TROUBLESHOOTING GUIDE
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TROUBLESHOOTING GUIDE FOR PR-33-S AND PR-33-AC
Contents
Instrument diagnostics ........................................................................................................................................ 2
Interpreting the optical image and diagnostic values ......................................................................................... 4
Typical faults and causes ................................................................................................................................... 7
Preventive maintenance inspection plan ............................................................................................................ 9
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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Instrument diagnostics
The K-Patents Process Refractometers PR-33-S and PR-33-AC have an internal built-in web server as a
display. The instrument’s webpage can be viewed through a laptop, or a handheld Field Communicator unit
FC-11 can be used to view the same information from its own user interface. FC-11 is specially designed for
service, troubleshooting and configuring of the K-Patents instruments.
Figure 1 Instrument diagnostics can be reached through a laptop or FC-11.
The instrument’s web server can be reached through the IP-address of the instrument. The preset IPaddress for the PR-33 series is 169.254.23.33. The FC-11 automatically connects to the instrument if the
address has not been changed. To obtain connection between sensor and laptop, type the IP-address on the
search/address field of the browser. The webpage opens in all commonly used browsers. Sometimes the IPaddress of the computer needs to be configured prior to establishing the connection, especially if there is no
router used between the instrument and the laptop. Furthermore, the PR-33-S is powered over Ethernet.
Therefore, a PoE switch is required.
IP configuration for Windows 7
The connection to the instrument is established using a router between the laptop and the instrument. In the
event of no router available or other difficulties in connecting to the instrument, follow the instructions below.
The IP-address of the computer can be configured through Windows control panel by selecting Network and
Sharing Centre, adapter settings and choosing LAN connection properties with a right click of the mouse (1).
Then select the Internet Protocol Version 4 (TCP/IPv6) and click properties (2). A window will open that
allows configuring of the IP-address. The first two sets of numbers in the IP-address should be the same as
in the sensor’s IP-address, however, the IP-addresses should not be totally identical (3). The Subnet mask is
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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given automatically. Make sure the PC’s wireless function is disabled.
Figure 2 Configuring of instrument’s IP-address when connecting without router
Web Browser Display
The instrument’s interface opens in a web browser, where you can find the menu guided verification
procedure, diagnostics, optical image, slope and raw image. Also the mA-output range and chemical curve,
and nD calibrations can be configured and examined through the web page.
Figure 3 The webpage of the instrument contains measurement, diagnostic data, optical images and
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
verification procedure
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Interpreting the optical image and diagnostic values
The diagnostics tab on the instruments webpage contains most of the tools for troubleshooting. The optical
image can be used for inspecting the condition of the optics. The diagnostic values provide information about
the measurements, conditions inside the instrument and mA outputs. All these values can be used to
evaluate the stability of the measurement and condition of the electronics and optical components of the
instrument.
Figure 4 Diagnostics tab shows the current diagnostic values and optical image
Optical Image and Slope
The optical image can be described as a window to the process medium. However, it also gives information
about the condition of the prism and the optics. Scratches or coating layers on the prism can be identified
through the optical image. Altering shapes are formed with every change in the prism-process interface.
Generally, the instrument has two different optical images, i.e. the raw image and IDS scaled optical image.
The raw image is the real response signal from the fotocells of the CCD-element, which is also unique to
every instrument. Consequently, the IDS image was developed to unify the optical images making the
instrument more user friendly. The IDS image is created by mathematical scaling of the raw image to a
rectangular shape improving the measurement stability on high and low refractive index (RI) ranges.
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
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Figure 5 IDS image on the left and raw image on the right
The detection of the measurement point is based on the steepest slope from the optical image (borderline of
activated vs inactivated light reflection). The slope image gives a derivative graph of the optical image that
can be used to examine the quality of the optical image and stability of the measurement.
Figure 6 Optical image and slope without sample
Without a sample on the prism surface the optical image should always return to “box” shape. Any outside
light can also affect the shape of the optical image, therefore, the prism should be covered when inspecting
the optical image. If the optical image is not shown as above, the prism should be cleaned with a glassfiber
brush, and inspected for scratches or marks.
Figure 7 Optical image and slope during measurement
During operation the optical image bends at a certain position which depends on the RI of the measured
medium. Also a clear dip appears on the slope image. A greater dip on the slope image demonstrates better
optical image quality and more stable measurement.
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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The QF-value is related to the quality of the optical image and the slope (higher QF is better). However, the
sharpness of the slope and the QF-value can vary significantly depending on the application. The best way
to exploit the QF-values is to follow and record the changes in the QF which can reveal the changes on the
prism surface.
If the prism is damaged, there can be several dips on the slope which can disturb the measurement. As long
as the slope of the real measurement point is steep, the measurement is not lost. In the case of prism
coating the slope typically weakens which can lead to losing the measurement. However, low optical image,
high spikes, irregular form of the optical image or very weak slopes indicate that actions are required.
Typically, visual check of the prism condition and cleaning with a glassfiber brush is enough to resolve
measurement related problems. Replacement of the prism needs to be considered if there are any marks on
the prism surface.
Diagnostic Values
The instrument has several diagnostic values that can be used to inspect the condition of the instrument and
for troubleshooting purposes. Especially, the LED and the QF-value can be informative when interpreting the
optical images.
Explanation Units / Range
CONC Concentration several units
TEMP Temperature °C / °F
CCD Light activation of the CCD %
nD Refractive index -
CALC Calculated concentration raw value
QF Quality factor typically 0-200
LED Amount of light from the LED 0-100 %
HD TEMP Inside temperature alarm at 65 °C
HD HUM Inside humidity alarm at 60 %
Table 1 Instrument diagnostic values
Interpretation of the Diagnostics
Measurement status: Indicates the current situation of the measurement. It also provides error messages.
The messages can be the following: Normal operation, No sample, Prism wash, Recovering, No sensor,
High sensor humidity, etc.. The complete list of different messages with descriptions can be found in the
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
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instructions manual.
TEMP = Temperature element of the instrument is located at the tip of the sensor probe, thus the
temperature element is one of the first components affected by instrument leakages. Typically the leakages
are detected from abnormal temperature readings as the resistance of the PT-1000 temperature element
increases when corroded. If the electric circuit is cut off, the temperature will drop to -273.14 °C.
QF = Quality of the optical image which is individual for every application. Quality factor expresses the
steepness of the slope in the optical image and thus the stability of the measurement. However, in some
applications QF values might be about 40-50 which is still good, whereas in other applications the QF is
about 170. Therefore, it is important to keep track of the QF value so that the changes in QF are taken
record of. Significantly decreased QF values are generally seen with bad optical images that is a result of
prism coating or erosion.
LED = Optimal value for LED is between 3-25 %. Higher LED values indicate blockage on the light path,
which can be a result of coating or prism erosion. High LED values are often shown with bad optical images,
i.e. with weak slopes.
HD TEMP = High temperatures can damage the electric components. Prolonged high temperatures inside
the sensor may result in short circuits on the electric boards and component failures.
HD HUM = High humidity inside the sensor is harmful to the electric components. High humidity could also
indicate leakages, but it is common that the humidity starts to increase inside the instrument after the dryer
got saturated over time. Generally, high humidity can be resolved by changing the dryer, which is also
recommended every time the sensor cover is removed.
Typical faults and causes
1. Description: Measurement is constantly showing 0 in DCS
Cause(s): Error message on the measurement status, such as No optical image, no sensor, short circuit, etc.
During certain error messages the instrument gives “default” mA-output, this is configured to give 4 mA as
preset.
Figure 8 Default mA-output activation when the instrument has a measurement related error message
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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Solution: Troubleshoot the issue indicated by the error message.
2. Description: No optical image, low image quality
Cause(s): The CCD-element does not receive enough light to determine the borderline of reflected light vs
shadow on the optical image. Lack of light in 90 % of the cases is caused by coated or eroded prism. Liquid
leakage through the prism gasket fits this category. Remaining 10 % of the faults are related to the other
optical or electrical faults, such as broken optical fiber or detached flat cable. Severely bad optical images
are generally seen with these error messages.
Solution: Clean the prism with a glass fiberbrush and check the optical image. If that does not help, check
the prism for any scratches or marks. The prism needs to be replaced if there are any visible marks on the
polished surfaces. The leakage can be detected from abnormal temperature readings and increased head
humidity. Services can be done only by K-Patents or a trained service person.
3. Description: Spiking concentration outputs
Cause(s): Coating of the prism or prism erosion causes a bad optical image and unstable measurement.
Solution: Clean the prism. If the prism is eroded, service accordingly. If the coating is a constant problem,
consider other installation position or additional washing system.
4. Description: Cannot receive signals from the sensor or establish connection through Ethernet
Cause(s): Faulty processor card, typically originates from weak cable connections or component failure due
to excessive humidity or temperature inside the sensor. Another potential cause may be a liquid leakage
inside the sensor.
Solution: The cables should be inspected, and if the problem is not resolved, the processor card needs to be
replaced by K-Patents or a trained service person. If the sensor has leaked liquid, most likely all the
electronics and optics need to be replaced.
5. Description: Inaccurate measurement
Cause(s): These issues are generally related to prism coating, which may result in a constantly increasing
concentration reading. It is also common that the fault is found in the reference measurement method (lab
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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instrument).
Solution: Clean the prism of the sensor carefully and check the optical image. Proceed with the built-in
verification procedure. If the verification fails, the instrument needs to be inspected by qualified person
before recalibration.
Figure 9 Verification procedure for checking the calibration
Preventive maintenance inspection plan
Generally, the instrument is maintenance free, but in order to ensure a functioning K-Patents instrument, the
following preventive maintenance inspection plan is proposed. The weekly PMI plan includes only recording
of the diagnostic values without any service procedures. The annual plan includes also the verification
procedure and prism check for scaling or wear. In addition, there are some specific applications such as
aggressive solvents that require replacement of the flow cell o-ring gasket every 3 months.
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
TROUBLESHOOTING GUIDE
FOR PR-33-S AND PR-33-AC
January 9, 2015
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Weekly check list
Date CONC CALC TEMP QF LED HD HUM HD TEMP SIGNED BY
If you have any questions, please do not hesitate to contact us.
Respectfully,
K-PATENTS
K-PATENTS OY • Postal Address: P.O.Box 77, FI-01511 Vantaa, Finland • Street Address: Elannontie 5, FI-01510 Vantaa, Finland • Tel. int.+358 207 291 570
Fax int.+358 207 291 577 • info@kpatents.com • www.kpatents.com • VAT No. FI03035575 • Business ID 0303557-5 • Registered in Helsinki
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