Vaisala PR-43-AC, PR-43-AP User Manual

M212438EN-C

User Guide

Sanitary Process Refractometer

PR-43-AC/AP

PUBLISHED BY

Vaisala Oyj

Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland P.O. Box 26, FI-00421 Helsinki, Finland

[phone]

Visit our Internet pages at www.vaisala.com.

© Vaisala Oyj 2020

No part of this document may be reproduced, published or publicly displayed in any form or by any means, electronic or mechanical (including photocopying), nor may its contents be modified, translated, adapted, sold or disclosed to a third party without prior written permission of the copyright holder. Translated documents and translated portions of multilingual documents are based on the original English versions. In ambiguous cases, the English versions are applicable, not the translations.

The contents of this document are subject to change without prior notice.

Local rules and regulations may vary and they shall take precedence over the information contained in this document. Vaisala makes no representations on this document’s compliance with the local

rules and regulations applicable at any given time, and hereby disclaims any and all responsibilities related thereto.

This document does not create any legally binding obligations for Vaisala towards customers or end users. All legally binding obligations and agreements are included exclusively in the applicable supply contract or the General Conditions of Sale and General Conditions of Service of Vaisala.

This product contains software developed by Vaisala or third parties. Use of the software is governed by license terms and conditions included in the applicable supply contract or, in the absence of separate license terms and conditions, by the General License Conditions of Vaisala Group.

		Table of contents
Table of contents
1.	About this document.....................................................................................	5
1.1	Version information..........................................................................................	5
1.2	Related manuals................................................................................................	5
1.3	Documentation conventions...........................................................................	5
1.4	Trademarks........................................................................................................	6
2.	Product overview............................................................................................	7
2.1	Vaisala Sanitary Process Refractometers PR 43 AC and PR 43 AP...........	7
2.2	Safety..................................................................................................................	7
3.	Installation..........................................................................................................	9
3.1	Choosing mounting location...........................................................................	9
3.2	Checklist for pipe mounting............................................................................	9
3.3	Checklist for mounting in tank, vessel or large pipe...................................	10
3.4	Mounting guide.................................................................................................	11
3.5	Electrical connections.....................................................................................	12
4.	Prism wash........................................................................................................	16
4.1	Prism coating...................................................................................................	16
4.2	Prism wash.......................................................................................................	16
4.2.1	Recommended wash pressures and times............................................	17
4.2.2	Prism wash systems.................................................................................	18
4.2.3	Prism wash nozzles.................................................................................	22
5.	Technical data................................................................................................	25
5.1	Compatibility...................................................................................................	25
5.2	Refractometer rangeability...........................................................................	25
5.3	Sanitary process refractometer PR-43-AC..................................................	25
5.3.1	PR-43-AC model code............................................................................	26
5.3.2	PR-43-AC mounting hardware model code.........................................	28
5.3.3	PR-43-AC specifications.........................................................................	32
5.3.4	PR-43-AC parts list.................................................................................	34
5.3.5	PR-43-AC mounting specifics................................................................	37
5.3.6	Mounting specifics for EHEDG certified PR-43-AC configuration....	44
5.3.7	3-A Sanitary Standard compliance.......................................................	44
5.4	Sanitary process refractometer PR-43-AP.................................................	46
5.4.1	PR-43-AP model code............................................................................	47
5.4.2	PR-43-AP mounting hardware model code........................................	49
5.4.3	PR-43-AP specifications........................................................................	50
5.4.4	PR-43-AP parts lists................................................................................	52
5.4.5	PR-43-AP mounting specifics................................................................	55
5.4.6	Mounting specifics for EHEDG certified PR-43-AP configuration....	58
5.4.7	3-A Sanitary Standard compliance.......................................................	59
Appendix A: Refractometer verification..................................................		60

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Appendix B: PR-43 refractometer verification form..............................	62
Appendix C: EU declaration of conformity..............................................	63
Warranty............................................................................................................	65
Technical support............................................................................................	65
Recycling...........................................................................................................	65

2

List of figures

List of figures

Figure	1	Refractometer models.....................................................................................	7
Figure	2	PR-43-AC and PR-43-AP mounting guide.................................................	11
Figure	3	The M12 connector...........................................................................................	12
Figure	4	Connecting refractometer cable to refractometer.................................	13
Figure	5	Wiring with analogue output only..............................................................	13
Figure	6	Wiring options with both analogue and digital outputs......................	14
Figure	7	Wiring options with both analogue and digital outputs
		and RJ45 ethernet connector.......................................................................	14
Figure	8	Connections in M12 and RJ-45 connectors...............................................	15
Figure	9	Prism wash system for steam.......................................................................	19
Figure 10		Wiring for prism wash system for steam.................................................	20
Figure	11	Prism wash system for high pressure water.............................................	21
Figure	12	Wiring for prism wash system for high pressure water........................	22
Figure 13		Wash nozzles for flowcell AFC-HSS-XXX-XX-NC...................................	22
Figure 14		Process connection of wash nozzle in flowcell.......................................	24
Figure	15	PR-43-AC rangeability...................................................................................	25
Figure 16		PR-43-AC dimensions....................................................................................	26
Figure	17	Refractometer cover assembly...................................................................	34
Figure 18		PR-43-AC assembly.......................................................................................	36
Figure 19		Mounting with sanitary ferrule, pipe diameter 80 mm
		(3 in) or more....................................................................................................	37
Figure 20		Flow cell AFC-HSS-H10 for pipe diameter 25 mm (1 in)
		and H15 for pipe diameter 40 mm (1.5 in)................................................	38
Figure	21	Flow cell AFC-HSS- with wash nozzle connection (-NC)
		H10 for pipe diameter 25 mm (1 in) and H15 for pipe
		diameter 40 mm (1.5 in)................................................................................	39
Figure 22		Flow cell AFC-HSS-H20 for pipe diameter 50 mm (2 in)
		and H25 for pipe diameter 65 mm (2.5 in)..............................................	40
Figure 23		Flow cell AFC-HSS- with wash nozzle connection (-NC)
		H20 for pipe diameter 50 mm (2 in) and H25 for pipe
		diameter 65 mm (2.5 in)................................................................................	41
Figure 24		Side flow cells..................................................................................................	42
Figure 25		I-Line fitting for PR-43-AC...........................................................................	43
Figure 26		Mounting with sanitary ferrule, pipe diameter 80 mm
		(3 in) or more EHEDG certified configuration........................................	45
Figure 27		Dimensions of an inserted refractometer PR-43-AP-H25-L170........	46
Figure 28		Flush mounted refractometer PR-43-AP-T10-L00................................	47
Figure 29		Refractometer cover assembly....................................................................	52
Figure 30		PR-43-AP assembly.......................................................................................	54
Figure	31	Insertion of probe refractometer PR-43-AP-H25..................................	56
Figure 32		Flush mounting probe refractometer PR-43-AP-T10-L100.................	57
Figure 33		I-Line fitting for PR-43-AP............................................................................	58
Figure 34		EHEDG certified PR-43-AP...........................................................................	59
Figure 35		Universal sample holder PR-1012...............................................................	60

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PR-43-AC/AP User Guide M212438EN-C

List of tables

Table	1	Document versions (English)...........................................................................	5
Table	2	Related manuals..................................................................................................	5
Table	3	Wash medium parameters for integral wash nozzles in PR-43-AP......	17
Table	4	Wash medium parameters for flowcell wash nozzle AFC.......................	17
Table	5	Flowcell -H10 or -H15........................................................................................	23
Table	6	Flowcell -H20 or -H25......................................................................................	23
Table	7	Flowcell -H30......................................................................................................	23
Table	8	Flowcell -H40.....................................................................................................	23
Table	9	Prism wash nozzle selection..........................................................................	24
Table 10		Sanitary compact refractometer for pipelines..........................................	27
Table	11	Mounting hardware without wash nozzles................................................	28
Table 12		EHEDG certified mounting hardware..........................................................	28
Table 13		Mounting hardware with wash nozzles.......................................................	29
Table 14		Mounting hardware, mini flow cell...............................................................	30
Table 15		Mounting hardware, Varivent DN65 connection......................................	30
Table 16		Mounting hardware...........................................................................................	31
Table	17	PR-43-AC specifications..................................................................................	32
Table	18	Refractometer cover assembly parts list....................................................	34
Table 19		PR-43-AC assembly parts list........................................................................	36
Table 20		I-Line fitting for PR-43-AC.............................................................................	43
Table	21	Mounting materials...........................................................................................	45
Table 22		SANITARY PROBE REFRACTOMETER for large pipelines
		and vessels..........................................................................................................	47
Table 23		SANITARY PROBE REFRACTOMETER with prism wash
		for large pipelines and vessels......................................................................	49
Table 24		Mounting hardware for PR-43-AP refractometer....................................	50
Table 25		PR-43-AP specifications.................................................................................	50
Table 26		Refractometer cover assembly parts list....................................................	52
Table 27		PR-43-AP assembly parts list........................................................................	54
Table 28		Verification results display..............................................................................	62

4

Chapter 1 – About this document

1. About this document

1.1 Version information

This document provides instructions for installing and using the Vaisala K PATENTS® Sanitary Process Refractometers PR 43 AC and PR 43 AP.

This product manual is delivered to the end user with a Vaisala K PATENTS® product. Information in this manual is subject to change without notice. When the manual is changed, a revised copy is published at www.kpatents.com.

Table 1 Document versions (English)

Document Code	Date	Description
M212438EN-C	April 2020	Manual updated to new format, template, and document
		code. Minor changes to content.
IM EN PR43ACAP	September	Changed K-Patents to Vaisala.
2.00	2019
IM EN PR43ACAP	June 2018	IP rating updated.
1.12

1.2 Related manuals

Table 2 Related manuals

	Document Code	Name
	M212455EN	Sanitary Process Refractometer PR-43 Series User Guide
	IM-EN-MI	Multichannel User Interface MI Instruction Manual
	IM-EN-CI	Compact User Interface CI Instruction Manual
	IM-EN-PR43IAAX	Process Refractometer PR-43-…-IA/AX/CU Instruction Manual

1.3 Documentation conventions

WARNING! Warning alerts you to a serious hazard. If you do not read and follow instructions carefully at this point, there is a risk of injury or even death.

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CAUTION! Caution warns you of a potential hazard. If you do not read and follow instructions carefully at this point, the product could be damaged or important data could be lost.

Note highlights important information on using the product.

Tip gives information for using the product more eˆciently.

Lists tools needed to perform the task.

Indicates that you need to take some notes during the task.

1.4 Trademarks

Vaisalaâ and K-PATENTS® are registered trademarks of Vaisala Oyj. Linuxâ is a registered trademark of Linus Torvalds.

Windowsâ is either a registered trademark or trademark of Microsoft Corporation in the United States and other countries.

Varivent® is a registered trademark of GEA Tuchenhagen GMBH.

All other product or company names that may be mentioned in this publication are trade names, trademarks, or registered trademarks of their respective owners.

6

Chapter 2 – Product overview

2. Product overview

2.1 Vaisala Sanitary Process Refractometers PR 43 AC and PR 43 AP

The sanitary refractometers PR 43 AC and PR 43 AP provide a digital interface detection system for alimentary industry.

The PR 43 AC/AP measures the refractive index nD and the temperature of the process

medium. The concentration of the process liquid is calculated from these values when the composition of the process medium is known.

The output values of the refractometer are transmitted through mA output and digitally through an Ethernet connection by using a UDP/IP protocol (for specification see PR-43 general manual). mA output is available with mA output cable (mA only) or with a split cable (mA and Ethernet).

Figure 1 Refractometer models

2.2 Safety

This product has been tested for safety. Note the following precautions:

WARNING! Only licensed experts may install electrical components. They must adhere to local and state legislation and regulations.

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PR-43-AC/AP User Guide

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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.

Wear protective eyewear.

Wear protective gloves.

Precautions when removing a sensor from the process line :

•Check that the process line is depressurized and drained

•Loosen the flowcell screws cautiously; be prepared to tighten again

•Ensure you are clear of any possible spillage and you have a clear emergency escape path

8

Chapter 3 – Installation

3. Installation

3.1 Choosing mounting location

The refractometer mounting location should be chosen with care to ensure reliable readings from the process.

The mounting location needs to be such that sediments or gas bubbles cannot accumulate by the refractometer. Good flow velocity is essential in keeping the prism clean.

CAUTION! If the process pipe vibrates, support the pipe. A vibrating pipe might damage the inline refractometer mounted on it.

A Vaisala K PATENTSâ inline refractometer can be located either indoors or outdoors in most climates. However, when a refractometer 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), as light from outside reaching the prism through the pipe wall may disturb the measurement.

The refractometer cover should not be exposed to high temperature radiation. In most cases, draft and natural convection provide suˆcient air cooling if the air gets to flow freely around the refractometer 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 air cooling is improved by blowing pressurized air against the refractometer cover. The pressurized air can be supplied by the ventilation system. It is also possible to mount a PR 14038 cooling cover for cooling with water.

CAUTION! Always mount the refractometer so that the interconnecting cable points downwards from the refractometer head.

3.2 Checklist for pipe mounting

The PR 43 AC and PR 43 AP are mounted in a pipe. Vaisala recommends a flow velocity between 1 and 3 m/s (3–10 ft/s). If the flow velocity exceeds 6 m/s (20 ft/s), there is a risk of cavitation. Cavitation may damage the refractometer and the piping. Too slow a flow velocity may cause erraneous measurement readings due to coating of stratification (layering) of the sample on the prism.

The diameter and form of the pipe and the process temperature all a‹ect the measurement and need to be taken into account.

•If the process pipe diameter varies, select the position with the smallest diameter(and accordingly highest velocity). Then the prism stays clean better.

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•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 close to the dilution point. However, make sure complete mixing has occurred at mounting location.

•If the temperature varies along the process pipe, select the position with the highest process temperature. That minimizes the risk of coating, because higher temperature means higher solubility and also lower viscosity.

•Often the position with the highest process pressure (= after pump + before valve) has favorable flow conditions without sedimentation or air trapping risks.

•The refractometer should be conveniently accessible for service.

3.3 Checklist for mounting in tank, vessel or large pipe

A probe refractometer PR 43 AP can be inserted with a flange or clamp into tanks and vessels which either don’t have a scraper or where the mixer doesn’t touch the vessel wall. A probe refractometer can also be flush mounted in a cooker where the scraper touches the wall.

•The inserted probe refractometer is mounted close to a stirrer to ensure representative sample of the process liquid and to keep the prism clean.

•The refractometer should be conveniently accessible for service.

10

3.4 Mounting guide

<![if ! IE]> <![endif]>access	<![if ! IE]> <![endif]>Upper pipe bend	<![if ! IE]> <![endif]>High pressure	<![if ! IE]> <![endif]>Small diameter High temperature High velocity >1.5m/s (>5ft/s)
<![if ! IE]> <![endif]>Easy

<![if ! IE]> <![endif]>Easy access

<![if ! IE]> <![endif]>Ambient air cooling

<![if ! IE]>

<![endif]>Prevent outside light

Figure 2 PR-43-AC and PR-43-AP mounting guide

Chapter 3 – Installation

<![if ! IE]>

<![endif]>High temperature

<![if ! IE]>

<![endif]>High pressure

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3.5 Electrical connections

The refractometer has an M12 connector in the refractometer for power supply, mA output and Ethernet connections.

Figure 3 The M12 connector

PR-43 refractometers are powered with 24 VDC. For connecting the refractometer to Multichannel user interface MI, see the Instruction manual for Multichannel User Interface MI. For connecting the refractometer to Compact user interface CI, see the Instruction manual for Compact User Interface CI. See the following figure for instruction how to connect the M12 refractometer cable.

12

Chapter 3 – Installation

	Turn to tighten
Aligng roo ve and	Connector screw thread
guide

P4-031

Figure 4 Connecting refractometer cable to refractometer

The PR-43 refractometer provides both analog (mA) and digital output signals. See the following figure for the wiring when only analog output is used.

PR-43 REFRACTOMETER

M-12-8 pin, A-code, M non-Ex

PR-8680

F	M12-8 pin, A-code, F	PR-8432
	Field plug	Power supply and
		mA output cable

max. 200m (656ft)

Figure 5 Wiring with analogue output only

The following figure shows the options for connecting the refractometer with both analog and digital outputs. Both Compact user interface CI and Multichannel user interface MI use the digital output signal.

13

PR-43-AC/AP User Guide									M212438EN-C
	PR-43 REFRACTOMETER
	M-12-8 pin, A-code, M					PR-8431
	non-Ex
						Split cable M12
						M12-8 pin, A-code, F
						Ethernet (M12-4 pin, D-code,M)
F						mA, 24V
	10m (33ft)
10m (33ft)						M
	PR-43 REFRACTOMETER							PR-8431
	M-12-8 pin, A-code, M
								Split cable M12
	non-Ex
								M12-8 pin, A-code, F
								Ethernet (M12-4 pin, D-code,M)
	PR-8430							mA, 24V
F	Platform 4 cable							1m (3ft)
	M12-8 pin, A-code, F+M
	Ethernet, mA, 24V
90m (295ft)	max. 90m (295ft)			M		F			M
	PR-43 REFRACTOMETER								PR-8431
	M-12-8 pin, A-code, M	PR-8660
									Split cable M12
	non-Ex
		Platform 4 cable extender							M12-8 pin, A-code, F
		M12-8 pin, A-code, F+M							Ethernet (M12-4 pin, D-code,M)
	PR-8430					PR-8430			mA, 24V
F									1m (3ft)
	Platform 4 cable					Platform 4 cable
	M12-8 pin, A-code, F+M					M12-8 pin, A-code, F+M
	Ethernet, mA, 24V					Ethernet, mA, 24V
180m (590ft)	max. 90m (295ft)	M		F	max. 90m (295ft)		M	F		M

Figure 6 Wiring options with both analogue and digital outputs

The following figure shows the wiring options when both analogue and digital outputs are used, with RJ45 ethernet connector.

PR-43

REFRACTOMETER

M-12-8 pin, A code, M

Unclassi ed area

F

10m (33ft)

PR-8444-001/010

Split cable M12 M12-8 pin, A-code, F Ethernet (RJ 45) mA, 24V

1m (3ft) or 10m (33ft)

PR-43

REFRACTOMETER

M-12-8 pin, A code, M

Unclassi ed area

F

PR-8430-___

Platform 4 cable

M12-8 pin, A-code, F+M Ethernet, mA, 24V

90m (295ft)	max. 90m (295ft)	M
PR-43		PR-8660
REFRACTOMETER		Platform 4 cable extender
M-12-8 pin, A code, M		M12-8 pin, A-code, F+M

	Unclassi ed area	PR-8430-___	PR-8430-___
	F
		Platform 4 cable	Platform 4 cable
		M12-8 pin, A-code, F+M	M12-8 pin, A-code, F+M
		Ethernet, mA, 24V	Ethernet, mA, 24V

180m (590ft)

max. 90m (295ft)

M

F

max. 90m (295ft)

M

Figure 7 Wiring options with both analogue and digital outputs and RJ45 ethernet connector

14

Chapter 3 – Installation

Figure 8 Connections in M12 and RJ-45 connectors

In split cables the power cable and the mA output cable are marked near the end of the cable. Power cable:

•White: +24DC

•Brown: GND

mA output cable:

•White: mA+

•Brown: mA-

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4. Prism wash

Prism wash requires a system for wash control and diagnostics. This can be achieved with Multichannel user interface (MI) with a relay module.

4.1 Prism coating

Deposit build-up on the prism surface disturbs the measurement. Anabnormally high concentration reading, an upward concentration (CONC) drift, decreased QF value or increased LED value may indicate coating.

In most applications the prism will keep clean due to the self-cleaning e‹ect. If coating occurs, check the following:

•Suˆcient flow velocity

•A temperature di‹erence between the process fluid and refractometer probe may cause coating. This may happen with small flows if the thermal insulation is inadequate. In some cases it helps to also insulate the clamp connector.

In case of a coating problem, the preferred solution is to try to increase the flow velocity, for example, by installing a pipe portion with smaller diameter.

Installing a wash nozzle can be considered, if increasing the velocity does not provide a solution. For more information, see Prism wash (page 16).

4.2 Prism wash

Three alternative wash media can be used for prism wash:

•Steam

•Water

•High pressure water

Relay modules in a Multichannel user interface MI can be configured to control the prism wash cycle, see MI manual, Chapter 6, "Module cards" and Chapter 7, "Prism wash".

CAUTION! Important: In food industry applications, wash medium must be culinary steam or safe water. Shut-o‹ valve and check valve must meet 3-A sanitary standards.

Culinary steam: Means steam produced using a system meeting criteria in the 3-A Accepted Practices for a Method of Producing Steam of a Culinary Quality, Number 609.

Safe Water: Means water from a supply properly located, protected, and operated, and shall be of safe, sanitary quality. The water shall meet the standards prescribed in the National Primary Drinking Water Regulation of the Environmental Protection Agency (EPA) as referenced in The Code of Federal Regulations (CFR), Title 40, Parts 141, 142, and 143.

16

Chapter 4 – Prism wash

4.2.1 Recommended wash pressures and times

The following tables provide the recommended wash pressures and times.

Table 3 Wash medium parameters for integral wash nozzles in PR-43-AP

	Minimum above	Maximum above	Wash	Recover	Interval
	process pressure	process pressure	time	y
Steam (SN)	2 bar (30 psi)	4 bar (60 psi)	3 s	20 30 s	20 30
					min
Water (WN)	2 bar (30 psi)	4 bar (60 psi)	10 s	20 30 s	10 20 m
					in
High pressure water	15 bar (220 psi)	40 bar (600 psi)	10 s	20 30 s	10 20 m
(WP)					in
Table 4 Wash medium parameters for flowcell wash nozzle AFC
	Minimum above	Maximum above	Wash	Recover	Interval
	process pressure	process pressure	time	y
Steam (SN)	3 bar (45 psi)	6 bar (90 psi)	3 5 s	20 30 s	20 30
					min
Water (WN)	3 bar (45 psi)	6 bar (90 psi)	10 15 s	20 30 s	10 20 m
					in
High pressure water	25 bar (350 psi)	35 bar (500 psi)	10 15 s	20 30 s	10 20 m
(WP)					in

CAUTION! 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.

In water wash, water temperature should be above the process temperature.

The check valve pressure drop is 0.7 bar (10 psi).

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4.2.2 Prism wash systems

WARNING! In high pressure wash systems, pressure increase can occur in a closed pipe section when the high pressure pump is operated. It is recommended to mount a pressure relief valve in the pipe section. Relief pressure should be according to pipe pressure rating.

The following figures describe the prism wash system for steam.

18

Chapter 4 – Prism wash

Figure 9 Prism wash system for steam

19