Manul de Usuatio BTG TCR-25XX TCT-25X1 RET-25X2

USER MANUAL

TCR-25X1 / TCR-25X2 / TCT-25X1 / RET-25X2 Total Consistency Transmitter

Disclaimer The contents of this document are subject to revision without notice due to continued progress in methodology, design, and manufacturing. manufacturing. BTG shall have no liability for any error or damages of any kind resulting from the use of this document. © BTG 2011. Original Instructions

BTG Instruments AB P.O. Box B ox 602 SE-661 29 Säffle Sweden Phone: +46 533 426 00 www.btg.com

Disclaimer The contents of this document are subject to revision without notice due to continued progress in methodology, design, and manufacturing. manufacturing. BTG shall have no liability for any error or damages of any kind resulting from the use of this document. © BTG 2011. Original Instructions

BTG Instruments AB P.O. Box B ox 602 SE-661 29 Säffle Sweden Phone: +46 533 426 00 www.btg.com

Table of contents c ontents Important Information Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1

Prod Produc uctt Int Intro rodu duct ctio ion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1.1 1.2 1.3 1.4 1.5

2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Type Plate Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 CE Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12

Inst Instal alla lati tion on Inst Instru ruct ctio ions ns . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 2.4.1 2. 2.4. 4.1. 1.1 1 2.5 2.5.1 2. 2.5. 5.1. 1.1 1 2. 2.5. 5.1. 1.2 2 2. 2.5. 5.1. 1.3 3 2. 2.5. 5.1. 1.4 4 2. 2.5. 5.1. 1.5 5 2.5.1.6

M2072/3en

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 Unpacking, Sluice Valve Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Unpacking, Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 15 Welding Instructions, Sluice Valve Variant. . . . . . . . . . . . . . . . . . . . . . . 15 Welding Instructions, Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . 17 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 Sensor Electronics Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Measuring Gap Angle Adjustment, Sluice Valve Variant . . . . . . . . . . . . 20 Mounting the Probe, Sluice Valve Variant . . . . . . . . . . . . . . . . . . . . . . . 22 Mounting the Probe, Weld-in Stud Variant. . . . . . . . . . . . . . . . . . . . . . . 24 Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 25 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Conn Connec ecti tion on of Comm Commun unic icat atio ion n Pla Platfo tform. rm. . . . . . . . . . . . . . . . . . . . . . . . . 25 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 26 PCD-1000 Probe Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Dime Dimens nsio ions ns an and d Ins Insta tallllat ation ion Clea Cleara ranc nces es . . . . . . . . . . . . . . . . . . . . . . . . 26 Meas Me asur urin ing g Gap Gap an angl gle e Adj Adjus ustm tmen entt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Weld We ldin ing g and and Mo Moun unti ting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Elec Electri trica call Con Conne nect ctio ions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Wate Wa terr Con Conne nect ctio ions. ns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Table of contents

I

3

Serv Se rvic ice e Ins Instr truc ucti tion ons s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.1 3.1.1 3.2 3.2.1 3. 3.2. 2.1. 1.1 1 3. 3.2. 2.1. 1.2 2 3.2.2 3.2.3 3. 3.2. 2.3. 3.1 1 3. 3.2. 2.3. 3.2 2 3. 3.2. 2.3. 3.3 3 3.2.4 3. 3.2. 2.4. 4.1 1 3.2.5 3.3

4

Part Pa rts s lis listt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4.1 4.2 4.2.1

II

Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 35 Regular Maintenance of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 35 Service Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 36 Removing the Transmitter from the Pipe . . . . . . . . . . . . . . . . . . . . . . . . 36 Slui Sluice ce Va Valv lve e Var Varia iant. nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Weld We ld-in -in Stud Stud Va Vari rian antt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Changing O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Changing Probe with Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Disa Disass ssem embl blin ing g the the Prob Probe e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Asse Assemb mbliling ng the the Pro Probe be . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 LED LE D Int Inten ensi sity ty Ad Adju just stme ment. nt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Removing the Electronics Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Asse Assemb mbliling ng the the Sen Senso sorr Ele Elect ctro roni nics cs Bo Box x . . . . . . . . . . . . . . . . . . . . . . . . 44 Reinstalling the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 46

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 49 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 50 PCD-1000 Probe Cleaning Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Table of contents

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Important Information

Important Information This user manual contains all necessary instructions for installation, maintenance, and basic service of the transmitter. Safety instructions and regulations for installation and service are found in the BTG Safety Manual, M2076.

NOTE! Always read the safety instructions before installation and service of the transmitter! The transmitter is operated using the CPM communication platform. For operation instructions, see the CPM operation manual, OM2006 for TCR, OM2009 for TCT. Commissioning instructions are found in the transmitter specific chapter of the CPM operation manual.

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TCR 2501 / TCR 2502 / TCT 2501 / RET 2502

1

Important Information

2

TCR 2501 / TCR 2502 / TCT 2501 / RET 2502

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1.1 - General

1

Product Introduction 1.1 General TCR The TCR PeakTotal is a true total consistency transmitter, it is thus virtually insensitive to variations in filler and fines content as well as changes in fiber properties. TCR is available in versions with one output (TCR-25x1) and with two outputs (TCR-25x2). The second output can for example be calibrated for ash. Based on BTG’s patented Peak method for optical analysis PeakTotal covers total consistencies in the range of 0.5 to 10%. The transmitter is mounted in-line close after the pump and provides real time results. The PeakTotal is available in a retractable standard version (TCR-250x) and a light version (TCR-251x) to use when retraction system is not needed which combines lean design with top functionality and quick ROI. The probe is unique low-maintenance probe, without electronic components attached which makes the transmitter insensitive to variations in temperature and vibration.

Fig

1 TCR-251x

Fig

2 TCR-250x

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TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Product Introduction

3

1.1 - General

TCT-2501 BTG's TCT-2501 PeakOne is an in-line transmitter for measuring total consistency of pulp suspensions in the range 0.01-3%. It measures the large and fine particles individually and can because of that deliver an accurate total consistency value independently of variation in fiber, fines or ash. The pulp brightness or color does not affect the measurement. The transmitter is mounted in-line without any special bypass arrangement and provides real time results. The PeakOne is available in a retractable standard version (TCT-2501) and a light version to use when retraction system is not needed (TCT-2511) which combines lean design with top functionality and quick ROI. The PeakOne has a unique low-maintenance probe, without electronic components attached which makes the transmitter insensitive to variations in temperature and vibration.

Fig

3 TCT-2501

Fig

4 TCT-2511

4


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1.1 - General

RET-2502 BTG's RET-2502 PeakTwo is an in-line transmitter for measuring ash and total consistency of pulp suspensions in the range 0.01-3%. It can easily be calibrated to secure stable and accurate ash consistency based on laboratory ash determination. Ash and total consistency values are independent of variation in pulp brightness or color. The transmitter is mounted in-line without any special bypass arrangement and provides real time results. The PeakTwo is available in a retractable standard version (RET-2502) and a light version to use when retraction system is not needed (RET-2512) which combines lean design with top functionality and quick ROI. The PeakTwo has a unique low-maintenance probe, without electronic components attached which makes the transmitter insensitive to variations in temperature and vibration.

Fig

5 RET-2502

Fig

6 RET-2512

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5

1.2 - Technical Data

1.2 Technical Data General Type In-line smart optical total consistency transmitter for pulp suspension. Manufacturer BTG, Säffle, Sweden Measuring Principle Peak Method using 880 nm light. For TCR performed by reflection. For TCT/RET performed by transmission. Quality Assurance Quality-assured in accordance with ISO 9001. Designed in accordance with relevant CE standards. Product Safety According to IEC 61010. Fulfills all relevant electrical product safety requirements and is labelled and listed for: European CE, Australian , US/Canada ETL (Edison Technical Laboratories).

Function Specifications Output Signal Total consistency in %, mg/l, or g/l Ash consistency in %, mg/l, or g/l (TCR-25x2 and RET-25x2 only) User Interface Illuminated display and keypad on the CPM Alarm function Provides alarm signal on low and hi gh consistency level, unstable signal Calibration Sets Four separate calibration sets, individually programmable, and externally controllable using a binary-coded switch Communication Platform For information about the communication platform, including input and output signals, see separate user manual for the CPM, M2066.

6


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Process Specifications Pressure Rating PN16 (16 bar at 20°C, 230 psi at 68°F) Consistency Limits TCR-25xx: TCR-25x2

0.5 - 10 % pulp consistency 0 - 10 % ash consistency

TCT-25x1:

0.01 - 3.00 % total consistency

RET-25x2:

0.01 - 3.00 % total consistency 0.01 - 2.00 % ash consistency

Flow Limits TCR: TCT / RET:

1.3 - 5 m/s 1.5 - 5 m/s

Process Temperature Limits Max. 120 °C [248 °F] Min. 5 °C [16 °F] Ambient Temperature Limits Probe Max. 80 °C [176 °F] Electronics: Max. 50 °C [122 °F] Damping 0 - 99 s

Support System Specifications Supply Voltage 100-240 ±10% V AC, 50/60 Hz, Single phase to CPM Supplied with 24 V DC from the CPM Power Consumption Max 50 VA, a 2A slow blow fuse must be used

Performance Specifications Repeatability ±0.002 %Cs

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7


Physical Specifications Mounting Min. pipe diameter:

100 mm [4"] (TCR-250x / TCT-25x1 / RET-25x2) 80 mm [3.2”] (TCR-251x)

Materials Wetted parts: Stainless steel, EN 1.4404, equiv. to ASTM 316L Sensor electronics box: Painted aluminum Degree of Protection Equivalent to IP65, NEMA 4x Connection Optical connection between probe and sensor electronics box, 5 m [16 ft]. Weight Transmitter, TCR-250x: 3.1 kg [6.8 lb] Transmitter, TCR-251x: 1.0 kg [2.2 lb] Transmitter, TCT-2501: Transmitter, TCT-2511:

3.4 kg [7.5 lb] 1.3 kg [2.9 lb]

Transmitter, RET-2502: Transmitter, RET-2512:

3.4 kg [7.5 lb] 1.3 kg [2.9 lb]

Sluice valve: Sensor electronics box:

4.0 kg [8.9 lb] 0.3 kg [0.7 lb]

LED product Class 1 According to IEC/EN 60825-1 Wavelength: 880 nm (invisible light)

8


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1.3 - Dimensions and Mounting

1.3 Dimensions and Mounting Fig

7 Dimensions and clearances Transmitter, sluice valve variant

Transmitter, weld-in stud variant

Min 300 12"

338 13.3"

100 4"

" 5 1 . 5 1 6

300 12"

0 " 0 8 2

Min Ø100 4" Min Ø100 / 4" (TCT / RET) Min Ø80 / 3.2" (TCR) Ø50 2"

8 " 0 3 . 1 4

Ø46 1.8" " 0 5 . 9 3

0 " 5 0 2 1

Sensor electronics box

52 2"

Ø4.5 0.2" Ø9 0.4"

6 " 2 5 1

19 0.7"

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114 4.6"

23 0.9"

5 " 2 1

" 0 5 . 9 3

101.5 4"

13 0.5" 0 " 5 0 2 1


9

1.4 - Type Plate Explanations

1.4 Type Plate Explanations Fig

8 Type sign

1

2

BTG Instruments AB Industrigatan 1-3 66129 Säffle SWEDEN

3

TYPE

4 5

NO

TCT-2501/SS/EP/15/5 12345678

LED PRODUCT

Class 1 6

1. Manufacturer 2. Warning sign The device is designed for industrial use. Installation, handling and service must only be carried out by trained and authorized personnel and according to relevant standards. Read the manual for detailed information and pay special attention to the warning signs!

3. Transmitter Model and Variants The transmitter model and variant is specified according to the code system explained below:

TCT-2501/SS/EP/15/5 A

BC D

E

F G

A

Transmitter Model TCR-25

B

TCT-25 Mounting variant

0

Sluice valve variant



1

Weld-in stud variant



C

Output signals

1

One output

One output

N/A

2

Two outputs

N/A

Two outputs

D SS

Wetted Part Material Stainless Steel, EN 1.4404

E EP

Stainless Steel, EN 1.4404

Stainless Steel, EN 1.4404

Rubber Material EPDM

F

EPDM

EPDM

Measuring Gap Size

15

N/A

Gap size 1.5 mm

Gap size 1.5 mm

30

N/A

Gap size 3.0 mm

Gap size 3.0 mm

G 5

10

RET-25

Fiber length Standard length, 5 meter

Standard length, 5 meter

Standard length, 5 meter


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1.4 - Type Plate Explanations

4. Manufacturing number BTG internal product identification number.

5. LED Product Class Only applicable for transmitter type TCR-25xx.

6. CE-marking The Transmitter is approved according to CE directives.

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11

1.5 - CE Declaration

1.5 CE Declaration When using the units in other combinations than those tested for, BTG can not guarantee CE directive conformity. The units in combination with customer-installed external devices may conform with EMC and safety requirements when properly installed and CE-marked equipment is used.

The system operator is responsible for CE directive conformity. Conformity must be verified by inspection.

CE Declaration of Conformity According to EN 17050-1:2005 BTG Instrumen ts AB P.O. Box 602 S- 661 29 SÄFFLE, Sweden

Manufacturer’s Name Manufacturer’s Address

declares that the product: Product Name Model Number

Total Consistency Transmitter TCR-2501/-2511 alt. with FCM-8000/FCI-1000/HCM-8000 modules TCR-2502/-2512 alt. with FCM-8000/FCI-1000/HCM-8010 modules TCT-2501/-2511 alt. with FCM-8000/FCI-1000/HCM-8000 modules RET-2502/-2512 alt. with FCM-8000/FCI-1000/HCM-8010 modules

complies with the amendments and requirements of the:

Low Voltage D irective 2006/95/EC EMC Directive 2 004/108/EC PED Directive 97/23/EC RoHS 2 002/95/EC WEEE 2 002/96/EC

and c onforms with the following product standards and PED conformity assessment proce dure Safety

EN ISO 12100-1

LVD

EN 61010-1- 2nd ed.

EMC

EN 61000-6-2: 99/ EN 61000-6-4: 04

PED

Pressure equipment for piping.

In accordance to Article 1, Table 9, art.3 (3), Annex II (Sound eng. practise) Must not bear CE-marking

Sluice valve device acc. to ASME

CSA/CRN 0C11058.5

WEEE RoHS Quality System

-n.a.-, not Annex 1 compatible ISO 9001 monitored by Lloyd’s Register Quality Assurance

Säffle, September 2010

Björn Fahlin, DoO

12


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2.1 - Unpacking

2

Installation Instructions 2.1 Unpacking 2.1.1

Fig

Unpacking, Sluice Valve Variant

9 Unpacking, sluice valve variant 1 1 x Measuring probe 2 1 x Sensor electronics box 3 1 x Sluice valve 4 1 x Communication Platform, CPM 5 1 x Blind flange (optional) 6 1 x PCD-1000 probe cleaning system (optional, with probe pre-mounted) 7 1 x User Manual CD (not shown) 8 1 x BTG Software installation CD (optional, not shown) 9 1 x Communication cable (optional, not shown)

1

2

3 4

5

6

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TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Installation Instructions

13

2.1 - Unpacking

2.1.2

Unpacking, Weld-in Stud Variant

Fig 10 Unpacking, weld-in stud variant 1 1 x Measuring probe 2 1 x Sensor electronics box 3 1 x Weld-in stud 4 1 x Coupling 5 1 x O-ring 6 1 x Blind flange 7 Communication Platform, CPM 8 1 x User Manual (not shown) 9 1 x BTG CalWin installation CD (optional, not shown) 10 1 x Communication cable (optional, not shown)

6

2

5 4

3

1

7

14


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2.2 - Welding Instructions

2.2 Welding Instructions 2.2.1

Welding Instructions, Sluice Valve Variant

Tools required: Block wrench, 13 mm 4 x braces (supplied by customer)

DANGER

1

2

3

CHECK PIPES! Risk for corrosive, toxic, or aggressive liquids or gases with high pressure or high temperature.

D=45 mm (1.8")

DANGER Use protective clothing

4

5

6

7

60 mm (2.4")

60 mm (2.4")

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15


8

9

10

X=60mm

X=60mm

Y

Y Y=X

11

Y=X

12

NOTE! Remove any welding and grinding beard inside the pipe,to reduce the risk of pulp stuck.

13

14

16

15


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2.2.2

Welding Instructions, Weld-in Stud Variant

Tools required: Torque wrench, 10 mm

DANGER

1

2

3


D=40 mm (1.6")


4

5

60 mm (2.4")

60 mm (2.4")

6

7

8

X=60mm

NOTE! Remove any welding and grinding beard inside the pipe,to reduce the risk of pulp stuck. Y Y=X

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17


9

10

11

10 Nm

18


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2.3 - Mounting Instructions

2.3 Mounting Instructions 2.3.1

Sensor Electronics Box

Tools required: Screwdriver Mount the electronics box to a none vibrating position, such as a wall or pole, by fastening the wall bracket to a flat surface. Use four suitable screws.

Fig 11 Recommended clearances

5 " 2 1

0 " 5 0 2 1

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19


2.3.2

Measuring Gap Angle Adjustment, Sluice Valve Variant

Tools required: Allen key, 4 mm, 5 mm

NOTE! The red spot on the protractor indicates the position of the measuring gap.

1

2

Normal pulp: The probe measuring gap must have a 45° angle from the pulp flow. If the pulp flow corresponds to arrow A or B, the angle must be adjusted. Unscreened pulp: The probe measuring gap must have a 135° angle from the pulp flow. If the pulp flow corresponds to arrow C or D, the angle must be adjusted.

A

D

B

C

3

180° DANGER High pressure in the equipment

DANGER! The transmitter must always be removed from the pipe when the angle is adjusted.

4

5

180°

20


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6

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21


2.3.3

Mounting the Probe, Sluice Valve Variant

NOTE! If the pipe pressure is higher than 5 bar (72 psi), we recommend that the pipe is depressurized during mounting of the probe into the sluice valve.

Tools required: Small brush Block wrench, 17 mm Socket wrench, 19 mm Allen key, 4 mm

Consumables required: Lubricant for O-rings (use MOLYKOTE 111 or equivalent for EPDM O-rings)

DANGER

1

2

Use protective clothing

4

3

A B

C

22


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WARNING

5

6

7

8

9

Equipment damage

WARNING! Avoid bending the fiber cable while mounting the back cover.

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23


2.3.4

Mounting the Probe, Weld-in Stud Variant


DANGER

1

2

3

4


WARNING Equipment damage

WARNING! Avoid bending the fiber cable while mounting the transmitter.

A

NOTE! The asterisk on the protractor indicates the position of the measuring gap.

135°

Normal pulp: The probe measuring gap must have a 45° angle from the pulp flow as shown in step 4, figure A. Unscreened pulp: The probe measuring gap must have a 135° angle from the pulp flow as shown in step 4, figure B.

24

B

45°

5

10 Nm


M2072/3en

2.4 - Connection Instructions

2.4 Connection Instructions 2.4.1

Electrical Connections

2.4.1.1

Connection of Communication Platform


WARNING! The power to the communication platform must be turned off when connecting the communication platform to the sensor electronics box.

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25

2.5 - Optional Accessories

2.5 Optional Accessories 2.5.1

PCD-1000 Probe Cleaning System

NOTE! These instructions are only valid for installation of the PCD-1000 with TCT-2501 or RET-2502 probe pre-mounted.

2.5.1.1

Dimensions and Installation Clearances

Fig 12 PCD-1000 Dimensions and clearances

700 28"

Min 300 12"

0 " 4 5 . 1 5

0 " 5 2 5 2

Min Ø100 4"

1 " 5 2

3 " 3 3 . 1 5

26


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2.5.1.2

Measuring Gap angle Adjustment

Tools required: Allen key, 4 mm Block wrench, 10mm, 16 mm

NOTE! The screw on the protective sleeve indicates the position of the measuring gap.

1

A

The probe measuring gap must have a 45° angle from the pulp flow. If the pulp flow corresponds to arrow B or C, the angle must be adjusted.

D

B

C

2

180°

3

4

180°

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27


5

6

7

8

180°

9

28

10


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2.5.1.3

Welding and Mounting

Tools required: Block wrench, 13 mm, 16 mm

DANGER

1

2

3


D=45 mm (1.8")


4

5

6

7

60 mm (2.4")

60 mm (2.4")

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29


8

9

10

X=60mm

X=60mm

Y

Y Y=X

11

Y=X

12

13

14

30


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15

16

0 " 5 2 5 2

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17

18

19

20


31


2.5.1.4

Electrical Connections

Tools required: Small screwdriver

1

DANGER

3

2

PCD-1000

Hazardous voltage in the equipment

M 1 O D O C N D + G

CPM

V 4 2 +

HCM

P1 P2 P3

P1

DO + -

+ +

-

-

100-240 V AC

PE N

L

S

S = Shield connected to cable gland

3

NOTE! For FCM connection, a jumper must be connected between DO1 and +COM as shown in figure.

2 x 2 x 0.75 mm2 (2 x 2 x AWG18)

PCD-1000 M 1 O D O C N D + G

CPM

V 4 2 +

FCM

P1 P2 P3

P1

DO + -

+ +

-

-

100-240 V AC

PE N

L

S

S = Shield connected to cable gland

32

1 x 2 x 0.75 mm2 (1 x 2 x AWG18)


M2072/3en


2.5.1.5

Water Connections

Water inlet

Water outlet

3-6 bar (45-90 psi)

D=8.5 mm [0.33"]

2.5.1.6

D=17.2 mm [0.68"]

Air Connections

Air Connection Hose: Ø6-4

4-8 bar (58-100 psi) or at least half the process pressure

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33


34


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3.1 - Maintenance Recommendations

3

Service Instructions 3.1 Maintenance Recommendations 3.1.1

Regular Maintenance of the Transmitter

Maintenance needs will depend on the transmitter position, media influence, and ambient conditions.

Regular maintenance includes: •

Quarterly inspection of rubber seals in contact with media containing high concentration of chemicals (black liquor, chlorine etc.) to prevent leakage.

•

Semi-annual inspection inside the cover for possible leakage.

Long-term maintenance includes: •

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Replacement of media exposed rubber seals typically after 3-5 years operation.

TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Service Instructions

35

3.2 - Service Actions

3.2 Service Actions 3.2.1

Removing the Transmitter from the Pipe

3.2.1.1

Sluice Valve Variant

NOTE! If the pipe pressure is higher than 5 bar (72 psi), we recommend that the pipe is depressurized before removal of the probe from the sluice valve.

Tools required: Allen key, 4 mm Block wrench, 17 mm Socket wrench, 19 mm

DANGER

1

2

3

4

Use protective clothing

36


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5

6

C B

WARNING! Avoid bending the fiber cable while removing the transmitter.

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A


37


3.2.1.2

Weld-in Stud Variant


DANGER

1

2

3

4




WARNING! Avoid bending the fiber cable while removing the transmitter.

5

10 Nm

38


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3.2.2

Changing O-rings

Consumables required: Lubricant for O-rings (use MOLYKOTE 111 or equivalent for EPDM O-rings)

Parts required: Sluice valve variant: O-ring ∅37.47x5.34, 27014018 O-ring ∅36.2x3, 27014000 Weld-in stud variant: O-ring ∅39.2x3, 27003060 All O-rings that need to be changed on a regular basis are shown in fig 14 below.

Fig 13 O-rings, sluice valve variant 1 O-ring 2 O-ring

∅37.47x5.34 ∅36.2x3

1

2

Fig 14 O-ring, weld-in stud variant 3 O-ring

∅39.2x3

3

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39


3.2.3

Changing Probe with Electronics

NOTE! The disassembling and assembling instructions in section 3.2.3.1 and section 3.2.3.1 are only relevant for sluice valve variant transmitters. A LED intensity adjustment, as described in section 3.2.3.3, must however be performed for all transmitter variants when changing the probe.

3.2.3.1

Disassembling the Probe

Tools required: Allen key, 4 mm

NOTE! Make a note of the angle of the probe measuring gap in relation to the flow before disassembling the probe. The angle is indicated by the red spot at the protractor, at the back of the probe.

1

WARNING

2

Equipment damage

WARNING! Avoid bending the fiber cable while disassembling the probe.

40


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3.2.3.2

Assembling the Probe

Tools required: Allen key, 4 mm

1

NOTE! The angle of the probe measuring gap in relation to the flow must be set according to the notes made during disassembling.

2

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41


3.2.3.3

LED Intensity Adjustment

After the change is performed, a LED intensity adjustment must be carried out before the transmitter can be put back into operation. The procedure for the adjustment varies depending on the type of transmitter. See the CPM operation manual for additional instructions on how to access the parameters mentioned below.

TCR-25xx 1. Reinstall the transmitter to the pipe according to appropriate instructions in section 2: Installation Instructions, and admit pulp to the line. 2. Connect the CPM to the transmitter and power up the transmitter. 3. On the CPM display, access the sensor configuration menu. 4. If you want to use the present calibration, perform the following: a. Access the LED intensity parameter view. b. Compare the displayed TCons value on the display with the actual consistency of the pulp in the line c. Increase the LED intensity parameter value by approximately 2 percentage units if the TCons value is too low, or decrease if the TCons value is too high. d. Repeat this procedure until the TCons value is equal to the actual consistency of the pulp in the line. 5. If you want to make a new calibration, perform the following: a. Change the value of parameter Adj. LED int. to 1. An automatic LED intensity adjustment will be started. This will adjust the LED intensity parameter to an appropriate value for the present pulp conditions. b. On the CPM display, access the calibration menu and perform a new calibration.

TCT-25x1 / RET-25x2 1. Connect the CPM to the transmitter and power up the transmitter. 2. Place the probe in a bucket with water of drinking quality (the probe tip must be held at least 10 cm [4”] from the wall and bottom of the bucket) 3. On the CPM display, access the sensor configuration menu. 4. Change the value of parameter Adj. LED int. to 1. An automatic LED intensity adjustment will be started. This will adjust the LED intensity parameter to a value where the signal in clear water (CW) is as close to 100% as possible. 5. Reinstall the transmitter to the pipe according to appropriate instructions in section 2: Installation Instructions, and admit pulp to the line.

42


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3.2.4

Removing the Electronics Card

NOTE! The electronics card should only be removed for trouble shooting purposes when referred from section 3.3: Troubleshooting .

Tools required: Small screwdriver Torx driver, T-10

WARNING

1

2

3

4

5

6

Equipment damage

WARNING! Avoid bending the fiber cable while removing the electronics card.

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43


3.2.4.1

Assembling the Sensor Electronics Box

Tools required: Torx driver, T-10

WARNING

1

Equipment damage

WARNING! Avoid bending the fiber cable while mounting the electronics card.

2

44

3


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3.2.5

Reinstalling the Transmitter

For mounting instructions and connection instructions, see section 2: Installation Instructions .

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45

3.3 - Troubleshooting

3.3 Troubleshooting Symptom

Probable Cause

Solution

1. No or incorrect output signal

1.1. Basic check

Make sure that the process is working as usual and pulp is flowing in the pipe. Make sure that power is supplied to the communication platform.

1.2. Electrical error

Remove the electronics card from the sensor electronics box according to section 3.2.4: Removing the Electronics Card . Check that the LED labeled +24V on the electronics card (see fig 15) is permanently lit. If LED +24V is off, check the wiring between the sensor electronics box card and the communication platform. If that does not help, change the sensor electronics box.

1.3. Software error

Remove the electronics card from the sensor electronics box according to section 3.2.4: Removing the Electronics Card . Check that the LED labeled CPU1 on the electronics card (see fig 15) is flashing regularly. Irregular flashing from LED CPU1 indicates probable software error. Contact BTG Service for further assistance.

1.4. Communication error

Remove the electronics card from the sensor electronics box according to section 3.2.4: Removing the Electronics Card . Check that the LED labeled COM on the electronics card is flashing (see fig 15), which indicates that the communication is working. If LED COM is permanently lit, check that the system cable is correctly connected to the sensor electronics box according to section 2.4.1.1 on page 23. If LED COM is off, check the wiring between the sensor electronics box and the communication platform for breaks. If the problem still remains contact BTG Service for further assistance.

2. Incorrect consistency measurement

46

2.1. Calibration needed

Make a complete calibration of the transmitter. See the CPM Operation Manual for further instructions.

2.2. Incorrect LED intensity configuration

Access the sensor configuration menu on the CPM and perform an automatic LED intensity adjustment (requires a recalibration) or adjust the LED intensity manually. See the CPM Operation Manual for further instructions


M2072/3en


Symptom

Probable Cause

Solution

3. Output signal varies with change in flow

3.1. Wrong probe angle relative to the flow.

Turn the probe so that the measuring gap is at a 45° angle from the pulp flow. For sluice valve variant, see section 2.3.2: Measuring Gap Angle Adjustment, Sluice Valve Variant . For weld-in stud variant, see section 2.3.4: Mounting the Probe, Weld-in Stud Variant .

4. Abnormally unsteady output signal

3.2. The transmitter is not mounted according to instructions. It may be installed at a point where the pulp suspension is layered, and the layering may vary with the rate of flow.

Check the installation with reference to the recommendations in the Installation Engineering Guide. Note the length of the turbulence damping zone after the pump.

4.1. Selected time-constant for damping is too short

Increase damping until signal stabilizes. See the CPM Operation Manual for instructions.

Fig 15 Electronics card 1 LED CPU1 - Software run indicator 2 LED COM Communication indicator 3 LED CPU2 - Not used 4 LED +24V - Power indicator

4

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3

2

1


47


48


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4.1 - Spare Parts

4

Parts list 4.1 Spare Parts

1

2 7

Item No.

Rec. spare parts

3

4 8

9

Part No.

Spare Part

Description

1

1

2

1

3 4 5 6 7

1 1 1 1 1

1 1 1 1

TCR-2501, Probe with electronics TCR-2502, Probe with electronics TCT-2501, Probe with electronics RET-2502, Probe with electronics TCR-2511 Probe with electronics TCR-2512 Probe with electronics TCT-2511 Probe with electronics RET-2512 Probe with electronics O-ring ∅39.2x3 O-ring ∅37.47x5.34 Sluice valve, complete Weld-in stud, flanged type TCR-2501 Cover, complete TCR-2501 Cover, complete TCT-2502 Cover, complete RET-2502 Cover, complete O-ring ∅36.2x3 Sluice kit TCT / RET Sluice kit TCR TCR-2511 Weld-on stud, complete

EPDM EPDM AISI 316 SS steel 2343

8 9 9 10

A0115105 B0011684 A0115238 B0011569 A0113563 B0011726 A0121541 B0011734 27003060 27014018 A0004796 A0043901 A0115170 B0011700 A0115220 A0115246 27014000 A0115139 B0011577 A0114728

TCR 2501 / TCR 2502 / TCT 2501 / RET 2502 Parts list

6

10

Qty

M2072/3en

5

EPDM

49

4.2 - Accessories

4.2 Accessories

1

Item No. 1 2 3 4

50

Rec. spare parts

2

3

Qty

Part No.

Spare Part

Description

1 1 1 1

A0054460 A0112953 A0111674 X20309

Blind flange complete CPM Communication cable CPM Communication cable BTG Software

Sluice valve variant only RS-485 - USB RS-485


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4.2 - Accessories

4.2.1

14

PCD-1000 Probe Cleaning System

1 2 3 4 5 2 9

6 7 9 6 5 4 3

16

13

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Rec. spare parts *

* *

* (*)

*

M2072/3en

12

11

10

8

15

Qty

Part No.

Spare Part

Description

1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1

27012871 27016179 27014448 27014455 27014430 27016419 27014828 27017326 26004895 A0016436 A0086082 A0085209 35008358 A0043901 A0051763 A0053124 B0100545

O-ring Ø44,2x3 O-ring Ø37,47x5,34 O-ring Ø59,0x1,6 O-ring Ø74,8x1,6 O-ring Ø80,0x1,6 O-ring Ø39,0x1,6 X-ring 69,22 x 5,34 X-ring Ø24,99x3,53 Guide Cylinder end cover Guide pin Solenoid valve Diaphragm valve Weld-in stud, flanged type Connection box, complete Circuit card Sealing kit

EPDM Polyurethane Nitril Nitril Nitril Nitril Nitril Nitril


Consist of item 1-8 and Silicone grease 48001887

51

Manul de Usuatio BTG TCR-25XX TCT-25X1 RET-25X2

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