Manual PCE-A 344W Microwave Consistency Sensor

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Hortense Gaines
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1 PCE Americas Inc. 711 Commerce Way Suite 8 Jupiter FL USA From outside US: +1 Tel: (561) Fax: (561) info@pce-americas.com PCE Instruments UK Ltd. Units 12/13 Southpoint Business Park Ensign way Hampshire / Southampton United Kingdom, SO31 4RF From outside UK: +44 Tel: (0) Fax: (0) info@pce-instruments.com Manual PCE-A 344W Microwave Consistency Sensor Version 1.1 Date of creation: Date of last change:

2 Safety precautions Before making any electrical connections, ensure that the supply voltage and frequency, as well as any other voltage is applied to meet the specifications given on the label of devices and in this manual. Incorrect connection may cause damage to the device. When installing, always observe the relevant safety regulations. Before carrying out any welding work near the appliance, make sure that the appliance is disconnected from the power supply and is not energized. Do not use the device with a damaged connecting cable insulation. In the case of damage to the cable, disconnect the device from the power supply and contact the manufacturer or seller service for replacing of the cable. In case of a fault device do not attempt to disassemble and to repair the device. In this case please contact the manufacturer or the customer service dealer for repair. During the installation, maintenance and operation of the device, remember that line of concentration measurement by the device (pipe) could be with hot water - be careful! The device must be installed in such a way as to provide easy access to control belay devices.

1 Application The microwave consistency sensor PCE-A 344W determines the bulk concentration of all substances entering into the composition of the suspension.

3 1 Application The microwave consistency sensor PCE-A 344W determines the bulk concentration of all substances entering into the composition of the suspension. It is insensitive to the type of fibers, their length, composition, grinding degree, color, and flow speed. The sensor is adapted to all types of a fibrous semi-finished product. The principle of operation is based on the precise measurement of permittivity of pulp (aqueous suspension) in the microwave range of electromagnetic waves. Sensor allows accurately measure the concentration of the pulp independently of its speed, lengths of fibers, freeness brightness, color and the type of pulp and requires minimal maintenance work after the installation. The appearance of sensor is on the Pic.1. Pic.1. The microwave consistency sensor PCE-A 344W with display unit. Constructively PCE-A 344W consists of a measuring unit is installed on the pipeline, and the display unit. The measuring unit comprises a transmitter and receiver of microwave radiation, temperature and conductivity pulp sensors and microprocessor electronics module for measuring the permittivity of the pulp taking into account its temperature and conductivity, concentration calculation and transmission of the measured data to the display unit. The display unit is used for receiving data from the measuring unit, the current value of the concentration, temperature, conductivity, forming the trend of measured values and current output signals, as well as adjusting coefficients for input. A compound of the measuring unit and the display unit provided cable comprising four twisted pairs.

4 2 Technical specifications Measurement range of consistency 0-8% Repeatability 0.02% Process temperature C Ambient temperature C Pipeline diameter 150 mm Pipeline pressure kpa Current output 4-20 ma Communication RS-232, RS-485 Pressure min. 1,5 bar Pressure max 10.0 bar Medium conductivity max mcm/cm the IP Code (International Protection IP 65 Rating) of the control panel and power supply unit Supply voltage of the control panel and VAC power supply unit max input current of the control panel 0.7A and power supply unit frequency range of the control panel 50-60Hz and power supply unit overvoltage category II the IP Code (International Protection IP 54 Rating) of the sensor supply voltage of the sensor unit 24VDC input current of the sensor unit 0.1A Attention! Specifications of consistency sensor is provided if the air content in mass not more than 1 % and the pressure in the measuring region setting unit is not less than 150 kpa. 3 Installation Measuring unit of consistency sensor is installed on a vertical or near-vertical pipe with DN 150 mm. The installation of the measuring unit on a horizontal pipeline is allowed after consultation with specialists of the company that manufactures consistency sensor. The measuring unit is installed in a pipeline as a part of pipeline and fastened thereto by tightening studs between standard flanges with rubber gaskets (Pic.2).

Pic. 2. Installation of measuring unit. Before installing the measuring unit is necessary to make the insertion into the pipeline. Appearance insert and method of attachment is on the Pic.3 Рic. 3.

Particular attention when welding pipe flanges should be paid to the alignment of fixing holes in the top and bottom flanges (tightening rods must be parallel to the tube stock lines as shown in Pic.

5 Pic. 2. Installation of measuring unit. Before installing the measuring unit is necessary to make the insertion into the pipeline. Appearance insert and method of attachment is on the Pic.3 Рic. 3. Method of attachment Appendix 1 shows drawings for manufacture of the insert. Particular attention when welding pipe flanges should be paid to the alignment of fixing holes in the top and bottom flanges (tightening rods must be parallel to the tube stock lines as shown in Pic.3). Before and after the installation place there must be a straight pipe with DN 150 mm and length not less than 200 mm. After the straight pipe with consistency sensor the additional manual valve must be installed to create a pressure in the pressure sensor at least 150 kpa at maximum machine performance. To control the pressure in the sensor area is necessary to install a manometer with a separation membrane.

6 In case of installation of the sensor with another DN of pipeline it is necessary to make reducers not less than 200 mm. The display unit is set in a convenient location for observation at a distance of 200 m from the measuring unit. Connection diagram in Appendix 2. The indication block is connected to the power supply VAC 50/60 Hz by the isolated cable of 3*0,75 size. Cable is put into the distribution cabinet, where is connected to the power supply through a circuit breaker (2A) and the power switch. 4 Controls After powering up and automatically download of the work program panel, the screen displays the current values of consistency, temperature and conductivity of the pulp. To view the trends of each measured values on the screen need to press the button "Consistency", "Temperature" or "Conductivity". To view the trend of the concentration need to press button on the panel "Consistency " and trend for the last 20 minutes of the sensor s work appears on the screen. To view the trend for other time intervals, you can use the arrows located below the graph. By clicking on the trend can obtain a digital value of the concentration at this time, which is displayed in the window on the left below the graph. It is possible to change scale of the trend. To change the maximum values must click on the maximum figure in the upper left corner of the graph, on the appeared numeric keypad enter a new maximum. The operation is completed by pressing the «ENT» on the numeric keypad. Similarly, you can change the minimum value of the trend by clicking on the minimum figure in the lower left corner of the graph. To view the trends of temperature and conductivity is possible in the same way as on the concentration. Button "Parameters" displays information about the work of sensor and has an auxiliary character. Button Settings is for correction of reading and scaling of the current output. 5 Input mode of corrections on concentration In this mode, the user is able to specify the calibration coefficients of the measuring sensor unit, if the characteristics of the pulp on this production do not correspond to the standard used for calibration of the sensor by the manufacturer. Possible difference between the readings and laboratory data may be due to the fact that the microwave sensor in its physical principle measures the volume concentration, and laboratory measurements give the weight concentration. Due to the free-air weight in the pulp results of volume concentration increase without affecting the weight, which leads to an overestimation of readings relative to

7 the laboratory data. On the other hand, when the paper manufacturing with a large percentage of mineral fillers, the proportion of which is 2-3 times higher than that of pulp can be observed under-readings compared with the results of laboratory analysis. For corrections two parameters used gain and offset. Typical values of these parameters after calibration by the manufacturer are: gain , offset After installation of sensor in pipeline performed laboratory measurements of concentration are Clab and at the time of sampling sensor readings recorded Csens. The gain is determined by the formula gain=сlab/сsens and input to the device in the Settings. The offset correction is carried out at constant (additive) difference readings from laboratory data. Increasing of offset leads to increasing of readings and conversely. The correction is carried out as follows: press button Settings, after pressing figure gain the numeric keypad appears used for enter new value of gain. To finish the operation press ENT on numeric keypad and Save on panel. Correct the offset analogously. 6 Setting current output The lower and upper limits of the current output on the concentration may be set programmatically. To install the current output limits must act by analogy with the input of correction coefficients described in Section 5. 7 Service Sensor does not require special maintenance. Periodically, at least 1 time per year, measuring unit should be removed from the pipeline and inspected inside. Upon detection of gummy deposits in the internal cavity of the measuring unit must carefully wash their by cloth moistened with an organic solvent. 8 Storage and transportation Consistency sensors should be stored on shelves in closed storage rooms at a temperature of -10 º C to +40 º C and relative humidity up to 80%. Consistency sensors transported packed in shipping containers, in closed vehicles under the following conditions: - ambient temperature from 25ºС to +50ºС;

8 - ambient relative humidity up to (95± 3)% at temperature 35ºС 9 Lifting and carrying Before lifting and carrying of device be sure it s disconnected from the power supply. The sensor and indication block (hereinafter components) carried separately manually. The connection cable between them must be disconnected. While transport device (its components) use procedure provided for lifting. Take it by lower edge of the side of the device. Do not use the connecting cable for device lifting. For carrying or transporting a special truck with a load capacity and dimensions according to these characteristics of the device described in this manual can be used. 10 Warranty The manufacturer guarantees compliance sensor passport characteristics if the consumer observes transport, storage, installation and operation rules. Warranty is 12 month from beginning of operation. The manufacturer is not responsible for warranty in the following cases: - malfunction due to improper transportation, installation, operation, and repair or modify by persons not authorized by the manufacturer to carry out such work; - mechanical damage in violation of the completeness and replacing parts without the permission of the manufacturer; Warranty questions and service: PCE Americas Inc. 711 Commerce Way Suite 8 Jupiter FL USA From outside US: +1 Tel: (561) Fax: (561) PCE Instruments UK Ltd. Units 12/13 Southpoint Business Park Ensign way Hampshire / Southampton United Kingdom, SO31 4RF From outside UK: +44 Tel: (0) Fax: (0)

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