pressure must be higher than process pressure to provide adequate washing, but excessive pressure may also cause premature damage or etching of the prism. Also, if the washing phase is programmed to last too long, the prism may wear out prematurely.

2. Install the steam pipes in the SDI valve, as instructed below. NOTE: All the necessary wash ttings are included in the valve.

3. Connect the steam wash system power supply.

For more information, please see K-Patents Steam Instructions.

Figure 11 Wiring steam wash system

For more information on controlling the prism wash cycle, please refer to chapter Conguring relays in K-Patents user documentation.

4.7 Before Installing and Removing PR-23-SD Sensor

WARNING: Always use the Safe-Drive™ Retractor tool for inserting and removing the

sensor. Removing the sensor without the Retractor tool may cause a life-threatening situation, if there is any pressure in the process pipe. Inserting or removing sensor without Retractor tool may also cause damage to the lip seal. Always store the Retractor tool indoors in a clean and dry location.

Successful sensor insertion and removal can only be guaranteed when the Retractor tool is used and the instructions for insertion or removal are carefully followed.

NOTE: Check the Retractor tool visually before starting installation / removal process. Make sure the handwheel rotates freely.

WARNING: If you detect leaking at any point of sensor installation or removal process, revert immediately to the previous step in the process. Do not continue installation / removal until the reason for leakage has been cleared and fixed.

Install and remove the sensor as instructed in the following chapters. For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23SD Safe-Drive™ Operation Guide Video).

4.8 Installing Sensor

Before you start

●

check that the gaskets and gasket surfaces are clean and undamaged

●

remove the sensor cable gland and unlock Inner casing

1. Insert the sensor to Inner casing so that the inner casing latch is slightly to the left of top and sensor cable passage is straight down.

2. When sensor ange is ush with the bottom of Inner casing, turn Inner casing 1/6 turn clockwise to lock it to the flange.

3. Push down the locking latch.

Put the Safe-Drive™ Retractor with sensor onto a table or similar surface so that the hand wheel has space to turn.

1. Fit Outer casing over Inner casing so that the groove on Inner casing matches the dot on Outer casing.

2. Turn the hand-wheel clockwise until it stops to draw the sensor into the Retractor.

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LIFT POINTS

Lift the Retractor (with sensor) handle up over the isolation

valve ange.

4 x M12

50Nm (37ft/lbs)

140 mm

(5.5")

1. Turn the Retractor a 1/6 turn to the right to lock the bayonet.

2. Push down the latch on Outer casing.

1. Close the blow-out ball valve underneath the isolation valve,

2. Lift up the isolation valve handle locking plate.

3. Open the isolation valve by turning the valve handle a quarter turn to the right.

Turn the hand-wheel counterclockwise until it stops.

WARNING: If you detect leaking, revert immediately to the previous step. Do not continue installation until the reason for

leakage has been cleared and xed.

Fit the four M12 nuts to the bolts holding the sensor to the isolation valve and screw them on with a 19 mm or 3/4” wrench.

90°

NOTE: Set the torque at 50 Nm.

1. Turn the wheel a quarter turn to the right.

2. Unlock the latch of the outer casing.

3. Turn the casing to the left until the handle is up on top.

1. Turn the hand-wheel to the left to drop the thread.

2. Lift off Outer casing.

1. Lift up the latch of the inner casing to unlock.

2. Turn the casing a 1/6 turn to the left to release it from the flange.

Lift Inner casing away from the sensor head.

1. Take off sensor nameplate and the gasket underneath.

2. Put interconnecting cable through the cable gland.

3. Connect the interconnecting cable to the sensor.

4. Screw the cable gland to the sensor.

1 & 5

5. Fit the gasket and nameplate onto the sensor and screw the nameplate back on.

Turn on transmitter power to power up the SD sensor system.

4.9 Box Flushing

Carry out box ushing before sensor removal when the sensor has been in process for several months. Box ushing removes dried process medium from isolation valve and

makes sensor removal easier.

WARNING: Do not activate box steam ush, if the sensor and the Retractor tool are not

installed to the isolation valve!

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1. Close the 1/4” valve to

OPEN

the nozzle (1).

2. Open the 1/4” valve to the box (2).

3. In the DTR transmitter, go to MENU › SENSOR STATUS and activate wash by pressing WASH button.

OPEN

Repeat the wash 3–5 times.

4. Close the 1/4” valve to the box (4).

5. Open the 1/4” valve to the nozzle (5).

4.10 Removing Sensor

1 & 5

Switch off the DTR to cut off power from the sensor.

1. Remove the sensor nameplate and the gasket underneath.

2. Screw off the cable gland.

3. Disconnect the interconnecting cable

4. Remove the cable from sensor

5. Place gasket and nameplate on the sensor head and screw the sensor nameplate back on.

NOTE: If another inline sensor is connected to the same DTR, disconnect the loose cable from the DTR and turn power on again.

1. Unlock the latch on Inner casing.

2. Lift Inner casing over the sensor head. Connect the casing to the sensor ange bayonet.

the flange.

2. Lock the inner casing latch.

1. Turn the casing a 1/6 turn to the right to lock it onto

1. Grab Outer casing with one hand on the handle and the other hand on the wheel. Fit Outer casing over Inner casing and all the way to the isolation valve bayonet keeping the handle upwards.

2. Rotate the hand wheel clockwise to get thread of the inner

casing running through the wheel.

1. Turn Outer casing a 1/6 turn to the right to lock it onto the

isolation valve.

2. Push down the outer casing latch.

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4 x M12

Open and remove the four M12 nuts on the bolts holding the sensor to the isolation valve using a 19 mm or 3/4” wrench.

Turn the hand wheel clockwise until it stops to remove the sensor from process.

140 mm

(5.5")

WARNING: If you detect leaking, revert immediately to the previous step. Do not continue removal until the reason for

leakage has been cleared and xed.

1. Lift up the isolation valve handle locking plate.

2. Close the isolation valve on by turning the handle a quarter turn to the left.

IM P O RTA NT: The isolation valve is properly closed

when the handle points away from the sensor and the locking plate drops down over the handle.

3. Open the blow-out valve under the isolation valve.

Some process liquid should leak from the valve. If there is none, the valve may be defective.

WARNING: Watch out for splashing!

4. Carry out box ushing to get rid of any process liquid inside the isolation valve. See chapter 4.9 Box Flushing for instructions.

1. Lift the outer casing locking latch.

2. Turn Outer casing a 1/6 turn to the left so that the handle comes up on top.

LIFT POINTS

Take a good grip on the hand wheel and the handle and pull out the Safe-Drive™ Retractor with the sensor inside.

A rm hold of the tool is essential as the combination of the

tool and the sensor is noticeably heavier than Retractor alone.

NOTE: To ensure the isolation valve after the Safe-Drive tool with the sensor have been removed, you can bolt a standard

ANSI 1.5” 105 lbs blind ange to it with 1/2” (M12) bolts and

nuts.

WARNING: The sensor tip is hot and may be covered with liquor. It is recommended to rinse the sensor tip and the isolation valve with hot water.

Put the Safe-Drive™ Retractor with sensor onto a table or similar surface so that the hand wheel has space to turn.

1. Turn the wheel counterclockwise until the trapezoidal thread is all the way inside the outer casing and loose from the wheel.

2. Pull the outer casing off.

1. Open the latch on the inner casing.

2. Keep sensor steady with one hand and turn Inner casing counterclockwise with the other hand to unlock Inner casing from sensor.

3. Pull off the sensor.

4.11 Removing Wash Nozzle

Remove the wash nozzle as instructed in the following illustrations: For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23SD Safe-Drive™ Operation Guide Video).

WARNING: Always shut the main steam valve before performing any work on the

wash nozzle.

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1. Close the steam supply.

2. Close the 1/4” ball valve (1).

3. Remove the incoming steam pipe from the 1/4”

ball valve (2).

NOTE: Do not remove the

check valve!

4. Remove the nozzle guide (3).

5. Loosen the nozzle nut 1/4 turn at time with a 22 mm / 7/8 in wrench until you can pull the nozzle about 150 mm / 6 in outwards (1).

IM P O RTA NT: Do not open the nozzle not for more than 2 turns.

6. Close the 3/8” ball valve (2).

7. Loosen the nozzle nut

entirely (3).

NOTE: Only little process

liquid should ow from the

LOCK

nozzle. If process liquid

keeps on owing, the nozzle

isolation valve is damaged and it is not safe to remove the nozzle. Do not proceed with nozzle removal.

8. Pull the nozzle out of the isolation valve (4).

WARNING: The nozzle tip is hot and may be covered with liquor. It is recommended to rinse the nozzle tip and the isolation valve with hot water.

4.12 Installing Wash Nozzle

Install the wash nozzle as instructed in the following illustrations: For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23SD Safe-Drive™ Operation Guide Video).

WARNING: Always shut the main steam valve before performing any work on the wash nozzle.

OPEN

Check the nozzle and valve before installing the wash

nozzle. Use teon tape for

all thread connections.

1. Fasten the nozzle to the 3/8” isolation valve (1).

2. Tighten the nozzle nut (2).

3. Carefully open the 3/8”

nozzle isolation valve (3).

NOTE: If process liquid is

LOCK

leaking severely, close the isolation valve immediately and do not proceed with nozzle installation.

4. Push nozzle into the process pipe (4).

5. Fasten the nozzle guide (5).

6. Tighten up nozzle nut (2).

7. Attach steam pipe to 1/4”

ball valve (1).

8. Open the 1/4” ball valve (2).

9. Open the steam supply.

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4.13 Installing DTR Transmitter

The indicating transmitter DTR is a specialized computer designed to process data received from one or two sensors. The transmitter consists of a protecting enclosure, a front panel, an LCD display and a keyboard. Knockout padlock provisions are included for locks to prevent unauthorized access.

Figure 12 DTR transmitter

●

DTR transmitter location:

●

easily accessible

●

well lit, but no direct sunlight

●

dry

●

ambient temperature range of the transmitter is 0 – 45 °C (32–113 °F)

●

free of vibration or other such disturbances

●

Consider the interconnecting cable length when choosing the installation location. The standard delivery is 10 meter (33 feet) of cable and the maximum allowed length is 200 meters (660 feet). You can use your own cable as long as it meets IEC 61158-2 type A standard requirements. For more information, please refer to chapter Interconnecting cable specications in K-Patents user documentation.

●

Consider installing a drip shield to protect the transmitter from rain, sun and dust, especially if the transmitter is installed outside.

WARNING: The transmitter does not have a built-in power switch so it is always powered when connected to a power source. K-Patents recommends mounting an external power switch to control the power supply.

To install the transmitter

1. Install the transmitter vertically on an upright surface (wall) using the four mounting feet, preferably on the eye level of the user. WARNING: Do not drill mounting holes in the enclosure. That would affect the protection class of the enclosure and damage the electronics.

2. Connect the PR-23-SD sensor:

●

Remove the four (4) screws holding the sensor nameplate.

●

Connect the signal wires to terminals 1 and 2.

●

Connect the cable shield to terminal 3.

●

Tighten up the cable gland.

●

Screw the nameplate back on. NOTE: To avoid damage from stray voltages and short-circuiting, always disconnect the sensor cables from the transmitter before removing the sensor.

Figure 13 Sensor electrical connections

3. Open the front panel by loosening the front panel screw. WARNING: Always check that the power is off before opening the front panel. If the green power indicator light is on, there is still power in the system. To completely turn off the power, unplug the power supply cord or use the external power switch (if installed).

Figure 14 Opening transmitter front panel

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4. Connect the primary AC power to a separate terminal strip in the lower right-hand corner of the motherboard. The three terminals are marked 31/L, 32/N, and 33/ PE (protective earth), which is directly connected to the exposed metal parts if the transmitter.

5. Connect the wiring wash relay to solenoid valve from the RELAYS terminals.

6. Connect the 4-20mA output.

Figure 15 Transmitter H1 and motherboard connections

A 1 2 3 Connection for Sensor A, signal wires (1, 2), cable shield (3).

B 1 2 3 Connection for Sensor B, signal wires (1, 2), cable shield (3).

Motherboard

11 12

13 14

21 22 Relay 1, one contact output, max. 250 V AC, max. 3 A.

23 24 Relay 2, one contact output, max. 250 V AC, max. 3 A.

31 32 33

41 42

51 52 53 54 55

4–20 mA output 1, positive (11), negative (12), max. load 1000 Ohm, galvanically isolated.

4–20 mA output 2, positive (13), negative (14), max. load 1000 Ohm, galvanically isolated.

Power, L (31), N (32), protective earth (33), 100-240 V AC, 50– 60 Hz. An external power switch is recommended.

24V terminal for DTR internal use only. NOTE: Connecting terminal to external 24V supply will void warranty. Connecting external devices to 24V terminal will void warranty.

Switch inputs: switch 1 (51), switch 2 (52), switch 3 (53), switch 4 (54) and common (55). A voltage of 3 V DC is provided over each switch. The switch terminals are galvanically isolated.

7. OPTIONAL: Setting up an Ethernet connection. Data can be downloaded from the transmitter to a computer via an Ethernet connection. The Ethernet connector can be found on the underside of the front panel.

Figure 16 Ethernet connection location

For more information on Ethernet connection, please refer to chapter Ethernet connection specication in K-Patents user documentation.

5 Commissioning SD Sensor System

After installing the SDI valve, PR-23-SD sensor, and DTR transmitter, go through the following check list to make sure the SD sensor system is functioning correctly.

Commissioning checklist

Safe-Drive start-up

Tas k OK Failed Menu path Notes

Check that the wiring has been done according to the attached wiring diagram. Connect the power.

Check that the status is NORMAL OPER ATION (if there is a sample) NO SAMPLE (if the process pipe is empty) Check process temperatures.

Check the serial number. Check that the parameters

are set according to the delivery data sheet (DDS).

CALIBRATION › CHEMICAL & FIELD PARAMETERS

Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013

Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1

Congure the mA output. CALIBR ATION ›

Congure prism wash relay

(relay 1 or 2).

Prism wash test

Tas k OK Failed Notes

Observe the temperature and optical image for slight changes that indicate that wash is functioning. One or more of the following changes should take place:

- nD value decreasing (most apparent change)

- T value decreasing

- QF value decreasing or increasing

Calibration check

Tas k OK Failed Notes

Check that calibration corresponds to the lab results

OUTPUTS › mA OUTPUTS

CALIBR ATION › RE L AYS

CALIBRATION › CHEMICAL & FIELD PARAMETERS › FIELD PARAMETERS

For more information, see chapter

Conguring mA

Outputs in K-Patents PR-23 Instruction Manual. For more information, see chapter Conguring relays in K-Patents PR-23 Instruction Manual.

For more information, see chapter 5.1 Prism Wash Test in these instructions and chapter Prism wash in K-Patents PR-23 Instruction Manual.

For more information, see chapter 5.2 Calibration Check in these instructions and chapter Calibrating

the concentration measurement in

K-Patents PR-23 Instruction Manual.

5.1 Prism Wash Test

Prism wash system is essential for a fully functional refractometer. Regular testing of the prism wash is highly recommended.

The curve should react to the wash and the temperature change slightly.

NOTE: Your transmitter may not look excatly like the image above during the wash. The visible changes in the curve and the temperature depend on viscosity, steam pressure and temperatures of solids and steam and also to your version of the software.

Figure 17 Changes in concentrations during succesful prism wash

5.2 Calibration Check

Extract 3-5 samples in a couple of days’ time. Results from these samples can be used as a reference for calibration.

In case there are deviations from the lab results, check that washes are functioning correctly (see Prism wash test in the commissioning checklist). When comparing lab results if there is a consistent offset, perform a BIAS adjustment from CALIBRATION menu. For more information, see chapter Calibrating the concentration measurement in K-Patents PR-23 Instruction Manual.

Figure 18 BIAS

Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013

Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1

If there is a need for frequent calibration, make sure that wash is functional and remove the sensor to check visually that the prism is clean and has not been damaged. Re-install the sensor and run complete eld calibration (see chapter Entering eld calibration parameters in K-Patents PR-23 Instruction Manual). After this, contact your local supplier.

6 Operating and Monitoring SD Sensor System

The SD sensor system runs automatically and does not need to be separately operated. If there are no alarming changes in the diagnostic values or no alarm messages, you do not need to adjust the operation. The main task of the operator is to make sure that the washes and steam connections are functioning as they should.

To rehearse the use of DTR transmitter, please visit demo.kpatents.net.

K-Patents recommends that all new users participate in K-Patents training before using the product.

6.1 Preventive Maintenance Plan (PMP)

Preventive Maintenance Plan (PMP) should be adopted in order to prevent bigger maintenance procedures. Here are the recommended tasks:

Tas k Weekly Annual Notes

Check the functionality of diagnostics: X See the attached PMI checklist.

CONC (measurement value of output)

CALC (chemical curve of calibration)

TEMP (temperature)

QF (quality factor) Typically 30-100. If QF drops 20 units

LED (exposure time) Typically <30. If the LED value increases

HD HUM (internal humidity% of sensor)

Check the functionality of wash system. Check the steam pressure.

Remove the sensor and check the prism visually for dirt and wear. X

Inspect the check valve: clean the small holes and see that the valve sealing is intact.

This value should be closely monitored daily for a week to set the default reading for weekly inspections This is the default reading from the chemical curve concentration reading set in calibration, to which you can compare the CONC values to.

Process temperature.

below the normal level, perform a prism wash test (see Commissioning checklist).

signicantly, perform a prism wash test

(see Commissioning checklist). If HUM HD rises above 50%, the system issues an alarm to replace the desiccant. For more information, see K-Patents PR-23 Instruction Manual. See Prism wash test in Commissioning checklist. Typically 5- 6 bar (75-9 0 psi) over process pressure. If the prism looks worn, run an nD

verication and replace the prism,

if needed. For more information on nD verication, see K-Patents PR-23 Instruction Manual Replace the check valve every 2 years. For more information, see chapter 6.3 Check Valve Maintenance.

Clean the lter in the steam

connection line. Verify calibration. Do this as often as your own quality system

Please use the attached Preventive Maintenance Inspection (PMI) Checklist for recording the weekly preventive maintenance tasks.

6.2 Check Valve Maintenance

Check valve is one of the few moving parts in the wash system. Checking the valve sealing and cleaning the small holes in case of dirt particles annually is essential.

Figure 19 Taking check valve apart for maintenance

6.3 Resetting SD Sensor System

If the SD sensor system needs to be reset, you can either

●

Switch the power off and back on again,

●

Restart the sensor through transmitter from MENU › SENSOR STATUS › SLOPE › SENSOR RESTART or

●

Press the reset button, as instructed below.

and local requirements demand.

1. Open the DTR transmitter front panel.

2. Press the reset button on the inside of the front panel using a thin stick or a similar tool. The display will black out for a few seconds. The SD sensor system will be back up in operation within 30 seconds.

Figure 20 Reset button

Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013