Multiple Constituent Transmitter MCT Series Installation and Operation Manual

Multiple Constituent Transmitter MCT Series Installation and Operation Manual October, 2001 Manual D Software V4.0x Process Sensors Corporation 113 C...
Author: Reynard Allen
30 downloads 0 Views 572KB Size
Multiple Constituent Transmitter MCT Series Installation and Operation Manual October, 2001 Manual D Software V4.0x

Process Sensors Corporation 113 Cedar Street, S5 Milford, MA 01757 Tel: 508-473-9901 Fax: 508-473-0715 www.processsensors.com

Table of Contents 7.2 1.0 2.0 3.0

4.0

5.0

6.0

7.0

Introduction Principle of Operation Sensor Components 3. 1 Light Source 3.2 Filter Wheel 3.3 Filter Wheel Motor 3.4 Detector 3.5 Electronics Installation 4. 1 Sitting the Sensor 4.2 Vibration 4.3 Strong Light 4.4 Temperature 4.5 Humidity & Dust-Window Air Purge 4.6 Optimum Viewing Distance 4.7 Reflections from Material Surface Power and Cable Connections 5. 1 AC Power Connections 5.2 Analog & Serial Cable Connections 5.3 Remote Displays & Operator Interfaces Operator Interfaces 6. 1 Wall Mounting Interface 6.2 Hand Held Interface 6.3 Initial Power-Up 6.4 Key Pad Set-Up Instructions-Operator Interface 7. 1 Menu Structure 7. 1. 1 Key Pad Lock 7.1.2 Display Selector 7. 1.3 Product Code Select 7. 1.4 Grab Sampling Averaging

7.3 7.4

8.0

9.0

10.0

11.0 12.0

On-Line Menu Calibration Parameters 7.4.1 Analog Output Channels 7.5 Calibration Routine 7.6 Diagnostics 7.7 Miscellaneous Gauge Calibration 8. 1 Approximate Calibration 8.2 Multi-Sample Calibration 8.3 On-Line Off Set Trim Adjustments 8.4 Linear Regression Statistics 8.5 Online Multi-Sample Statistics Accessories 9. 1 Window Air Purge Assembly 9.2 Product Loss Sensors 9.3 Network Interfaces 9.4 Cooling Panels 9.4. 1 Air Cooling 9.4.2 Water Cooling 9.5 Maintenance Alarm 9.6 Clean Window Alarm 9.7 Power Sampler 9.8 Local Display Unit (LDC) Output Signals 10. 1 Serial Communications 10. 1.1 Serial Requirements Customer Wiring Connections Maintenance 12.1 Routine Maintenance 12.1.1 Sensor Window 12.2 Self Diagnostic Warnings 12.3 Corrective Maintenance

Appendix IAppendix IIAppendix IIIAppendix IVAppendix VAppendix VIAppendix VII1

Main Menu Selections

Special Features Power Sampler Accessory Dry Basis Measurements Cal Check Standards Serial Commands PI Controller Output Outline Drawings

Warranty, Exclusions and Limitations The workmanship and the materials of all products manufactured by Process Sensors Corp. are warranted for a period of one year from the date of shipment. This warranty covers parts and labor required to correct defects within the scope of the Corporation’s warranty. Excluded from the warranty coverage are products a) which have been subjected to electrical, mechanical or other misuse or abuse b) which have been disassembled or repaired, or attempted to be, by other than PSC or its authorized servicing agents. The foregoing warranty shall be in lieu of all other warranties, expressed or implied, and the Corporation expressly disclaims any warranty for merchant ability or fitness for a particular purpose. Unless otherwise agreed in writing by the Corporation, repairs and replacement parts provided by the Corporation under its warranty shall be guaranteed only for the non expired portion of the original warranty on the repaired product. The liability of PSC to any purchaser or user of its products shall not in any case exceed the cost of correcting defects in a product as herein provided and, upon expiration of one year from the date of sale, all such liability shall terminate. In no event shall the Corporation be liable for interruption of operations, loss of profit, or special or consequential damages.

Software Updates Future revisions of the software that correct errors will be made available to customers at no charge. Improvements and enhancements to the software will be available for a nominal fee.

1.0 Introduction The MCT Series are near infrared photometric analyzers that use fixed infrared wavelengths to measure one, two or three constituents in a variety of products. The MCT is a “stand-alone” sensor with all items necessary for continuous monitoring being located in the sensor. Optional wall-mountable or hand-held operator interfaces are available for setup, calibration and maintenance.

2.0 Principle of Operation The molecular bonds O-H, C-H and N-H absorb infrared radiation at several specific wavelengths. The MCT generates these absorbance wavelengths and several other non-absorbing wavelengths using a rotating wheel containing up to 6 infrared filters. This chopped light is reflected from the surface of the product collected by optical components inside the sensor. The resultant electrical pulses from the reflected light are mathematically treated in ratio-based algorithms to compute raw measurements of the measured constituents. These raw values are then scaled by offset (zero) and sensitivity (span) factors to provide direct readings of the constituents. Compensation for aging of optical components and the variations in the reflectivity of different products is provided in the algorithm treatment of the filter reflectance values.

3.0 Sensor Components The MCT is housed in an epoxy painted cast aluminum Nema 4 housing. A rear bracket allows the sensor to be mounted, ensuring the light beam reflects from the product at all times.

3.1 Light Source A quartz-halogen light bulb running at reduced voltage generates infrared energy.

3.2 Filter Wheel Up to six infrared and visible filters are held in a circular disc. A single timing notch is machined in the edge of the disc.

3.3 Filter Wheel Motor A precision brushless DC motor is used to accurately rotate the filter disc in front of the infrared light beam.

3.4 Detector A thermoelectrically cooled PbS detector is used to convert the infrared light energy into electrical pulses. 1

3.5 Electronics The MCT contains the following electronic components: §

Power Supply, a 90-260 volt auto selection supply providing DC power to operate the sensor.

§

Main PCB, containing pre-amplifiers, detector controller, central processing system, analog and serial communications.

4.0 Installation 4. 1 Sitting the sensor The sensor is capable of operating at any orientation provided the light beam can reflect from the surface of the product.

4.2 Vibration The sensor mounting support and any items in contact with the sensor should be free from excessive vibration.

4.3 Strong Light Strong infrared light or direct sunlight should not be allowed to fall on the sensor window or erroneous reading may occur.

4.4 Temperature The sensor is designed to give satisfactory measurements within a temperature range of 32 to 120 deg. F (0 to 50 deg. C).

4.5 Humidity and Dust – Window Air Purge The head should be kept clear of excess humidity. It is important to prevent condensation on the sight window. Normal atmospheric dust will not affect the sensor reading but similar to humidity, accumulation of dust on the window will impair the sensor’s operation. The air purge attachment fitted to the sensor window requires a 1/4” (6mm) tube with a supply of clean oil free dry air at a pressure not exceeding 10 psi. at approximately 2 liters per minute.

2

4.6 Optimum Viewing Distance The optimum viewing distance is 8” (200mm) from the bottom of the sensor but any distance between 6” and 12” (150 - 300mm) is acceptable. Variations in product pass height of +/- 1” (25mm) around the 8’’ (200mm) nominal are permissible.

4.7 Reflections from the Material Surface It is essential to avoid specular reflections of the transmitted light from the product. Powdered and granular products cause no problems and the sensor light beam may be mounted at any angle to the top surface of the product. The closer the beam is to 90º from the surface the better the reflected signal strengths. Highly reflective and shiny sheet materials require that the sensor be angled so that the light beam is at approx. 80º-85º to the sheet surface.

Powdered & Granular Materials

Sheet & Reflective Materials

80-85* 8" or 200mm

3

5.0 Power and Cable Connections Refer to Section 11.0

5. 1 AC Power Connection The sensor is powered directly using the 6-foot (2mtrs) power cord provided. The input is auto ranging and accepts 90-260VAC volts, 15 amps. It is recommended that the power be supplied via a breaker or on/off switch mounted close to the sensor. An optional breaker switch is available from PSC.

5.2 Analog and Serial Cable Connections Customer data cables connect to the sensor by two 6-way I/O connectors on the rear of the sensor. Details of the respective terminals in these connectors are given in Section 11.0

5.3 Displays and Operator Interfaces The MCT may be set-up by using several operator interface and display modules. Wall Mountable:

This display interface is designed to be permanently connected to the sensor. It connects using a cable up to 500 feet (150 meters) in length.

Hand Held:

This interface is designed to be temporarily connected to any individual sensor using a 6-foot (2 meter) cable.

Both interfaces connect to the sensor using the 9 pin circular socket located on the rear of the sensor housing. Detailed descriptions of these interfaces are given in Sections 6.0 & 7.0 Host Computer:

This interface is a PC program designed to allow access to an individual sensors internal setup and calibration settings. It connects to the serial port of the sensor.

The PC software program has it’s own Operation Manual.

4

6.0 Operator Interfaces 6.1 Wall Mounting Interface The Wall Operator Interface is a display unit with keypad for user setup, calibration and routine interaction with the sensor. It is constructed in a cast aluminum housing rated for Nema 12 (IP 55). The display is a two-line 20 character vacuum fluorescent display. It may be mounted up to 100 feet from the sensor and obtains both power and communications from the sensor.

6.2 Hand Held Interface The Hand Held Interface is a portable interface that may be used and then disconnected from the sensor. It is constructed in a lightweight polycarbonate case complete with a two-line vacuum fluorescent display and user keypad. It offers the same interactive functions as the wall OI, but may be disconnected after use. It will operate with any MCT sensor and comes with a coiled 6ft-(2m) cable.

6.3 Initial Power-Up After installation and cable connection is complete, turn the power on at the breaker. The display on the operator interface will illuminate indicating power-up and the sensor will emit a flashing green light.

6.4 Keypad The front of the Operator Interface contains eight keys that allow the user to setup, calibrate and check internal diagnostics of the MCT.

5

Wall Mount Operator Interface

Handheld Operator Interface

6

Keypad

Keys:

7

Symbol:

UP/DOWN RIGHT/LEFT

Allows the user to move around the menu structure and to position the cursor in the desired place for setting numerical values.

PRODUCT CODE

Selects the desired Product Calibration Code.

ENTER

Confirms changes and commits them to permanent memory.

HAND

Computes an average value when a grabbed sample is taken.

DISPLAY ROTATE

Allows user to select each individual constituent

Operator Interface Panel

2X

8

7.0 Set-Up Instructions - Operator Interface The wall mountable and handheld operator interfaces both operate in identical ways; the only difference between the two is the size of the display and the style of enclosure. All the information required to operate and calibrate the MCT, is given on the 2-line/20 character vacuum fluorescent display.

7.1 Menu Structure The interface software is organized in a menu “tree” structure. Using the keypad on the front of the operator interface allows selection of the menu items. The lower half of the display changes as the user moves through the menu choices.

7.1.1 Keypad Lock The complete keypad may be ‘locked’ preventing use of any key until the correct key push sequence is made to unlock the keypad. Contact Process Sensors to obtain the lock and unlock sequences.

7.1.2 Display Selector

The MCT may be ‘Set-up’ to measure up to three constituents in a product. Depending on this set-up the MCT’s ‘Home Screen’ will be different. Home Screen for Single Constituent

Constit : 13.6% Prod: Prod A (01)

Home Screen for Dual Constituents

Constit 1 : Constit 2 :

9

3.6% 25.9%

01 01

Home Screen for Three Constituents

Constit 1 : 3.6% * Prod.: Prod A (01)

In the Three Constituent Mode the top line will scroll through the three constituents at 5-second intervals. An asterisk will be presented in the upper right corner indicating that the sensor is in the Three Constituent Mode. The constituents have identical menu structures and access to any of them is gained by selecting the desired constituent using the Display Rotate key. When in the dual or triple ‘Home Screens’, access to the menus is denied and only the, Display Rotate, Enter and Prod. Code # key are active.

Display Rotate Key – Single Constituent Mode When the MCT is measuring a single constituent the Display Rotate Key will act as a ‘Home’ key.

Display Rotate Key – Dual and Triple Constituent Modes Pressing the Display Rotate key once will select the first (constituent) menu

Constit 1: 3.6% Prod: Prod A (01)

Pressing Display Rotate a second time will select the second constituent menu

Constit 2: 25.9% Prod: Prod A (01)

01

Pressing Display Rotate a third time will revert the display to the two constituent 'home screen'

Constit 1: Constit 2:

01 01

01

Dual Mode

10

3.6% 25.9%

Triple Mode Pressing the Display Rotate a third time will select the third constituent menu

Constit 3: 34.5% Prod: Prod A (01)

01

Pressing Display Rotate a fourth time will revert the display to the three constituent 'home screen'

Constit 1: 3.6% Prod: Prod A (01)

*

Note: The Display Rotate key will rotate between the constituent menus at any lower level in the menus, e. g. When the display is on Constituent 1, Prod. Code 1, zero setting, pressing the Display Rotate will switch the display to Constituent 2, Prod. Code 1, zero setting.

7. 1.3 Prod. Code Select

Both constituents have 9 Calibration codes allowing the MCT to be calibrated for 9 different products. Each constituent has independent codes, but they are ‘tied’ for each product. The display will indicate, at the extreme right, the Prod. Code being used at any time. Changing the Prod. Code is made by pressing the Code Key # until the desired code is presented and then pressing ENTER to activate that number. Note: Calibrations can be extended to 50, call PSC for details.

11

Home Screen-Single Mode

Moisture: 3.6% 01 Prod: Prod A (01)

Press the code # key will scroll through the 10 product codes

Moisture: 3.6% 01 Prod.: Prod A (09) ???

Press ENTER to accept the desired Prod. Code

Moisture: 3.6% 01 New Cal Accepted

7. 1.4 Grab Sample Averaging

To aid in noting the sensor’s reading while a sample is grabbed from the conveyed product, the Grab Sample Key will compute an average of the sensors reading between TWO pushes of the key. To use this feature the display must be in a single constituent mode. Press Display Rotate to display the constituent of interest.

Moisture: 3.6% 01 Prod.: Prod A (01)

Pres the Grab Sample key. While it shows AVERAGING take a sample of the product.

Moisture: 3.6% 01 Averaging!!!

Press the Grab Sample Key a second time, to display the average of the first constituent.

Moisture: 3.6% 01 Average = 3.6%

Press the Display Rotate Key to show the average of the second and third constituent.

Oil: 25.9% 01 Average = 25.9%

Press the Grab Sample key a third time to exit the routine or wait 10 seconds and it will exit automatically. Press Display Rotate to return to the ‘Home’ screen.

12

7.2. Main Menu Selections The menu selections of each constituent are as follows: Online (Home) Calibration Parameters Calibration Routine Diagnostics Miscellaneous The display will normally start from the Online selection. Pressing the DOWN/UP arrow key will scroll the display through the menu selections. Pressing the RIGHT arrow will allow entry to the selected menu. Pressing the LEFT arrow ONCE will get back to the menu selection, pressing TWICE will get back to the HOME display. The following sections give a detailed description of the various menu choices available to set-up and calibrate the MCT using the operator display and interface. Press the DOWN arrow to select the desired menu field. To access this selection, press ENTER. All menus except Diagnostics are protected by a password.

13

Main Menu Selections Home Moisture: 12.89% Prod.: Prod A (01)

Moisture: 12.89% Damping: 5

Moisture = 5.1% 01 Sample Val: 0.0

Moisture: 12.89% CAL PARAMETERS

Moisture: 12.89% Password:0000

Displays Calibration Parameters

Moisture: 12.89% CAL ROUTINE

Moisture: 12.89% Password:0000

Enters Cal Develop

Moisture: 12.89% DIAGNOSTICS

Moisture: 12.89% First Diagnostic Value

Further Values

Moisture: 12.89% MISCELLANEOUS

Moisture: 12.89% Password:0000

Enters Misc. Menu

14

7.3 On-line Menu The user may make changes to the response time of the sensor and to the zero setting of the selected Calibration Channel directly from the ‘Home” screen. When at the ‘home’ screen, pressing the RIGHT arrow will display the Damping Time currently being used by the sensor. Press the RIGHT arrow to set the cursor under the digits use the UP/DOWN keys to set the desired value. Press ENTER to confirm the selection. From the Damping display press the DOWN arrow to access the Sample Value Trim screen. This screen allows the sensors reading to be adjusted to agree with the known moisture content of the sample it is viewing. Use the RIGHT key to move the cursor under the digits, use the UP/DOWN keys to set the desired value. Press Enter to confirm the value.

HOME Screen

Moisture: 5.1% 01 Prod.: Prod A (01)

Moisture: 5.1% 01 Damping: 1

Moisture = 5.1% 01 Sample Val: 0.0

15

7.4 Calibration Parameters Move down to display CAL Parameters Move right to enter the menu

Moisture= 12.89% CAL Parameters

Password: Move cursor under digits, move up/down to set the correct password, Press ENTER to accept

Moisture= 12.89% PASSWORD=0000

Moisture= 12.89% PASSWORD=____

Moisture= 12.89% PARA: PROD. A (01)

Moisture= 12.89% PARA: Prod E (05)

Prod. Code Selection: To view and adjust the settings stored in each of the 9 calibration channels, move the cursor under the digits, move up/down to set the desired value, then press Enter to confirm Move down to the next menu parameter

Zero Settings: Move the cursor under the digits, move up/down to set the desired value, then press Enter to confirm. Move up or down for other menu parameters

Span Settings: Repeat as per the offset setting adjustment

16

Moisture= 12.89% ZERO = -43.75

Moisture= 12.89% ZERO = -45.78

Moisture= 12.89% SPAN = 14.56

Moisture= 12.89% SPAN = 18.78

Analog Ranges: Move down to access the Analog Output Ranges.

Analog Out 1 High Setting: Move the cursor under the value. Move up/ down to set the desired value, press Enter to confirm.

Moisture= 12.89% Anout (1) HI: 100.0

Moisture= 12.89% Anout (1) HI: 50.00

Analog Out 1 Low Setting: Repeat as per previous parameters. Move Down to access Analog #2 settings, repeat as above.

Moisture= 12.89% Anout (1) LO: 00.00

Moisture= 12.89% Anout (1) LO: 20.0

Moisture= 12.89% Anout (2) HI: 100.0

Moisture= 12.89% Anout (2) HI: 50.00

Moisture= 12.89% Anout (2) LO: 00.00

Moisture= 12.89% Anout (2) LO: 20.0

Analog Out 2 Settings: Press DOWN to access Analog Out 2, then down again to access Analog Out 3. Repeat as per Analog 1 for different values compared to the default values of 0.0 and 100.0

17

7.4.1 Analog Output Channels The MCT has three analog output channels providing both milliamps and voltage signals. These channels may be designated to the constituent using an RS 232 command. The default designations are as follows: Single Constituent Mode #

Format

Constituent #

Analog 1

Isolated

1

Analog 2

Isolated

1

Dual Constituent Mode #

Format

Constituent #

Analog 1

Isolated

1

Analog 2

Isolated

2

Analog 3

Isolated

Selectable for 1 or 2

Triple Constituent Mode #

Format

Constituent #

Analog 1

Isolated

1

Analog 2

Isolated

2

Analog 3

Isolated

3

Refer to the User Terminal Drawing located in Section 11.0 for the location of the terminals for the analog signals.

18

7.5 Calibration Routine This menu selection allows the operator to correctly calibrate the sensor on the range of products being measured. When using this sequence, the following information will be required: 1.

Calibration Channel (1 through 9) that was used to generate the MCT readings for each sample.

2.

List of MCT readings with the corresponding laboratory determined moisture values for each sample.

Move DOWN to CAL Routine then move right to enter the menu

Password: Move cursor under digits, move up/ down to set the correct password, press Enter to accept and enter the menu

Number of Data Pairs: Move the cursor to the digits and use up/down to set the # of data pairs being used for the calibration. Min. is 2, max. is 25. Move down to the next menu choice.

Moisture= 12.89% CAL ROUTINE

Moisture= 12.89% PASSWORD = 0000

Moisture= 12.89% PASSWORD = 1234

Moisture= 12.89% Data pairs = 00

Moisture= 12.89% Data pairs = 05

Select the Cal. Code used by the sensor to generate the data pairs: 19

Move the cursor under the Prod. Code value and scroll up/down to set the correct value. Press Enter to accept. Move DOWN to enter the first data value.

Moisture= 12.89% Start: PROD A (01)

Moisture= 12.89% Start: PROD A (03)

Move the cursor under the digits for the first LAB value. Scroll up/down to set the value. Press Enter to save this value. Move the cursor under the digits and set the value. Press Enter to save.

Moisture= 12.89% Lab Val 01:2.56 Move DOWN to enter the corresponding MCT value. Press Enter to save the value.

Moisture= 12.89% MT VAL 01: 3.23 Repeat for all the data pairs When all pairs have been entered move Down to Calculate. Move the cursor to Y to calculate the regression coefficients and the new Zero and Span values. Selecting N will abort the calculation.

Moisture= 12.89% Calculate Y/N

20

Regression Statistics: The display will present the linear regression statistics of correlation coefficient CC and standard error SE. Move down.

Moisture= 12.89% CC:0.987 SE: 0.04 Calculated Calibration Settings: Using the regression statistics, the software will calculate the correct calibration settings for the data entered. Move down from the zero screen to view the Span value.

Moisture= 12.89% New Zero: -23.56

Move Down to Save the NEW values.

Moisture: 5.1% 01 New Span: 15.00

Move the cursor under the digit, then UP/DOWN to set the desired value. Press Enter to Save the settings. Press the LEFT arrow once to return to the CAL Routine selection, twice to go Home.

21

Moisture= 12.89% Save? :Prod A (01)

7.6 Diagnostics The MCT’s software continually monitors several internal electronic variables to ensure that the sensor is operating correctly at all times. If any of these parameters go out of pre-set limits then the MCT’s display will provide a warning message. Maintenance personnel may view the values of these parameters by selecting Diagnostics from the Main Menu. Move DOWN to DIAGNOSTICS and then move right to enter the menu. The Diagnostics menu selection is not protected by a password as none of the parameters displayed may be altered.

Moisture= 12.89% DIAGNOSTICS The Diagnostics Menu allows the user to view the status of various internal set up parameters, voltages and signal levels. Pressing the DOWN/UP key will scroll through the various parameters monitored by the system.

Moisture = 12.89% Thermistor: 3.20v

Moisture = 12.89% Cooler Drive: 1.61v

Moisture = 12.89% Gain: 156 (7.1v)

22

This parameter is the internal temperature signal of the Pbs detector.

This parameter indicates the voltage of the thermocooler being used to keep the detector at the set temperature of 20ºC.

This is the gain factor of the pre-amp and the strength of the largest filter signal on the detector.

Moisture = 12.89% Motor: 1101 rpm

This is the motor speed in rpm.

Moisture = 12.89% PSU VCC: +4.9v

This is the value of the +5 volt power supply.

Moisture = 12.89% PSU VP: +15.3v

This is the value of the +15 volt power supply.

Moisture = 12.89% PSU VP: -15.1v

This is the value of the -15 volt power supply.

23

Moisture = 12.89% F1-F6 Ext & Int: 2.75

These screens will display the live values of the 6 filter values, for both external and internal light beams.

Moisture = 12.89% INT Temp: 45.0C

This screen displays the sensor's internal temperature.

Ranges of Diagnostic Parameters: The Operator Interface Display will present fault warnings indicating that certain diagnostic values are outside of the acceptable ranges. The following table gives the range of values for each of the diagnostic parameters and the fault message that is displayed on the Operator Interface. Parameter Internal Filters External Filters. +5V + 15 V - 15 V Motor Speed Filter Wheel Slot Gain Cooler Drive Thermistor Int. Temp

24

Nominal Min. Max. Value Value Value 3.0-8.0 1.0 9.9 3.0-8.0 1.0 9.9 5.00 4.5 5.5 15.00 13.0 17.0 15.00 13.0 17.0 1100 1000 1200 No slot switch input for > 400 ms 100 1 255 2.5 0.1 4.5 2.5 0.1 9.0 42.0 25.0 65.0

Warning Message High/low Signals High/Low signals VCC Fault VP Fault VN Fault High/Low Motor Motor Stopped None None High/Low Thermistor None

7.7 Miscellaneous This menu selection allows users to setup several basic parameters and to view some reference data stored in the sensors memory. Press RIGHT to enter the menu. Press RIGHT again to move the cursor under the digits, Scroll up/down to set the correct password. Moisture = 12.89% MISCELLANEOUS

Number of Digits after the decimal point Using the Right arrow move the cursor under the digit and press up/down to set the desired number. The minimum is 1, the maximum 3. Press ENTER to save.

Network ID number For sensors used in multi-sensor networks each sensor may be given a discrete ID number in the range 1-9, a-z or A-Z.

Serial Number The serial number of the sensor main PCB is stored in memory for reference purposes.

25

Moisture = 12.89% Password: 000

Moisture = 12.89% # OF DIGITS: 1

Moisture = 12.89% Inst ID: 1

Moisture = 12.89% Ser. No. 1009

Software Version The revision of the Eprom is stored for reference. Password Change: The password that is needed to gain access to other menu selections may be customized. The default password is 0000. The display will default to this default value even if the password has been set to a different number. To change the password move the cursor under the digit and scroll up/down to set a new number. If the password is not known or forgotten consult Process Sensors for a special number to gain access to Miscellaneous. Enter this special password and then Enter a new password as above. The characters that may be used in the password are 0-9. The MCT series sensors arre fitted with software that continually monitors the cleanliness of the sensor window. This software may be switched ON/OFF by this command. More details of this "Dirty Window Alarm" are found in the Accessories section of the manual. Reset Software: Pressing the ENTER key will reset the software.

26

Moisture = 12.89% MCT200 V3.39E

Moisture = 12.89% New Password: 0000

Moisture = 12.89% Set Clean Window

Moisture = 12.89% Enter for Reset

8.0 Gauge Calibration The object of gauge calibration is to obtain a straight-line graphical relationship between the sensor’s reading and the true moisture value of a series of samples.

MT

Calibration Graph

10

* *

8

* *

6 * 4 * 2 0

2

4

6

8

10

12

14

16

True Moisture

8. 1 Approximate Calibration Select one of the Product Codes (1-9 or 1-50) that will be used to store the calibration setting for the product being measured. Ensure that this Code # has valid settings for both zero and span. Make or collect from the process two samples with moisture contents close to the lower and upper values expected to occur in the manufacturing process. Present the lower sample to the sensor and allow the sensors reading to stabilize. Adjust the sample value setting to make the sensor reading read the same as the true moisture of the sample. Present the upper sample to the sensor and allow the reading to stabilize. Note the sensor reading. Use the calibration routine in the Operator Interface (Section 7.5) or the MCT Viewer Software to correct the zero & span values. (see Viewer Software Users Guide)

27

8. 2 Multi-Sample Calibration- Static Samples A more accurate calibration may be obtained by using a larger quantity of samples. As for the approximate calibration, select the Product code that will be used to store the correct calibration settings. Make or collect from the process a series of sample (up to 25) with moisture contents covering the range expected in the process. Set the Span value to 25.0 and the Damp time to 1sec. Present the lowest sample to the sensor; adjust the zero setting to make the sensor’s reading agree with the true moisture content of the sample. Note the reading. Continue to present each of the other samples in turn, noting the sensor reading for each sample. Tabulate the results as follows: Sensor 3.7 4.5 7.6 9.5 8.2

True Value 3.7 5.2 8.3 10.3 8.9

Using the operator display module (refer to Section7.5): • • • • •

Select the Calibration Menu. Select the Product Code used to collect the above data. Enter the number of data pairs = 5 Enter the data pairs as requested by the display. After all 5 pairs have been entered, review the calibration statistics. Transfer the new calibration settings to the previously selected Code or to any other Code number.

The sensor is now accurately calibrated and is ready to be installed on the process line. Due to changes in the environment, and the way that the moisture is “held” in the process samples it will be necessary to adjust the zero setting to match the sensor display to the true moisture value of a grabbed sample.

28

8.3 On-line Offset Trim Adjustment Install the sensor on the moving process line. Grab 2-3 samples of the product and note the sensor’s reading for each sample. For a more accurate calculation of the sensor’s readings during the collection of the each sample, the sensor’s “grab sample average feature” may be used. Refer to section 7.3 for more details on the use of this feature. Calculate the average of the three sensor readings and of the three true moisture values. Adjust the zero setting as follows: New Zero = Old Zero - (Sensor Average - True Moisture Average)

8.4 Linear Regression Statistics The sensor’s computer calculates several statistics during its calibration routine; these statistics give a measure of the accuracy and quality of the calibration. Correlation Coefficient:

This is an expression of how well the sensor readings match the True values. 1.0 is perfect Greater than 0.9 is acceptable Less than 0.9 is not acceptable

Standard Error:

This is a gauge of the accuracy of the calibration. A perfect value is 0.0. Acceptable values are in the 0.0 to 0.5 range depending on the moisture ranges being measured.

8.5 Online Multi-Sample Calibration If, due to the nature of the product, it is not possible to make sample with varying moisture levels, then an online calibration may be necessary. Careful planning and sample taking is needed to ensure an accurate calibration. Samples should be taken at, at least 3 different moisture levels. Two samples should be taken at each moisture level. The moisture levels should be as wide as possible, but at least +/- 5% of the target moisture. In a similar way to the static calibration tabulate the paired data of sensor readings and laboratory determined true moisture values. Use the Operator Interface or PC software to calculate the correct Zero and Span settings.

29

Sample Handling: Representative sampling is a key factor in the calibration procedure. It must ensure that any sample taken from the line relates exactly to the displayed moisture reading logged as “the sensor reading”. Samples should be taken immediately downstream of the sensor and in the same plane as the measurement beam. This eliminates variations in the moisture content across or along a conveyor. Samples should only be taken from the surface of the product rather than by “digging” down to the bottom of the conveyor. This eliminates variations down through the bed of product. Samples should only be taken when the sensor reading is stable, avoiding time when the product moisture may be rising or falling. A sample of approximately 2 handfuls should be taken and immediately sealed in an airtight container or bag. Prior to laboratory analysis the sample should be allowed to stand for about 30 minutes to ensure homogeneous distribution of the moisture.

30

9.0 Accessories 9.1 Window Air Purge Assembly This assembly installs around the optical window to protect it from air borne contaminants. Air is connected via the ¼ inch (6mm) pipefitting and a sintered insert disperses the air around the optical window. Clean, dry, oil free air at 2-3 psig < 5 scfm should be connected. Only a nominal supply is required, high airflow in the tube tends to create a vortex and actually sucks dust into the tube.

9.2 Product Loss Sensors These are photoelectric proximity sensors that mount to the sensor. They “sense” the presence of the product under the sensor. When the product disappears they provide an input contact to the HOLD input in the sensor, to freeze the sensor’s readings and analog outputs until the product returns.

9.3 Network Interfaces The sensor may be fitted with a variety of interface modules that provide the sensor’s output data in the correct format for the network into which it is operating. Refer to the instructions provided with each option module for installation and output formats.

9.4 Cooling Panels The MCT series sensors may be fitted with a cooling panel to allow the sensor to be installed in environments where the temperature is greater than 50 C (120 F). The cooling panel is mounted on the bottom face of the sensor and may be used with either water or aircooling media. When used with air-cooling a Vortec Cooling Element will be provided. This element provides a stream of cold air to the panel. The requirements for either cooling media are as follows:

9.4.1 Air Cooling Connect the Vortec cooling element to the inlet port on the cooling panel. Connect a ¼” (6mm) inlet tube to the inlet of the cooler element. Supply clean, dry air at 80 – 100psi (6-7 bars) to the cooler.

9.4.2 Water Cooling Connect a ¼: (6mm) tube to the inlet and outlet connectors on the cooling panel. Supply cold water (65-80F/20-27C) at an approximate flow rate of 1cfm (0.3 liters/min). 31

9.5 Maintenance Alarm The MCT sensor may be fitted with an alarm card with a DC solid-state relay that will activate whenever any of the sensor’s internal alarms are triggered. Refer to the Maintenance Section for a listing of the alarms that will trigger the alarm contact.

9.6 Dirty Window Alarm All MCT sensors have a software routine that continually monitors the cleanliness of the sensor’s window. This routine may be activated in the Miscellaneous Menu selection. The routine requires that on initial installation, when the sensor has a clean window, that this clean state be ‘learned’ by the software. During the operation of the sensor, if the sensor’s signals drop to below 70% of the ‘learned’ clean window signal, and remain at that level for several minutes, then a warning message will be presented on the Operator Interface and a digital alarm flag will be sent out the serial port. When this message appears the window should be cleaned and the ‘clean’ level re-learned. If the feature is not required it may be switched off in the Miscellaneous Menu.

9.7 Powder Sampler The MCT sensor may be fitted with a Powder Sampler that allows the sensor to make measurements on free falling materials inside enclosed ducts. Refer to Appendix II for complete details of the hardware and software needed for this Powder Sampler.

9.8 Local Display Unit (LDU) The LDU is an LED display complete with a ‘Grab Sample’ button that is intended to be located alongside the production line close to the sensor and the point where samples will be collected from the line for calibration verification. The LDU connects to the sensor with a standard interconnecting cable and has a second cable connector for the Hand Held Operator Interface to connect to. Refer to the rear of the manual for the outline dimension and mounting detail drawing of the LDU. The LDU presents the sensor’s reading together with a display of the calibration channel being used. In the front of the unit is a push button switch. This switch initiates a short-term average when a sample is grabbed. To initiate the average: Push the button The display will show AVG Grab a sample from the product flow Push the button again The display will show the average of the sensor readings since the initial button push. The value will flash indicating that the value is the average. 32

After 10 seconds the display will revert to the normal live sensor reading.

10.0 Output Signals The MCT has the following signal interfaces available for connection to other devices. Analog Outputs:

Three 0–10 volts isolated. Three 4-20mA isolated. Load resistance 500 ohms Max.

Hold/Gated Input:

Facility for a contact closure input indicating a gap in the stream of product on the conveyor. When activated the sensors display and analog output signals will be “frozen” for the time the hold input is active.

10.1 Serial Communications The Sensor provides a choice of serial output formats, RS232 and RS485. RS232 is suitable for a single sensor to computer connection over a distance of up to 100 feet (30 meters). RS485 is suitable for connection of up to 16 sensors on a cable up to 3 miles (4.86Km) long.

10.1.1 Serial Requirements 1. RS232/485:

Baud Rate: 300 to 38400 (9600 default) Parity: None Data Bits: 8 Stop Bits: 1

2. Cables:

RS 232: 9 pin ‘D’ serial cable wired pin to pin RS 485: Shielded twisted pair.

33

11.0 Customer Wiring Connections All wiring connections are made to three quick-disconnect connectors mounted on the rear of the sensor enclosure. These connectors may have different signals coming to them from inside the sensor. The following diagrams show the standard configurations for these connectors.

POWER Terminal # 1 2 Gnd Symbol

Input Live Neutral Ground

ANALOG Connector (4-20mA outputs) – Standard configuration Terminal #

Signal

Constituent #

1

Gnd

1

2 3 4 5 6

4-20 mA Gnd 4-20 mA Gnd 4-20 mA

1 2 (1 if sensor is in single mode) 2 (1 if sensor is in single mode) 3 (not operational in single mode) 3 (not operational in single mode)

ANALOG Connector (0-10V outputs) – Alternate 1 Terminal # 1 2 3 4 5 6

34

Signal Gnd 0-10V Gnd 0-10 V Gnd 0-10 V

Constituent # 1 1 2 (1 if sensor is in single mode) 2 (1 if sensor is in single mode) 3 (not operational in single mode) 3 (not operational in single mode)

DIGITAL Connector (RS232, RS485 & Hold) – Standard Configuration

Terminal #

Signal

1

RS485 A RS485 B RS232 Tx RS232 Rx Digital Gnd Hold Input

2 3 4 5 6

DIGITAL Connector (RS485 In & Out) – Alternate 1 Terminal #

Signal

1

RS485 A - IN RS485 A - OUT RS485 B – IN RS485 B – OUT Digital Gnd Hold Input

2 3 4 5 6

Note: When sensors are fitted with network interface cards this Digital connector may be wired to meet the network format or it may be replaced with the network’s approved connector.

35

Rear of Sensor

36

Rear Analog/Digital Connector

Use the end of the Dust Cover to un-screw the ‘Retaining Ring’ in order to remove the 6 pin connector.

The ‘Flat part’ of the connect fits into the ‘Housing’, mating with a similar ‘Flat part’.

37

12.0 Maintenance Tools required for maintenance on the MCT sensor and Operator Interface are: Flat blade screwdriver 7/64” Allen Key 3/32” Allen Key 5/64’ Allen key 1/16” Allen Key

12.1 Routine Maintenance The MCT requires little or no routine maintenance.

12.1.1Sensor Window The ‘Clean Window Software’ continuously monitors the cleanliness of the MCT window. When the system detects a dirty window, a warning message will be displayed on the OI screen. The window needs to be cleaned to remove the contamination from it. Use a soft lint-free cloth or paper towel and glass cleaner fluid to remove dirt from the window. DO NOT USE AN ABRASIVE CLEANER TO CLEAN THE WINDOW. The window may be cleaned with the air purge shroud in place or the shroud may be removed to fully expose the window. Remove the four Allen screws that hold the shroud to the sensor. Clean the window and re-fit the shroud.

12.2 Self Diagnostic Warnings The MCT has built-in self–diagnostic software that monitors key elements of the sensor’s operation. When this software detects a fault, it transmits a fault status bit out the serial port and presents a warning message on the Operator Interface. If the optional maintenance alarm board is fitted the alarm contact will also be triggered.

38

The screen warning messages are:

Screen Message

Description

Corrective Action

High Signals

Too much signal

Check for proper product placement or no product

Low Signals

Too little signal

Check for proper product placement or no product

High Motor Speed

Motor rpm above 1200

Call PSC

Low Motor Speed

Motor Speed below 1000

Call PSC

Motor stopped

Wheel motion not detected

Call PSC

VCC Fault

High/Low 5v power

Measure 5v with multimeter

VN Fault

High/Low –15v power

Measure –15v with multimeter

VP Fault

High/Low +15v power

Measure +15v with multimeter

SPI Fault

No communication to OI

Check cable to OI

Dirty Window

Window contamination

Clean the window

High Temp

Internal Temp > 65ú

Fit Cooling System

12.3 Corrective Maintenance The MCT sensor and Operator Interface are modular in construction and an experienced electronic maintenance technician can replace any damaged components. The following components may be replaced in the field: Main Circuit Board Lamp Filter Wheel Motor Detector Power Supply Dome Mirror 39

Replacement of these parts requires that the MCT be removed from its plant location and brought to a clean room or maintenance shop.

MCT Enclosure The MCT sensor has two-part cast aluminum housing. The two sections are held together by four machine screws. These screws are held captive in the bottom half of the housing. Unscrew the four screws and place the upper half to one side.

Lamp Replacement This operation requires that the optical bench be removed from the bottom half of the sensor enclosure. 1. Unplug the analog cable from the main PCB. 2. Unplug the digital cable from the main PCB. 3. Locate the 6 screws that hold the optical bench into the enclosure. 4. Remove these screws and gently lift out the optical bench. The optical bench will still be connected to the power supply by the AC input cable. Remove this cable from the power supply. 5. Remove the two Allen screws that hold the power supply to the main board. 6. Disconnect the DC cable harness from the main board. 7. Unplug the lamp from the power supply. 8. Lay the sensor on its side and locate the two Allen screws that hold the lamp into the optical bench. 9. Remove both screws and take out the damaged lamp. 10. Install a new lamp assembly; do not touch the lamp glass with bare fingers. 11. Re-fit the retaining screws. 12. Re-connect the lamp to the power supply. 13. Re-connect the power supply harness and the power supply assembly to the main board. 14. Re-connect the AC cable to the power supply. 15. Re-install the optical bench in the bottom half of the enclosure. 16. Re-connect the Analog and digital cable to their respective sockets on the main board.

Motor Replacement This operation requires that the optical bench be removed from the bottom half of the sensor enclosure. 1. Unplug the analog cable from the main PCB. 2. Unplug the digital cable from the main PCB. 3. Locate the 6 screws that hold the optical bench into the enclosure. 4. Remove these screws and gently lift out the optical bench. The optical bench will still be connected to the power supply by the AC input cable. Remove this cable from the power supply. 5. Remove the two Allen screws that hold the power supply to the main board. 6. Disconnect the DC cable harness from the main board.

40

7. Remove the four Allen crews that hold the dome mirror/detector plate assembly to the optical bench. Disconnect the detector from the main board and set the assembly aside. 8. Remove the two Allen screws that hold the motor in the optical bench. Unplug the old motor from the main board. 9. Install the new motor; connect it to the main board. 10. Re-install the dome mirror/detector plate assembly and re-connect the detector to the main board. 11. Re-connect the power supply harness and the power supply assembly to the main board. 12. Re-connect the AC cable to the power supply. 13. Re-install the optical bench in the bottom half of the enclosure. 14. Re-connect the Analog and digital cable to their respective sockets on the main board.

Main Board Replacement This operation does not require the optical bench to be removed from the sensor enclosure. 1. 2. 3. 4.

Remove the top half of the sensor enclosure. Remove the four Allen screws that hold the main board to the optical bench. Gently lift up the main board and disconnect all the cable connectors from the board. Connect the various connectors to the main board and locate the new board on the top of the optical bench. 5. Re-install the four Allen screws.

Note: A main board replacement will require that many of the MCT setup and calibration parameters, be re-configured to match the new boards’ operation with that of the original board. Consult PSC for advice on this.

Detector Replacement This operation does not require the optical bench to be removed from the sensor enclosure. 1. 2. 3. 4. 5.

Remove the top cover from the sensor. Unplug the detector from the main board. Remove the two Allen screws that hold the detector in place. Install a new detector and re-fit the Allen screws. Plug the detector to the main board.

Power Supply Replacement This operation requires that the optical bench be removed from the bottom half of the sensor enclosure. 1. Unplug the analog cable from the main PCB. 2. Unplug the digital cable from the main PCB. 3. Locate the 6 screws that hold the optical bench into the enclosure. 41

4. Remove these screws and gently lift out the optical bench. The optical bench will still be connected to the power supply by the AC input cable. Remove this cable from the power supply. 5. Remove the two Allen screws that hold the power supply to the main board. 6. Disconnect the DC cable harness from the main board. 7. Lay the power supply assembly on the bench and take out the power supply module. 8. Install a new power supply on the plate. Make sure the insulating paper is fitted under the power supply. 9. Re-connect the power supply harness and the power supply assembly to the main board. 10. Re-connect the AC cable to the power supply. 11. Re-install the optical bench in the bottom half of the enclosure. 12. Re-connect the Analog and digital cable to their respective sockets on the main board.

42

Replacement Parts List Sensor P/N

Description

300035

Main Board (A1149)

300021

Power Supply (GLC65B)

200022

Detector Assy

200019

Lamp Assy

100031

Motor Assy

200013

Dome Mirror

200010

Sensor OI Cable Connector Assy

300027

Analog I/O Connector Assy

300028

Digital I/O Connector Assy

300002

Power Connector Assy

300030

Analog/Digital Cable Plug

300032

AC Power Cord – USA

300033

AC Power Cord – UK

300034

AC Power Cord – Europe

300031

I/O Connector Dust Cover

300003

DC Power Harness

43

Wall Operator Interface P/N

Description

210002

Display Module

210008

Interface Board

210008

Cable Connector Assy

210040

Keypad Board

Handheld Operator Interface 220015

Display Module

220016

Interface Board

44

Appendix 1 – Special Features Backdoor Password If the password for the MCT has been forgotten is unknown then a special ‘backdoor’ password will allow the user/engineer to view and change the old password. To use this ‘backdoor’ system proceed as follows: Press Display Rotate to present a single constituent Home screen. Scroll DOWN to MISCELLANEOUS. At the Password request enter the number 6811, then press ENTER. This will access the MISCELLANWOUS menu. Scroll down to NEW PASSWORD to see what the password was set to. Change it to any new password and press ENTER to save the new number. Keypad Lock All the keys on the Operator Interface may be ‘locked’ to prevent unauthorized users from making any adjustments. Holding down the UP arrow and pressing ENTER activates the ‘lock’. De-activation of the ‘lock’ is made with the same keystrokes, followed by entry of the Password. The Cal Code key will continue to operate when the sensor has a ‘locked’ keypad.

Hidden Menus for the MCT via Operator Interface Engineering Menu The MCT sensors contain a ‘hidden’ engineering menu that contains the filter algorithm coefficients and several other customization functions of the sensor. This menu should only be accessed by people experienced in the setup of the MCT for specific applications. Access to the Engineering Menu is gained by using a special password. At any password request enter the number 2882 and press ENTER. This will allow access to the menu.

45

Preamp Gain The MCT has a software adjustable preamp gain factor. This factor is the gain applied to the filter signals coming from the detector. The amplification applied to the signals is:

Amplification =

225 Gain Factor

The correct setup for the MCT is to have the largest filter signal, after amplification, to be 8.0 volts when viewing the product to be measured. This value is achieved by adjusting the gain factor. Algorithms The MCT uses the 6 filter signals in a pre-programmed algorithm. By selection of the correct filter coefficients, the different algorithms may be formed for the measured constituents

Basic Algorithm for Single and Dual Constituents: C2F2 + C3F3 + C4F4 + C5F5 C1F1 + C6F6 Filters F1 and F6 are both measure filters Filters F2, F3, F4 and F5 are all reference filters. Each filter has associated with it a coefficient, C1 – C6. These coefficients can be set to a value between +/-999. Typically coefficients will range between 0 and + 1.0 Basic Algorithm for Three Constituents C2F2 + C3F3 + C5F5 C1F1 +C4F4 C6F6 Filters F1, F4 and F6 are measure filters. Filters F2, F3 and F5 are all reference filters. Each filter has associated with it a coefficient, C1 – C6. These coefficients can be set to a value between +/-999. Typically coefficients will range between 0 and + 1.0 By setting the coefficients of the filters, different algorithms may be made for the constituents being measured by the MCT. Changes to the factory set coefficients requires the data sheet that was supplied with the MCT 200 as it lists the filters fitted to the MCT 200. 46

Viewing and changing the coefficients for the algorithms From the Gain Screen, press the DOWN arrow each time to view the coefficients set for the constituent shown on the top line of the display. Use the Display Rotate key to switch to the coefficients set for the second constituent. To change a value, move the cursor under the number and scroll up/down to set a new value. Press ENTER to save this value

The first constituent will use the measure filter F1 and will thus have C1=1 and C6=0.0 the coefficients for C2-C5 will variable, depending on the application of the sensor.

Moisture = 12.89% 01 C1: 1.0 Moisture = 12.89% 01 C2: 0.0

Pressing Display Rotate will show the coefficients used by the second constituent. This algorithm will use F6 as the measure filter so F1=0.0 and F6=1.0. Again the coefficients for F2-F5 will depend on the application.

Oil = 25.8% 01 C1: 0.0 Oil: 25.8% 01 C6: 1.0

Algorithm Math Treatment The MCT is capable of using two styles of math treatment of the basic algorithm. Linear:

C2F2 …..+ C5F5 C1F1 + C6F6

Log:

Log C2F2….+ C5F5 C1F1 + C6F6

The MCT uses the linear math treatment as default. The log treatment is used when the MCT is required to measure over very large ranges where the linear treatment may give a slightly non-linear response. The log treatment will linearize the MCT response and provide more accuracy in wide measurement applications. 47

Math Selection Codes Selecting the following code makes selection of the desired math treatment: Math Linear Log Press Enter to save

Code 0 1

Instrument Network ID # This line allows each sensor to be given a discrete number, when multiple sensors are connected using RS485.

Moisture: 3.3% 01 Algorithm (1=Log): 0

Moisture: 3.6% 01 Inst ID: 1

Main Board Serial # This lists the serial number of the main circuit board installed in the sensor.

Moisture: 3.6% 01 Ser No.

Software Revision This lists the revision of the software fitted to the sensor.

Moisture: 3.6% 01 MT 200 V2.11

Total CLR EEPROM Selecting Y will set all the values stored in EEPROM to their default values.

Moisture: 3.6% 01 Total CLR EEPROM Y/N

Sampler Mode This line allows the sensor to be set to operate in the Sampler Mode. It requires the power sampler accessory to be fitted to the sensor. Refer to Appendix II for full details of the smapler setup.

Moisture: 3.6% 01 Sampler: Y/N

48

Dual Mode The MCT May be switched Single to Dual Mode. The triple mode requires a different EPROM to be fitted to the sensor. Language Selection The MCT display system may be set to use a different language to English. The EPROM fitted to the MCT will allow the language to be switched betweeen English and one of the following languages: German, French, Spanish or Portuguese

Moisture: 3.6% 01 Dual: Y/N

Moisture: 3.6% 01 Language: Y/N

Dry Basis The MCT may be setup to present moisture readings as a % of the dry material. Selection of Y will activate this 'Dry basis' readout. Refer to Appendix III for greater details of this 'Dry Basis' readout.

Moisture: 3.6% 01 Dry: Y/N

Max Cal The number of Calibration Channels may be set to any number between 1 and 10. Move the cursor over the number set desired value. Press ENTER to save the value.

Moisture: 3.6% 01 Max Cal: 10

49

Averaging Modes The MCT 200 has a choice of three methods of ‘averaging’ the constituent readings, these are: Damping: This is a time constant based ‘smoothing’ of the readings. Real Time Averaging: This is a ‘pipeline’ average of the readings over a selected time. Gated: This is an ‘event’ based average of the sensor readings. The event being a contact closure at the sensors ‘hold’ input.

Selection of the 'averaging' mode is made by using the relevant code number Mode

Code

Damping

0

RTA

1

Moisture: 3.6% 01 Damp/RTA/Gate: 0

Gated 2 Press ENTER to save

Dead Band The MCT has built-in Smoothing Factor that operates at a +/- level either side of the sensor reading. The default value is 0.2, the minimum is 0.0 and the maximuim is 1.0

Moisture: 3.6% 01 Dead Band: 0.2

Reset Press ENTER to RESET the software. Customized settings will not be altered.

Moisture: 3.6% 01 Enter for Reset

To exit the Engineering Menu, press the LEFT arrow key TWICE 50

Appendix II – Powder Sampler Accessory The MCT Powder Sampler is an accessory that allows the MCT sensor to make measurements on products that are free falling inside enclosed ducts. It consists of a stainless steel tube, on the end of, which is a sample cup complete with glass viewing window. The sampler’s routine is controlled by s software routine in the sensor and an external solenoid valve. The routine allows the cup to fill, the sensor to make and average reading the sample is then ejected from the cup and the sequence repeats. A typical cycle time is 40 seconds Installation The sampler should be located in the process duct so that the sampler cup extends into the product flow. Insertion Depth The length of the welding spud supplied with the sampler determines the insertion depth of the sampler. The following table gives the relationship between the length of the welding spud and the insertion depth of the sampler. Spud Length (inches) 4.0 3.5 3.0 2.5 2.0 1.5

(mm) 102 89 76 64 51 38

Insertion Depth (inches) 4.0 4.5 5.0 5.5 6.0 6.5

(mm) 102 114 127 140 152 165

Installation of the welding spud. • • • • •

Cut a 3.25” (82.5 mm) hole in the duct at the desired location. Cut the welding spud to the length that will give the insertion depth desired. Weld the spud to the duct around the hole. Ensure that one of the boltholes is located at the 12 o’clock position. Bolt the sampler to the spud. Bolt the sensor to the sampler in the desired orientation. It may be installed in one of four positions. Sensor up, down, right or left.

Install a support bracket for the sensor. The sensor must not be left to hang from the sampler without any additional support! 51

The solenoid box should be mounted close to the installation of the sensor & sampler. A ¼” (6 mm) airline should be connected to inlet air port in the solenoid enclosure, and an air line from the solenoid box air outlet to the ‘tee’ fitting on the sampler. The Operator Interface should be mounted at a convenient location for operator interaction and both the sensor and Operator Interface should be connected to 110V or 220V as designated on the serial tag. Connect a three-wire cable between the operator interface plug and the terminal strip in the solenoid enclosure as shown in the attached drawing. Sequence Timer Setup The time sequence for the cycles of the sampler is held in the sensor memory. Access to the times are made via the Engineering Menu selected from the Operator Interface. The times control the sequence that allows the sampler to fill with sample, the sensor to take a reading and then the sample to be ejected. The sequence of events is as follows: Purge (Sample is blown out of the sample cup) Fill (Sample is allowed to fill the sample cup) Measure/sample (sensor will take a moisture reading) Delay (delay between the presentation of the moisture reading and the start of a new cycle)

It will take one cycle of the sampler before the sensor will present the moisture content of the sampled product. The factory set time sequence of the sequence timer is as follows: Purge = 10 seconds Fill = 20 seconds Sample = 10 seconds Delay = 2 seconds. These times can be adjusted to optimize the sequence to the flow rate of the product.

52

Changing the Sequence Times Use the Operator Interface. Use the down arrow to move the bottom line of the display to Miscellaneous. Press the right arrow to enter this selection. At the password request, set the password to 2882, then press ENTER. This will access the Engineering menu. The menu contains many items that if changed will influence how the sensor operates Use the down arrow to scroll through the selections until the display shows: SAMPLER: Y/N Press the right arrow to make the cursor flash on Y and press ENTER to activate the sampler mode. The sensor software will normally have been pre-set on delivery to make the sensor operate in the sampler mode, in which case the display will show: SAMPLER: ON Press the down arrow to access the times for the various cycles. SAMP PURGE = 0010 Use the right arrow to move the cursor under the digits, up/down arrows to set a new time and press ENTER to set the time. Press the down arrow to see the next time. SAMP FILL = 0020 Repeat as per the Samp Purge. Press the down arrow to see the next time. SAMP MEAS = 0010 Repeat as per Samp Purge. Press the down arrow to see the next time. SAM DELAY = 0002 Repeat as per Samp Purge.

53

Connections for Sampler MOISTURE : 25.4 % CONSTIT 2 : 35.6 %

1 POWER OUT

2

01 01

2 OPERATOR DISPLAY BOX

1 POWER IN LINE EARTH NEUTRAL

AIR PURGE SOLENOID LINE SOLENOID

RED EARTH GRN NEUTRAL RED

Sampler (Air purge) connections.

To activate Sampler mode, using the Operator Interface, proceed to Engineering and cursor down until the display reads: SAMPLER Y/N Place cursor over the Y and press Enter. The display will briefly flash SAMPLER ON Cursor down one and the display will read: SAMP PURGE = 0010 This is the time, in seconds that the air purge will be active. Move down one more and the display will read: SAMP FILL = 0020 This is the time allowed to fill the sampler with product. Next position down display will read: SAMP MEAS = 0010 This is the time allowed to take a measurement. Next, and last, is the SAMP DELAY = 0002 This is a delay before starting the cycle all over again. All the above values are modifiable. 54

Appendix III – Dry Basis Measurements It is common for some industries, particularly the wood panel industry to calculate the moisture in the wood particles as a percentage of the dry material rather than a percentage of the wet material. Wet % = Wet Weight – Dry Weight Wet Weight Dry % = Wet Weight – Dry Weight Dry Weight Conversion from Wet % to Dry % is as follows: % Dry =

% Wet x 100 (100-% Wet)

Conversion from % Dry to % wet is as follows: % Wet = % Dry x 100 (100 + % Dry The MCT may be configured to present moisture on a dry basis by selecting DRY: Y in the Engineering Menu. This selection does the following to the sensor parameters: 1. The displayed moisture readings are presented in the Dry Basis. 2. An asterisk appears in front of the ‘Moisture’ word in the display to alert users that the sensor is in the DRY mode. 3. The Calibration routine is modified to allow dry basis MCT and laboratory values to be used. Online Trim Adjustments When operating in the Dry Basis Mode, a change to the Zero parameter of the calibration will not make the same adjustment to the moisture reading. This is because the moisture reading is being modified by the wet to dry conversion factor. To allow users to make a simple trim adjustment to the sensors reading and additional calibration parameter is presented in the Cal parameters when in the Dry Basis Mode. This is: OFFSET. The default setting for it is 0.00. To make a reduction in the displayed moisture reading of 0.5, make the OFFSET be –0.5. To make an increase to the moisture reading of 0.8, make the OFFSET be + 0.8 When initially calibrating a sensor ALWAYS set the OFFSET to 0.00 55

Appendix IV - Calibration Check Standard – MCT Series The Process Sensors Calibration Check Standard provide users of the MCT Series NIR Transmitters with a quick way of verifying that the sensor’s calibration has not altered over time. The standard simulates moisture levels as follows: White:

Low Moisture

Blue:

High Moisture

Connection of the Standard to the MCT Sensor Locate the standard on the light shroud. Make sure that the two fixed pins mate with the holes in the light tube and then tighten the thumbscrew to ‘lock’ the standard in place. How to Use the Calibration Check Standards The Check Standards should be used on a periodic basis, daily, weekly or monthly, to check that the sensor is remaining stable and thus giving the correct moisture values. The standards may be used in two ways: a) As a quick low/high check of the sensors’ reading. In this manner it allows users to gain confidence in the stability of the sensor and in the accuracy of the initial calibration. b) As a way of transferring the calibration from one sensor to another. In this manner a newly purchased or repaired sensor can be quickly put into operation without the need for actual samples of product. Quick Calibration Check Using the standards to check the stability of the MCT requires that it be correctly calibrated using samples of the product(s) on which it is measuring. As soon as the sensor is satisfactorily calibrated, the reading of the low and high sides of the standard need to be noted. 1. Clip the standard onto the light tube. 2. Rotate the standard selector knob to the LOW position and tighten the locking nut. 3. With the MCT set on the same CAL Channel as used to measure the product, make a note of the MCT reading 56

4. Rotate the standard selector knob to the HIGH position and lock into place. Note the MCT reading. At any time in the future, inserting the check standard, and selecting the respective reflectors, will give the same values as previously noted above. If the MCT does not give the same readings to +/- 0.2, then the calibration of the MCT may be in error. Using the Check Standards with multiple calibration channels When the MCT is operating with multiple calibration codes, it is important to only use the check standard on the same Cal Channel. The differences in the calibration coefficients for the various products (zero & span) will give different readings for the check standards. Users may wish to use a vacant Cal Channel as a designated ‘CAL CHECK CHANNEL’. Doing this will allow two convenient values to be setup for the low and high standards. To use this method, decide on a low reading for the low standard, say 2.0 and a high value for the high standard, say 8.0. Now use the calibration development routine to calculate the zero & span values that make the MCT sensor read the 2.0 and 8.0 values. As the Cal Development routine requires 3 data pairs, one set of values needs to be entered twice. Finally store this zero & span value in the CAL CHECK CHANNEL, say # 9. When using the standards make sure that this CAL CHECK CHANNEL is selected prior to inserting the standards.

Calibration Transfer Once the values given by the two standards are known for a specific product calibration, they can be used as ‘stable samples’ for calibrating other sensors. The known values for the standards should be used as the LAB values in the Cal Development routine. 1. 2. 3. 4. 5.

For a new or repaired sensor set the span to 25.0. Select the Low standard and note the MCT reading. Select the High standard and note the MCT reading. Select the CAL DEVELOPMENT routine. Enter the data pairs of MCT reading and known standard values. Enter the High standard twice to get the 3 data pairs. 6. Compute the zero and span values that will make the sensor read the values of the standards. 7. Save these settings in the desired Cal Channel.

57

Appendix V - Serial Communications Protocol for MCT 200 Cables RS232: Via shielded twisted pair. Connection: Signa Digital l Connector # TX 3 RX 4 GND 5

9Pin ‘D’ Connector # 2 3 5

RS485: Via a shielded twisted pair. Connection: Refer to Section 11.0 Communications Programmers writing software should refer to the command list below. The communications is a simple request/reply system. The host computer sends a request and the MCT 200 sends a reply. Hence there are no special protocols or handshaking involved and it is also quite easy for a person to communicate with the MCT 200 via a simple terminal. The timing of the replies it deliberately locked to the wheel revolutions and hence the maximum communications rate is approx. 18 requests/replies per second. Should the wheel or motor fail then a timing software system of 10 loops per second takes over so communications is not lost. When using RS485 a leading “$” or “#” followed by a single, alphanumeric “ID” character wakes up the target unit and it responds with a reply. Each unit on the RS485 daisy chain has a unique ID and hence all units may be accessed across a simple single twisted pair cable. Normally ID’s are A-Z, and the default ID is 9. Hence when adding more MCT 200’s to an existing and running RS485 system, the user will look for the ID 9 unit and assign it a new ID. This process can be repeated for each new unit added. The BAUD rate may be changed by a serial command, but this should not be necessary as the filter data can be extracted at the default 9600 rate and the BAUD rate is not the limiting factor at this communications speed. Maximum BAUD rate is 57600. The communications circuits default to RS485 but circuits automatically detects RS232 signals and when detected the serial stream is automatically routed to the RS232 input and the RS485 goes into a high impedance state. Also the sleep system, which normally requires the correct ID to wake up, is woken up to permit normal RS232 style communications where the ID are not needed. This can be useful as an engineer can walk up to a system, which is on RS485, and plug in a portable PC and immediately start a session, man to machine, with the MCT 200. When the RS232 is unplugged the MCT 200 automatically returns to RS485 and the first # or $ will force the ID system to operate again. 58

RAW? SPAN= SPAN? DAMP= DAMP? WTIM GAIN= GAIN? F1= F1? RESET VER? ID= ID? ANHI= ANHI? ANLO= ANLO? VCC? VP? VN? ZERO= ZERO? LOG= LOG? HOLD? DTYPE= DTYPE? SERNO= SERNO? CAL= CAL? SIG1?

SIG4?

TEMP? AGC 59

RAW?c where c is constituent 0-1. Raw moisture (no SPAN or ZERO) SPAN=n c s.ss where n is CAL (1-10) c is constituent 0-1 (or 0-2 for three constit) SPAN?n c DAMP=n d.dd Response time of the measured signal DAMP?n Returns the wheel revolution time in uS. GAIN=n where n =1 to 255. Actual Gain=(255/n) F1=c f.ff where c is constituent 0-1 RESETS the MCT 200 (like power on). EPROM version. Format ID=n where n must be alphanumeric. Format ANHI=n x.xxx where n=0 for DAC1 and n=1 for DAC2. ANHI=n a.aa where n is CAL (1-10) c is constituent 0-1 (or 0-2 for three constit) ANHI?n same Measured 5v . Measured +15v. Measured –15v. ZERO=n c s.ss where n is CAL (1-10) c is constituent 0-1 ZERO?n c where n is CAL (1-10) c is constituent 0-1 LOG=c x where c is constituent 0-1 x=1 for LOG Reads HOLD switch input level. DTYPE=n n=0,1,2 Sets DAMP mode Electronics serial number (string) CAL=n n is selection 1-10 (CAL CODE) Returns 1 revolution filter data (fast) as string of 12 hex numbers of 3 chars each. To convert to 0-10V values divide hex number by 409.5. Filter data string is F1F1’F2F2’F3F3’F4F4’F5F5’F6F6’ where Fn is signal from the product and Fn’ is the internal compensation signal. Returns 4 revolution data (avg) as string of 12 hex numbers of 3 chars each. To convert to 0-10V values divide hex number by 409.5. Filter data string is F1F1’F2F2’F3F3’F4F4’F5F5’F6F6’ where Fn is signal from the product and Fn’ is the internal compensation signal. Read thermistor volts, note colder gives higher volts. Call the automatic GAIN sub this sets best gain in EEPROM.

MAX? BAUD= CODE= CODE? F2= F2? MOIST? CDRV= CDRV? CTARG= CTARG? DIG= DIG? C1= C1? C2= C2? C3= C3? C4= C4? C5= C5? C6= C6? AVG? DUAL= DUAL? PROD=

Returns largest of all filter signals, used to see if GAIN is OK. Replies at current BAUD then flips to new BAUD. Set Password Read Password. F2=c f.ff where c is constituent 0-1 MOIST?c c=const 0 or 2, where 0 = constituent 1 (e.g. moisture) and 1 = constituent 2 (e.g. oil or coat weight), fault status of 3 hex digits is appended. Take over cooler drive. Read cooler drive (volts) Cooler target volts typically 2.5. Note volts increase with colder temp. Set display digits 0-3 C1=c f.ff where c is constituent 0-2 C values are the constants applied to each filter value in the algorithms. C2=c f.ff where c is constituent 0-1

AVG?c c=0 returns MOISTURE avg c=1 returns OIL DUAL=1 for MCT200, DUAL=0 for MCT 200

PROD=c ppppppppp where c is the Cal Code 0-10 and ppp is a string of 9 characters. PROD? PROD?c returns the string for the selected Cal Code (Constituent variabel is 0-1 for 2 constituent software and 0-2 for three constituent) Maximum values (RS232485 Commands) ZERO – 9999to + 9999 (float) SPAN – 999999to + 999999 (float) F1, F2 and C1 to C6 -9999 to + 9999 (float) DAC 0-10v (float) GAIN 1-255 (integer) DAMP 99 (integer) CAL 1-10 (integer) 60

Abbreviated RS232/485 Commands The following listing is the minimum set of commands that a HOST COMPUTER program will require to be able to display the measured constituent, select different calibration channels, make changes to the calibration coefficients (zero & span) and review sensor diagnostics. Constituent MOIST? MOIST?c c=const 0 or 1, where 0 = constituent 1 (e.g. moisture) and 1 = constituent 2 (e.g. oil or coat weight), fault stat 2HEX is appended. Calibration Parameters CAL= CAL=n n is selection 1-10 (CAL CODE) CAL? ZERO= ZERO=n c s.ss where n is CAL (1-10) c is constituent 0-1 ZERO? ZERO?n c where n is CAL (1-10) c is constituent 0-1 SPAN= SPAN=n c s.ss where n is CAL (1-10) c is constituent 0-1 SPAN? SPAN?n c DAMP= DAMP? ANHI= Format ANHI=n x.xxx where n=0 for DAC1 and n=1 for DAC2. ANHI? ANLO= ANLO?

Diagnostics ID= ID? VER? WTIM VCC? VP? VN? TEMP?

Format ID=n where n must be alphanumeric. EPROM version. Returns the wheel revolution time in uS. Measured 5v . Measured +15v. Measured –15v. Read thermistor volts, note colder gives higher volts.

CDRV?

Read cooler drive (volts)

SIG1?

Returns 1 revolution filter data (fast) as string of 12 hex numbers of 3 chars each. To convert to 0-10V values divide hex number by 409.5. Filter data string is F1F1’F2F2’F3F3’F4F4’F5F5’F6F6’ where Fn is signal from the product and Fn’ is the internal compensation signal.

61

Appendix VI - PI Controller Output The MCT series gauges include a ‘Controller Output’ that may be used to make a change to process machinery to achieve a desired moisture (process variable) level. This ‘Controller Output’ operates using a PI control algorithm. This PI algorithm must be ‘tuned’ for the particular process loop. Without such tuning, it will not be able to function correctly. The PI Control Algorithm The PI control algorithm comprises three elements: Proportional – also known as Gain Integral – also known as Reset Dead-Band The algorithm used in the MCT series gauge uses a combination of these three elements: Proportional and Integral Proportional, Integral and Dead-Band Selecting the Controller Output Selection of the Controller Output is made via the Engineering Menu of the Operator Interface: At any Password request enter a Password of 2882 and press the ENTER key. Use the DOWN Arrow to scroll through the menu selections till the display reads: CONTROL: Y/N Move the cursor over the Y and press the ENTER key The display will momentarily show: CONTROL: ON

62

When selected the Controller Output will be available on the second analog output channel of the sensor The display will then show the following control parameters: CON TARG: 0.00% This is the set point target. Its default value is 0.000 Minimum value is 0.00 Maximum value is 100.00 CON PROP: 1.00 This is the Gain of the control output. It is the ‘step’ change in the output that is made to correct the difference between the measured variable and the set point Gain = Output/Input Increasing the value will cause the output to move in a larger step. Minimum value is 0.0 Maximum value is 99.99 CON INT: 1.00 sec This is the automatic reset that moves the output whenever there is an error between the process variable and the set point. The value is measured in SECONDS. This is the time it takes the reset (or integral) element to repeat the action of the proportional element. The lower the value the faster the proportional action takes place, the higher the value the less frequently it takes place. Default value is 1.00 Minimum Value is 0.00 Maximum Value is 99.99 CON DEAD: 0.00% This is the DEAD-Band of the control system. When the measured variable is inside the Dead-Band the integral reset will stop. The Dead-Band is a value +/- either side of the set point. Default value is 0.00 Minimum value is 0.00 Maximum value is 99.99

63

Control Output Signals The output signal from the controller feature is either a DC voltage or current depending on the terminals used. Voltage: The voltage is a 0 –10V signal where: 5v is provided when the measured variable is at the set point value. ABOVE 5V when the process variable is LESS than the set point. BELOW 5V when the process variable is GREATER than the set point. Current: The current is a 4-20mA signal where: 12mA is provided when the measured variable is at the set point. ABOVE 12mA when the process variable is LESS than the set point. BELOW 12ma when the process variable is GREATER than the set point.

64

Appendix VII – Outline Drawings

65

Declaration of Conformity European Standards Equipment:

MCT Series of Infrared absorption transmitters

The above equipment complies with the following European Directives. Electromagnetic Compatibility Directive 89/336/EEC Amending Directive 91/263/EEC, 92/31/EEC, 93/68/EEC Low Voltage Directive Amending Directive

73/23/EEC 93/68/EEC

In order to achieve this the instrument was tested to the following standards: For EMC EN55022 Class B. EN61000-3-2 and EN61000-3-3 Generic Emission standard for Residential, Commercial and Light Industry. For LVD EN61010-1 (1993) Safety requirements for electrical equipment for measurement, control and laboratory use-General requirements

Manger Responsible:

Ian Johnson

Position:

QC Manager

Date:

August 1st 2001

66

If you have any questions or need technical service please contact Process Sensors Corporation’s Technical Department: Process Sensor Corporation 113 Cedar Street-S5 Milford, MA 01757 Tel: 508-473-9901 Fax: 508-473-0715 [email protected]

You can also visit our website:

67

www.processsensors.com