pr-21 series user guide im-en-pr21sen-c

IM-EN-PR21S-C

User Guide

Process RefractometerPR-21 Series

PUBLISHED BY

Vaisala Oyj

Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland

P.O. Box 26, FI-00421 Helsinki, Finland

+358 9 8949 1

Visit our Internet pages at www.vaisala.com.

© Vaisala 2021

No part of this document may be reproduced,published or publicly displayed in any form or byany means, electronic or mechanical (includingphotocopying), nor may its contents be modified,translated, adapted, sold or disclosed to a thirdparty without prior written permission of thecopyright holder. Translated documents andtranslated portions of multilingual documents arebased on the original English versions. Inambiguous cases, the English versions areapplicable, not the translations.

The contents of this document are subject tochange without prior notice.

Local rules and regulations may vary and theyshall take precedence over the informationcontained in this document. Vaisala makes norepresentations on this document’s compliancewith the local rules and regulations applicable atany given time, and hereby disclaims any and allresponsibilities related thereto.

This document does not create any legallybinding obligations for Vaisala towards customersor end users. All legally binding obligations and

agreements are included exclusively in theapplicable supply contract or the GeneralConditions of Sale and General Conditions ofService of Vaisala.This product contains software developed byVaisala or third parties. Use of the software isgoverned by license terms and conditionsincluded in the applicable supply contract or, inthe absence of separate license terms andconditions, by the General License Conditions ofVaisala Group.This product may contain open source software(OSS) components. In the event this productcontains OSS components, then such OSS isgoverned by the terms and conditions of theapplicable OSS licenses, and you are bound by theterms and conditions of such licenses inconnection with your use and distribution of theOSS in this product. Applicable OSS licenses areincluded in the product itself or provided to youon any other applicable media, depending oneach individual product and the product itemsdelivered to you.

http://www.vaisala.com/

Table of contents

1. About this document.......................................................................................71.1 Version information.............................................................................................71.2 Documentation conventions.............................................................................. 71.3 Trademarks...........................................................................................................8

2. Product overview.............................................................................................. 92.1 Safety....................................................................................................................112.2 Storage conditions, packaging and transportation....................................... 122.3 In-line refractometer sensor............................................................................. 12

3. Mounting............................................................................................................. 143.1 Choosing sensor mounting location................................................................143.2 Mounting examples............................................................................................173.3 Mounting sensor.................................................................................................193.4 Pipe mounting checklist...................................................................................203.5 Checklist for mounting in tank, vessel or large pipe......................................21

4. Indicating transmitter DTR..........................................................................224.1 Mounting indicating transmitter......................................................................224.2 Electrical connections.......................................................................................23

4.2.1 Interconnecting cable................................................................................ 234.2.2 Connecting sensor......................................................................................244.2.3 Connecting indicating transmitter............................................................254.2.4 Power terminals for AC power................................................................... 314.2.5 Power terminals for 24 V DC power.......................................................... 314.2.6 Relay connections.......................................................................................324.2.7 Reset button................................................................................................34

5. Prism wash systems....................................................................................... 355.1 Prism coating.....................................................................................................355.2 Prism wash with integral steam nozzle..........................................................365.3 Prism wash with integral high-pressure water nozzle..................................385.4 Prism wash with flow through cells................................................................ 425.5 Recommended wash pressures and times.................................................... 43

6. Startup and use............................................................................................... 456.1 Startup............................................................................................................... 45

6.1.1 Initial check................................................................................................. 456.1.2 Calibration check........................................................................................466.1.3 Testing prism wash.....................................................................................46

6.2 Using indicating transmitter............................................................................466.2.1 Keyboard functions.................................................................................... 476.2.2 Display setup.............................................................................................. 48

6.3 Viewing system information............................................................................506.4 Viewing sensor status........................................................................................51

6.4.1 Optical image...............................................................................................516.4.2 Diagnostic values........................................................................................526.4.3 Temperature measurement....................................................................... 536.4.4 Sensor head humidity................................................................................ 53

6.5 Sensor verification............................................................................................ 53

Table of contents

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7. Configuration and calibration................................................................... 547.1 Configuring output signal damping............................................................... 54

7.1.1 Exponential damping.................................................................................547.1.2 Linear damping...........................................................................................557.1.3 Slew rate limit..............................................................................................56

7.2 Configuring output signal hold functionality.................................................577.2.1 External hold............................................................................................... 587.2.2 Hold during wash........................................................................................587.2.3 Tolerance time.............................................................................................587.2.4 QF threshold................................................................................................597.2.5 Hold source interactions............................................................................597.2.6 Hold and signal damping.......................................................................... 60

7.3 Configuring refractometer system................................................................. 607.3.1 Configuring relays......................................................................................607.3.2 Configuring input switches....................................................................... 627.3.3 Configuring mA outputs............................................................................64

7.4 Calibrating concentration measurement....................................................... 667.4.1 Chemical curve........................................................................................... 687.4.2 Selecting display units and display decimals..........................................687.4.3 Field calibration.......................................................................................... 697.4.4 Entering field calibration parameters...................................................... 707.4.5 Direct BIAS adjustment............................................................................. 70

7.5 Configuring prism wash.................................................................................... 717.5.1 Wash cycle....................................................................................................717.5.2 Setting prism wash parameters................................................................767.5.3 Mechanical zero adjustment......................................................................77

7.6 Sensor rangeability........................................................................................... 78

8. Regular maintenance.....................................................................................798.1 Checking the sensor humidity level................................................................798.2 Checking the prism and prism gaskets.......................................................... 798.3 Disassembling and assembling the sensor.................................................... 79

8.3.1 Disassembling the sensor......................................................................... 808.3.2 Removing electronic cards PR-10301 and PR-10201................................81

9. Troubleshooting.............................................................................................. 829.1 Hardware............................................................................................................82

9.1.1 Blank display............................................................................................... 859.1.2 Diagnostic LEDs..........................................................................................869.1.3 Display unreadable.....................................................................................889.1.4 Troubleshooting messages....................................................................... 899.1.5 Diagnostic message priorities.................................................................. 94

10. Indicating transmitter DTR specifications............................................9610.1 Compatibility.....................................................................................................96

10.1.1 Transmitter program versions...................................................................9610.2 Model code.........................................................................................................97

10.2.1 Indicating transmitter model codes......................................................... 9710.2.2 Interconnecting cable model code...........................................................97

10.3 Transmitter parts list.........................................................................................9810.4 Specifications.................................................................................................... 98

10.4.1 Indicating transmitter specifications....................................................... 9810.4.2 Interconnecting cable specifications..................................................... 100

11. Sensor specifications....................................................................................10111.1 Model codes...................................................................................................... 101

PR-21 Series User Guide IM-EN-PR21S-C

2

11.2 PR-21-S part list............................................................................................... 10311.3 Sensor PR-21-S................................................................................................ 10511.4 Standard specifications.................................................................................. 10711.5 PR-21-S process refractometers in potentially explosive atmosphere..... 108

11.5.1 Equipment................................................................................................. 10811.6 Intrinsically safe refractometers PR-21-…-IA.................................................110

11.6.1 Equipment....................................................................................................11111.6.2 Intrisincally safe mounting........................................................................11411.6.3 Isolator/barriers..........................................................................................116

12. Ethernet connection specification.......................................................... 11712.1 Cable requirements and connection.............................................................. 117

12.1.1 Ethernet cable specification..................................................................... 11712.1.2 Connecting Ethernet cable....................................................................... 119

12.2 Connection settings..........................................................................................12112.2.1 IP settings for DTR..................................................................................... 12112.2.2 IP settings for stand-alone computer..................................................... 122

12.3 Testing Ethernet connection.......................................................................... 12312.3.1 Troubleshooting connection....................................................................124

12.4 Instrument homepage.....................................................................................12512.4.1 Remote panel............................................................................................ 12612.4.2 Sensor verification certificate.................................................................. 127

12.5 Collecting data using Ethernet.......................................................................12712.5.1 Communication protocol..........................................................................12712.5.2 Request-response pair specification...................................................... 12912.5.3 Error message specification......................................................................131

13. Sensor verification........................................................................................ 13313.1 Refractive index nD verification..................................................................... 133

13.1.1 Handling R.I. liquids.................................................................................. 13413.2 Verification procedure.................................................................................... 13413.3 Sensor verification certificate........................................................................ 13713.4 Corrective action.............................................................................................140

14. Regulatory compliance and certifications..........................................14214.1 EC Declaration of Conformity for PR-21 series of refractometers............. 14214.2 Declaration of Conformity for PR‑21‑…‑IA models (ATEX)........................ 144

Appendix A: Principle of measurement................................................... 146

Appendix B: PR-21 sensor verification form............................................148

Appendix C: Field calibration form........................................................... 149

Appendix D: DTR command selection tree............................................. 150

Appendix E: STR/Divert mode command selection tree...................... 151

Warranty........................................................................................................... 153

Technical support........................................................................................... 153

Recycling.......................................................................................................... 153

Table of contents

3

List of figures

Figure 1 Sensor LPH, model PR-21-S............................................................................10Figure 2 Refractometer equipment PR-21-S.............................................................. 10Figure 3 Labels.....................................................................................................................11Figure 4 Sensor structure.................................................................................................12Figure 5 Image detector system.................................................................................... 13Figure 6 Mounting guide 1/2........................................................................................... 15Figure 7 Mounting guide 2/2.......................................................................................... 16Figure 8 Sandvik LPL and LPS........................................................................................ 17Figure 9 Flange LPL and LPS.......................................................................................... 18Figure 10 DIN, JIS and ANSI 150lbs or 300lbs flanges...............................................19Figure 11 Mounting procedure........................................................................................20Figure 12 Indicating transmitter dimensions and mounting feet measures....... 23Figure 13 Wiring of PR-21-S with DTR...........................................................................24Figure 14 Opening indicating transmitter front panel.............................................. 27Figure 15 External power switch.....................................................................................28Figure 16 Motherboard (AC power)...............................................................................29Figure 17 Motherboard (24 V DC)..................................................................................30Figure 18 Location of reset button.................................................................................34Figure 19 Mounting of integral steam nozzles with DIN, JIS, ANSI

and Sandvik connections................................................................................37Figure 20 Mounting summary of integral prism wash system................................ 38Figure 21 Mounting drawing for integral high‑pressure wash system.................40Figure 22 Wiring drawing: High‑pressure wash system for water..........................41Figure 23 Prism wash with flow through cells.............................................................42Figure 24 Flow through cell nozzles...............................................................................43Figure 25 Main display alternatives................................................................................45Figure 26 DTR keyboard and Main menu for sensor B..............................................48Figure 27 Display setup menu......................................................................................... 49Figure 28 Main display format selection.......................................................................49Figure 29 System description............................................................................................51Figure 30 Typical optical images.....................................................................................52Figure 31 A slope graph.....................................................................................................52Figure 32 Exponential damping...................................................................................... 55Figure 33 Linear damping................................................................................................. 56Figure 34 Slew rate damping............................................................................................57Figure 35 Effect of tolerance time on output.............................................................. 59Figure 36 Damping stops during hold...........................................................................60Figure 37 Relay menu for relay 1...................................................................................... 61Figure 38 Output menu for mA Output 1......................................................................65Figure 39 Default mA output values..............................................................................66Figure 40 Concentration calibration layers...................................................................67Figure 41 Using FIELD SAMPLE soft key...................................................................... 70Figure 42 Automatic prism wash cycle...........................................................................71Figure 43 Wash logic.......................................................................................................... 73Figure 44 Wash cycle..........................................................................................................75Figure 45 Mechanical zero adjustment..........................................................................78Figure 46 Sensor rangeability.......................................................................................... 78Figure 47 Ribbon cable connector.................................................................................. 81Figure 48 Transmitter card positions............................................................................. 83Figure 49 Motherboard PR‑10600 and H1 interface card PR‑10701...................... 84Figure 50 Troubleshooting blank display......................................................................85Figure 51 Checking power supply.................................................................................. 86


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Figure 52 Diagnostic LED functions...............................................................................88Figure 53 Indicating transmitter serial number labels.............................................. 96Figure 54 Indicating transmitter DTR and STR parts (STR-specific

parts in italics)...................................................................................................98Figure 55 Probe parts....................................................................................................... 103Figure 56 Sensor................................................................................................................ 105Figure 57 Refractometer system PR‑21‑…‑FM............................................................109Figure 58 FM nameplate................................................................................................... 110Figure 59 Refractometer system PR‑21‑S‑...‑IA............................................................111Figure 60 IA nameplate..................................................................................................... 112Figure 61 Intrinsically safe parts..................................................................................... 113Figure 62 Warning sticker......................................................................................................Figure 63 Intrinsically safe wiring, PR‑21‑S‑…‑IA........................................................ 115Figure 64 Isolator unit wiring...........................................................................................116Figure 65 Connecting DTR to computer....................................................................... 117Figure 66 Connecting DTR to LAN................................................................................. 118Figure 67 Connecting DTR to hub or switch................................................................118Figure 68 Connecting DTR to WLAN.............................................................................118Figure 69 Using fiber optics Ethernet........................................................................... 119Figure 70 Ethernet connector on underside of front panel.....................................121Figure 71 Typical IP configuration for stand-alone laptop when

connected to DTR; laptop wireless (WLAN) turned off....................... 122Figure 72 Ping OK.............................................................................................................. 124Figure 73 Ping error message.........................................................................................124Figure 74 Instrument homepage open in browser................................................... 126Figure 75 DTR remote panel........................................................................................... 127Figure 76 Sample holder: Part number PR‑5002...................................................... 133Figure 77 Verification, pre-verificaton checks............................................................135Figure 78 Verification display......................................................................................... 135Figure 79 Typical optical images................................................................................... 136Figure 80 Verification in progress..................................................................................136Figure 81 Verification completed successfully (here only with one RI liquid).. 137Figure 82 Instrument verification page open in browser........................................138Figure 83 Instrument verification certificate.............................................................. 139Figure 84 Verification failed............................................................................................140Figure 85 Finding verification information for sensor verification form............. 141Figure 86 Refractometer principle................................................................................ 146Figure 87 Optical images................................................................................................. 147Figure 88 Optical image detection................................................................................147

List of figures

5

List of tables

Table 1 Document versions (English)..............................................................................7Table 2 Recommended wash pressures and times...................................................44Table 3 Chemical curve parameters.............................................................................. 68Table 4 Diagnostic LEDs................................................................................................... 87Table 5 Hardware troubleshooting................................................................................89Table 6 Measurement troubleshooting..........................................................................91Table 7 Wash troubleshooting........................................................................................93Table 8 Indicating transmitter DTR and STR model codes..................................... 97Table 9 Interconnecting cable model code................................................................. 97Table 10 Indicating transmitter specifications..............................................................98Table 11 Interconnecting cable specifications........................................................... 100Table 12 PR‑21‑S models.................................................................................................... 101Table 13 Transmitter models for 100 … 240 V AC...................................................... 102Table 14 Transmitter models for 24 V DC.....................................................................102Table 15 Cables.................................................................................................................... 102Table 16 Standard specifications.................................................................................... 107Table 17 Request-response pair specification............................................................ 129Table 18 Verification results display...............................................................................148


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1. About this document

1.1 Version informationThis document provides instructions for installing, using and maintaining Vaisala K‑PatentsâProcess Refractometer PR‑21‑S.

Table 1 Document versions (English)

Document code Date Description

IM‑EN‑PR21S, C June 2021 Model codes and specifications updated. Minor structure and styleupdates.

IM‑EN‑PR21S, B December 2019 Model codes, specifications updated.

IM‑EN‑PR21S, A September 2019 K‑Patents → Vaisala change, new covers.

1.2 Documentation conventions

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

Caution warns you of a potential hazard. If you do not read and followinstructions carefully at this point, the product could be damaged or important datacould be lost.

CAUTION!

Note highlights important information on using the product.

Tip gives information for using the product more efficiently.

Lists tools needed to perform the task.

Chapter 1 – About this document

7

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

1.3 TrademarksVaisalaâ and K-PATENTSâ are registered trademarks of Vaisala Oyj.

Linuxâ is a registered trademark of Linus Torvalds.

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

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


8

2. Product overviewThe Vaisala K-PATENTSâ In-line Refractometer is an instrument for measuring liquidconcentration in the process line. The measurement is based on the refraction of light in theprocess medium, an accurate and safe way of measuring liquid concentration.

The in-line refractometer sensor measures the refractive index nD and the temperature ofthe process medium, see Figure 1 (page 10). This information is sent through theinterconnecting cable to the indicating transmitter, see Figure 2 (page 10). The indicatingtransmitter DTR calculates the concentration of the process liquid based on the refractiveindex and temperature, taking pre-defined process conditions into account. The output ofthe DTR is a 4 … 20 mA DC output signal proportional to process solution concentration.Process data can also be downloaded to a computer via an Ethernet cable. The labels on therefractometer show the technical model specifications of the refractometer, see Figure 3(page 11).

Chapter 2 – Product overview

9

Figure 1 Sensor LPH, model PR-21-S

Figure 2 Refractometer equipment PR-21-S


10

Model: INDICATING TRANSMITTERProduct code: DTR-U-GP-ACS/N: T06802Tag:100-240 V AC, 50/60 Hz, 30 VA Made by VAISALA Oyj, Vantaa, Finland

www.vaisala.com IP66

Dual transmitter label

Figure 3 Labels

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

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

Precautions when removing the sensor from the process line:

• Make positively sure that the process line is not under pressure. Open a vent valve tothe atmosphere.

• For a prism wash system, close a hand valve for the wash medium and disable the washvalve.

• Loosen the flange or clamp cautiously, be prepared to tighten again.• Be out of the way of any possible splash and ensure the possibility of escape.• Use shields and protective clothing adequate for the process medium, do not rely on

avoidance of contact with the process medium.• After removal of the sensor, it may be necessary to mount a blind cover for security

reasons.

Wear protective eyewear.

Wear protective gloves.


11

It is the user’s responsibility to follow manufacturer’s safety and operating instructions. Theclient’s organization has the responsibility to develop and maintain occupational safety andcreate a safety culture where individuals are expected to follow safety instructions at alltimes. Any negligence towards safety instructions or failure to comply with safe practicesshould not be tolerated. It is the manufacturer’s responsibility to produce goods that aresafe to use when instructions are followed.

The process medium may be hot or otherwise hazardous. Use shields and protectiveclothing adequate for the process medium. Do not rely on avoidance of contact with theprocess medium.

2.2 Storage conditions, packaging andtransportation

Soft shell packaging prevents damage to the refractometer. Transport the device in itsoriginal packaging.

Before storing, remove any dirt and grease from the refractometer and make sure that it isdry.

Storage conditions:

• Temperature: −40 …+40 °С (−40 … +104 °F)• Humidity: No condensation

2.3 In-line refractometer sensorThe process refractometer sensor is shown in Figure 4 (page 12). The measurement prism(A) is flush mounted in the oblique surface near the tip. The light source (B) is a lightemitting diode.

The process refractometer uses a CCD element (C) which has 3648 photocells in a rowintegrated on one chip.

A

B

CD

EF G

Figure 4 Sensor structure


12

The image detector output is a pulse train, as shown in Figure 5 (page 13). This number ofhigh pulses corresponds to the position of the shadow edge in the optical image. Thenumber of high pulses is a direct measure of the critical angle. The sensor processor card (E)receives the raw data from CCD element (C) and the temperature probe (F).

The digital image sensor (C) is separated from the process heat by fiber optics (D) and thethermal isolation (G). It is housed in the air-cooled sensor head.

a. Optical image

b. CCD element

c. CCD output

V

Figure 5 Image detector system


13

3. Mounting

3.1 Choosing sensor mounting locationThe sensor is delivered with mounting guides attached. The sensor is designed to beinstalled directly in a process line. If the sensor is located outdoors, protect the sensoragainst direct exposure to sunlight and rain.

Air-cooling

Normally, draught and natural convection provide sufficient air cooling. Criteria for efficientair-cooling:

• Mount the sensor with the main axis horizontal, see Figure 7 (page 16).• Make sure that there are no obstacles for air to flow around the sensor head.• Make sure that the sensor cover is not exposed to high temperature radiation.

If the ambient temperature is higher than 45 °C (113 °F) the air-cooling should be improvedby blowing pressurized air against the sensor cover. This is also recommended when theprocess temperature is above 110 °C (230 °F) and the ambient temperature is above 35 °C(95 °F). The pressurized air can be supplied by the ventilation system. If no air is available itis possible to wrap a copper coil for cooling water around the sensor head cover.

Process flow conditions

The sensor is designed to make the prism self-cleaning. To ensure a representative sampleand also prism cleaning action, a good process flow should be directed against the prismsurface. A flow velocity above 1.5 m/s (5 ft/s) is recommended. For lower velocities prismwash (Section 4) should be considered. Flow velocity is calculated from v[m/s] = 21.2 * Flow[lit/min]/d²[mm]; v[m/s] = 0.125 * Flow[Gpm]/d²[in]. Accumulation ofsediment or of gas bubbles should be prevented. If the process pipe vibrates, support thepipe.


14

Prevent outside light .

+.M

ax. cable length

Display on eye-level ( Sensor A

+ Sensor B) 200 �

Easy access

Am

bient air cooling

E·)

��

�@

�-

--

External m

ain switch

High pressure High tem

perature Ethernet

2 x

4-2

0 m

A

10

0-2

40

V A

C

Easy access Upper pipe bend

High pressure

Small diam

eter High tem

perature High velocity >1.5 m

/s (>5 ft/s)

Figure 6 Mounting guide 1/2

Chapter 3 – Mounting

15

Figure 7 Mounting guide 2/2


16

3.2 Mounting examplesFor mounting drawing for desired pipe diameter and connection type, contact yourrepresentative.

No special mounting parts are needed to mount the process refractometer. For all processpipe diameters just a standard piece of 88.9 x 3.6 steel pipe is used as adapter. For smallprocess pipe diameters the piece of pipe is sealed in the other end to form a flow cell. Forexamples of different mounting options, see Figure 8 (page 17), Figure 9 (page 18), andFigure 10 (page 19).

For flanged mounting, the user has to provide the counter flange. For clamp mountingVaisala provides a weld-on ring. Flow cells can be supplied by Vaisala.

Figure 8 Sandvik LPL and LPS


17

20.3

516.50

11.9

302

5.5139

2.563.50

5.1130

10.7

271.50

LPL: DIN, JIS and ANSI 150 lbs or 300 lbs

20.3

516.50

5.9

149.50

5.5139

2.563.50

5.1130

4.7

119

LPS: DIN, JIS and ANSI 150 lbs or 300 lbs

Figure 9 Flange LPL and LPS


18

Figure 10 DIN, JIS and ANSI 150lbs or 300lbs flanges

3.3 Mounting sensorFollow these instructions when mounting the sensor.


19

Figure 11 Mounting procedure

1. Make sure the sensor is connected to the process line.

2. Identify the sensor by the serial number (a).

3. Check flow direction.If the fitting has a fixed flange, the bolt holes should allow proper flow alignment of theprobe. If this is not the case, remove the two fixing bolts (see PR-21-S part list(page 103) sensor item 2.2). The sensor flange (b) can then be freely rotated.Save the bolts, as they are useful at dismounting or if the sensor needs to be sent forservice fixed flange is recommended.

4. If there is a strong cooling effect that might cause prism coating, make sure that thesensor flange is heat-insulated.For more information, see Prism coating (page 35).

If the process medium is hot and sticky, heat the probe by using hot water beforemounting. A cool prism tends to get rapidly coated.

3.4 Pipe mounting checklistMost in-line refractometer models are mounted in a pipe. The recommended minimum flowvelocity is 1.5 m/s (5 ft/s). The diameter and form of the pipe and the process temperatureaffect the measurement and need to be taken into account.

1. If the process pipe diameter varies, select the position with the smallest diameter (andaccordingly highest velocity). Then the prism keeps better clean.

2. If the refractometer is used in a feed-back control loop, make the time lag short. Whena dilution valve is controlled, for example, mount the refractometer close to the dilutionpoint. However, make sure complete mixing has occurred at mounting location.


20

3. If the temperature varies along the process pipe, select the position with the highestprocess temperature. Then the risk of prism coating is minimized, because highertemperature means higher solubility and also lower viscosity.

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

5. The sensor is accessible for service.

3.5 Checklist for mounting in tank, vesselor large pipe

A probe sensor PR-21-S can be inserted with a flange or clamp into tanks and vessels whicheither do not have a scraper or where the mixer does not touch the vessel wall.

1. The inserted probe sensor is mounted close to a stirrer to ensure representative sampleof the process liquid and to keep the prism clean.

2. The sensor is accessible for service.3. Make sure that free cooling air reaches the refractometer sensor cover.


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4. Indicating transmitter DTR

4.1 Mounting indicating transmitter

Warning! The DTR does not have a built-in power switch. The system is always powered on when connected to a power source. It is recommended to mount an external power switch to control the DTR’s power supply.

Varoitus! DTR:ssä ei ole sisäänrakennettua virtakytkintä. Järjestelmän virta on aina päällä, kun se on kytketty virtalähteeseen. DTR:n virransyötön ohjaamiseksi on suositeltavaa asentaa ulkoinen virtakytkin.

Varning! DTR har ingen inbyggd strömbrytare. Systemet är alltid påslaget när det är anslutet till en strömkälla. Rekommendationen är att montera en extern strömbrytare för att styra strömförsörjningen till DTR:er.

Advarsel! DTR har ikke nogen indbygget afbryder. Systemet er altid tændt, når det er tilsluttet en strømkilde. Det anbefales at montere en ekstern afbryder til styring af DTR'ens strømforsyning.

Hoiatus! DTR-il puudub sisseehitatud toitelüliti. Süsteem on alati pinge all, kui on toiteallikaga ühendatud. DTR-i toiteallika juhtimiseks on soovitatav paigaldada väline toitelüliti.

Внимание! DTR н е имеет встроенного переключателя питания. Если система подключена к источнику питания, она всегда включена. Для управления подачей питания на DTR рекомендуется установить внешний переключатель питания.

Įspėjimas! DTR ne turi įmontuoto maitinimo jungiklio. Sistema visada įjungiama, kai ji yra prijungta prie maitinimo šaltinio. DTR maitinimo šaltiniui valdyti rekomenduojama sumontuoti išorinį maitinimo jungiklį.

Ostrzeżenie! DTR nie zawiera wbudowanego wyłącznika zasilania. Zasilanie systemu jest włączone zawsze, gdy jest on podłączony do źródła zasilania. Wskazane jest wykonanie zewnętrznego wyłącznika zasilania do sterowania zasilaniem DTR.

Varování! DTR nemá vestavěný vypínač napájení. Po připojení ke zdroji napájení je systém vždy zapnutý. Pro ovládání napájení DTR se doporučuje namontovat externí vypínač.

Figyelmeztetés! A DTR nem rendelkezik beépített hálózati kapcsolóval. A rendszer mindig be van kapcsolva, ha áramforráshoz csatlakozik. A DTR tápellátásának vezérléséhez ajánlott egy külső tápkapcsolót felszerelni.

Warnung! Der DTR ist nicht mit einem eingebauten Netzschalter ausgestattet. Das System ist immer eingeschaltet, wenn es an eine Stromquelle angeschlossen ist. Es wird empfohlen, einen externen Netzschalter zu installieren, um die Stromversorgung des DTR zu steuern.

Waarschuwing! De DTR heeft geen ingebouwde voedingsschakelaar. Het systeem is altijd ingeschakeld wanneer het is aangesloten op een voedingsbron. Het wordt aanbevolen om een externe voedingsschakelaar te monteren om de voeding van de DTR te regelen.

Avertissement ! Le DTR n’est pas équipé d’un interrupteur d'alimentation intégré. Le système est toujours sous tension lorsqu'il est connecté à une source d'alimentation. Il est recommandé de monter un interrupteur d'alimentation externe pour contrôler l'alimentation du DTR.

¡Advertencia! El DTR no tiene un interruptor de encendido integrado. El sistema siempre está encendido cuando está conectado a una fuente de alimentación. Se recomienda montar un interruptor de encendido externo para controlar la fuente de alimentación del DTR.

Avvertimento! Il DTR non dispone di un interruttore di alimentazione integrato. Il sistema è sempre acceso quando è collegato a una fonte di alimentazione. Si consiglia di montare un interruttore di alimentazione esterno per controllare l'alimentazione del DTR.

Warning


22

Mount the indicating transmitter indoors, preferably in an easily accessible, well-lit and dryarea. Avoid vibration. Take interconnecting cable length into consideration when choosingthe mounting location.

The enclosure is mounted vertically on an upright surface (wall) using four mounting feet,see the following figure. The LCD is best viewed when approximately at the eye level of theuser.

In sanitary installations, the recommendation is to use a DTR with stainless steel enclosure. Ifstandard polycarbonate enclosure is used, install it as remotely as practical from productareas or connections.

Do not drill mounting holes in the enclosure as that affect the protectionclass of the enclosure and damage the electronics.CAUTION!

mm[in]

267

[10.

5]

226 [8.9] 159 [6.25]

278

[10.

94]

152 [6.0]

Figure 12 Indicating transmitter dimensions and mounting feet measures

4.2 Electrical connections

4.2.1 Interconnecting cableThe cable contains a pair of twisted signal wires and a cable shield, see Figure 16 (page 29).Standard delivery is 10 m (33 ft) of cable. The maximum length of an interconnecting cableis 200 m (660 ft). The signal wires are interchangeable (non-polarized). The cable shield isconnected to the protective earth at the indicating transmitter.

The junction box enables the use of customer’s own cable as long as it meets IEC 61158-2type A standard requirements, see Interconnecting cable specifications (page 100).

More information

‣ Connecting sensor (page 24)

Chapter 4 – Indicating transmitter DTR

23

4.2.2 Connecting sensorOld PR‑01‑S cables (model codes PR‑8001‑XXX) can be used if they are in good shape andshorter than 100 m (328 ft).

Figure 13 Wiring of PR-21-S with DTR


24

More information

‣ Interconnecting cable (page 23)

4.2.3 Connecting indicating transmitter

Warning! Check that the power is off before opening the front panel. If the green power indicator light is on, there is still power in the system. To completely turn the power off, use the external power switch.

Varoitus! Tarkista, että virta on katkaistu, ennen kuin avaat etupaneelin. Jos vihreä virran merkkivalo palaa, järjestelmässä on edelleen virtaa. Katkaise virta kokonaan ulkoisella virtakytkimellä.

Varning! Kontrollera att strömmen är avstängd innan du öppnar frontpanelen. Om den gröna indikatorlampan lyser är det fortfarande ström i systemet. Använd den externa strömbrytaren för att stänga av strömmen helt.

Advarsel! Kontroller, at strømmen er slukket, før frontpanelet åbnes. Hvis den grønne strømindikatorlampe er tændt, er der stadig strøm i systemet. Brug den eksterne afbryder for at slukke helt for strømmen.

Hoiatus! Enne esipaneeli avamist kontrollige, et süsteem poleks pinge all. Kui roheline toitemärgutuli põleb, on süsteemis endiselt pinge all. Toite täielikuks väljalülitamiseks kasutage välist toitelülitit.

Внимание! Перед открытием передней панели убедитесь, что питание отключено. Если горит зеленый индикатор питания, система находится под напряжением. Чтобы полностью отключить питание, используйте внешний переключатель питания.

Įspėjimas! Prieš atidarydami priekinį skydelį, patikrinkite, ar maitinimas išjungtas. Jei šviečia žalia maitinimo indikatoriaus lemputė, sistemoje vis dar veikia maitinimas. Norėdami visiškai išjungti maitinimą, naudokite išorinį maitinimo jungiklį.

Ostrzeżenie! Przed otwarciem panelu przedniego sprawdzić, czy zasilanie jest wyłączone. Dopóki świeci się zielona kontrolka zasilania, system znajduje się pod napięciem zasilania. W celu całkowitego wyłączenia zasilania należy użyć zewnętrznego wyłącznika zasilania.

Varování! Před otevřením předního panelu zkontrolujte, zda je napájení vypnuto. Pokud svítí zelená kontrolka napájení, je v systému stále přítomno napájení. Chcete-li napájení zcela vypnout, použijte externí vypínač.

Figyelmeztetés! Az előlap kinyitása előtt ellenőrizze, hogy a készülék ki van-e kapcsolva. Ha a zöld tápellátás jelzőfény világít, akkor a rendszer még áram alatt van. A készülék teljes kikapcsolásához használja a külső tápkapcsolót.

Warnung! Prüfen Sie, ob das Gerät ausgeschaltet ist, bevor Sie die Frontblende öffnen. Wenn die grüne Betriebsanzeige leuchtet, liegt noch Spannung an. Verwenden Sie den externen Netzschalter, um das Gerät vollständig auszuschalten.

Waarschuwing! Controleer of de stroom is uitgeschakeld voordat u het voorpaneel opent. Als het groene stroomindicatielampje brandt, staat er nog stroom op het systeem. Gebruik de externe voedingsschakelaar om de stroom volledig uit te schakelen.

Avertissement! Vérifiez que l'alimentation est coupée avant d'ouvrir le panneau avant. Si le voyant d'alimentation vert est allumé, le système est toujours sous tension. Pour mettre l'appareil complètement hors tension, utilisez l'interrupteur d'alimentation externe.

¡Advertencia! Verifique que la alimentación está desconectada antes de abrir el panel frontal. Si la luz indicadora de encendido de color verde está encendida, aún hay energía en el sistema. Para apagar completamente la alimentación, use el interruptor de encendido externo.

Avvertimento! Verificare che l'alimentazione sia spenta prima di aprire il pannello anteriore. Se la spia di alimentazione verde è accesa, il sistema è ancora alimentato. Per spegnere completamente l'alimentazione, utilizzare l'interruttore di alimentazione esterno.

Warning


25

Warning! Install the external power switch in accordance to the local installation requirements.

Varoitus! Asenna ulkoinen virtakytkin paikallisten asennusvaatimusten mukaisesti.

Varning! Installera den externa strömbrytaren i enlighet med lokala installationskrav.

Advarsel! Installer den eksterne afbryder i overensstemmelse med de lokale installationskrav.

Hoiatus! Paigaldage väline toitelüliti vastavalt kohalikele paigaldusnõuetele.

Внимание! Установите внешний переключатель питания в соответствии с местными требованиями к установке.

Įspėjimas! Išorinį maitinimo jungiklį sumontuokite laikydamiesi vietinių įrengimo reikalavimų.

Ostrzeżenie! Zewnętrzny wyłącznik zasilania musi być zamontowany zgodnie z miejscowymi wymaganiami dotyczącymi instalacji elektrycznych.

Varování! Externí vypínač nainstalujte v souladu s místními požadavky na instalaci.

Figyelmeztetés! A külső tápkapcsolót a helyi telepítési követelményeknek megfelelően kell felszerelni.

Warnung! Beachten Sie beim Installieren des externen Netzschalters die örtlichen Vorschriften.

Waarschuwing! Installeer de externe voedingsschakelaar conform de plaatselijke installatievereisten.

Avertissement! Installez l'interrupteur d'alimentation externe conformément aux exigences d'installation locales.

¡Advertencia! Instale el interruptor de encendido externo según los requisitos de instalación locales.

Avvertimento! Installare l'interruttore di alimentazione esterno in base ai requisiti di installazione locali.

Warning

All the electrical terminals of the indicating transmitter are behind the front panel. To accessthem, first open the enclosure cover. Then loosen the front panel screw in the figure below,and swing open the front panel. All terminals are now accessible.


26

1

2

Figure 14 Opening indicating transmitter front panel

1 Power indicator light2 Front panel screw

Make sure that you mount an external power switch for the divert control unit that is close tothe unit and easily reachable. Make sure that you mark it as a disconnecting device. Thefollowing figure shows the recommended external power switch, spare part nr PR‑10900.The ratings of the switch are 10 A and 250 V.


27

000

100 … 240 V AC / 50 … 60 Hz

Figure 15 External power switch


28

The following figure shows the motherboard of the indicating transmitter for AC power.

6

Figure 16 Motherboard (AC power)


29

The following figure shows the motherboard of the indicating transmitter for 24 V DC power.

+ -POWER

6

Figure 17 Motherboard (24 V DC)

The following table describes the terminals on the H1 interface card PR‑10701 and on thetransmitter motherboard PR‑10600.

Terminal Usage

On H1

A 1 2 3 Connection for Sensor A, signal wires (1, 2), cable shield (3).

B 1 2 3 Connection for Sensor B, signal wires (1, 2), cable shield (3).

On motherboard

11 12 4 … 20 mA output 1, positive (11), negative (12), max. load 1000 Ω,galvanically isolated.

13 14 4 … 20 mA output 2, positive (13), negative (14), max. load 1000 Ω,galvanically isolated.

21 221) Relay 1, one contact output, max. 240 V AC, max. 3 A, fuse with voltage250 V AC, max fuse size 3 A, speed slow.

23 241) Relay 2, one contact output, max. 240 V AC, max. 3 A, fuse with voltage250 V AC, max fuse size 3 A, speed slow.


30

Terminal Usage

31 32 331) Power, L (31), N (32), protective earth (33), 100 … 240 V AC, 50 … 60 Hz,fuse with voltage 250 V AC, max. size 10 A and speed slow. An externalpower switch is mandatory.

Power, + (31), - (32), protective earth (33), 24 V DC ± 10%, fuse withvoltage min 48 V DC, max. size 4 A and speed fast.

41 42 24 V terminal for DTR internal use only.

Connecting terminal to external 24 V supply voidsthe warranty. Connecting external devices to 24 Vterminal voids the warranty.

51 52 53 54 55 Switch inputs: switch 1 (51), switch 2 (52), switch 3 (53), switch 4 (54)and common 3 V for all inputs (55). The switch terminals are galvanicallyisolated.

1) Wiring to terminals should be min. 1.5 mm2 (AWG 18). The fuse voltage should be 250 V, max. size 10 A and fuse speed slow.Torque used is 0.5 Nm … 0.6 Nm. Stripping length is 8 mm for wires.

4.2.4 Power terminals for AC powerThe primary AC power is connected to a separate terminal strip 31/32/33 marked POWER inthe lower right-hand corner of the motherboard. The three terminals are marked 31/L, 32/Nand 33/ (protective earth). The power terminal 33/ is directly connected to the exposedmetal parts of the indicating transmitter DTR. Wiring to the terminals must be of min.1.5 mm2. The fuse voltage should be 250 V, max. size 10 A and fuse speed slow. Ensure thatthe protective fuse in the building system complies with local requirements.

4.2.5 Power terminals for 24 V DC powerThe DC power is connected to a terminal stripe marked POWER in the lower right-handcorner of the motherboard. The three terminals are marked 31/+, 32/− and 33/(protectiveearth). The power terminal is directly connected to the exposed metal parts of the indicatingtransmitter DTR. Fuse voltage should be min. 48 V DC, max. size 4 A and fuse speed fast.Ensure that the protective fuse in the building system complies with local requirements.

The 24 V DC power to this terminal stripe must be supplied from a secondary circuit which isdouble or reinforced insulated from the mains supply within the limits for a limited-energycircuit (maximum 200 VA/U) according to the IEC 61010-1.


31

4.2.6 Relay connections

Warning! Connect only AC or DC power to relays. You can connect AC power to both relays or DC power to both relays, but never connect AC in one and DC in the other relay.

Varoitus! Kytke releisiin vain vaihtovirta tai tasavirta. Voit kytkeä vaihtovirran molempiin releisiin tai tasavirran molempiin releisiin, mutta älä koskaan kytke yhteen releeseen vaihtovirtaa ja toiseen releeseen tasavirtaa.

Varning! Anslut endast en AC- eller DC-strömkälla till reläer. Du kan ansluta en AC-strömkälla till båda reläerna eller en DC-strömkälla till båda reläerna, men aldrig ansluta en AC-strömkälla till det ena reläet och en DC-strömkälla till det andra.

Advarsel! Tilslut kun vekselstrøm eller jævnstrøm til relæerne. Du kan slutte vekselstrøm til begge relæer eller jævnstrøm til begge relæer, men tilslut aldrig vekselstrøm til det ene og jævnstrøm til det andet relæ.

Hoiatus! Ühendage releed ainult vahelduvvoolu- või alalisvooluvõrku. Võite mõlemad releed ühendada kas vahelduvvooluvõrku või alalisvooluvõrku, ent mitte kunagi ühte releed vahelduvvooluvõrku ja teist alalisvooluvõrku.

Внимание! Подключайте к реле только питание переменным или постоянным током. К обоим реле можно подключить питание переменным или постоянным током, но никогда не подключайте к одному реле питание переменным током, а к другому ----- питание постоянным током.

Įspėjimas! Prijunkite tik AC arba nuolatinę srovę relėms. Galite prijungti kintamąją srovę prie abiejų relių arba nuolatinę srovę prie abiejų relių, bet niekada nejunkite kintamosios srovės vienoje ir nuolatinės srovės kitoje.

Ostrzeżenie! Do przekaźników podłączać tylko AC lub DC. Do obu przekaźników może być podłączone zasilanie AC lub zasilanie DC, ale nie wolno podłączać zasilania AC do jednego, a zasilania DC do drugiego przekaźnika.

Varování! K relé připojte pouze střídavé nebo stejnosměrné napájení. Můžete připojit střídavé napájení k oběma relé nebo stejnosměrné napájení k oběma relé, ale nikdy nepřipojujte k jednomu relé střídavé a k druhému stejnosměrné napájení.

Figyelmeztetés! Csak AC vagy csak DC tápellátást csatlakoztasson a relékhez. Csatlakoztathat AC tápellátást mindkét reléhez, vagy DC tápellátást mindkét reléhez, de soha ne csatlakoztasson az egyikhez AC, a másikhoz pedig DC tápellátást.

Warnung! Nur Wechselstrom oder Gleichstrom an die Relais anschließen. Sie können Wechselstrom an beide Relais oder Gleichstrom an beide Relais anschließen, dürfen aber keinesfalls Wechselstrom an ein und Gleichstrom an das andere Relais anschließen.

Waarschuwing! Sluit alleen AC- of DC-voeding aan op relais. U kunt AC-voeding aansluiten op beide relais of DC-voeding op beide relais, maar sluit nooit AC-voeding aan op het ene en DC-voeding aan op het andere relais.

Avertissement! Connectez uniquement une alimentation CA ou CC aux relais. Vous pouvez connecter une alimentation CA aux deux relais ou une alimentation CC aux deux relais, mais ne connectez jamais une alimentation CA à un relais et une alimentation CC à l'autre relais.

¡Advertencia! Conecte solo la alimentación de CA o de CC a los relés. Puede conectar la alimentación de CA a ambos relés o la alimentación de CC a ambos relés, pero nunca podrá conectar una alimentación de CA en un relé y una alimentación de CC en el otro relé.

Avvertimento! Collegare ai relè solamente l'alimentazione CA o CC. È possibile collegare l'alimentazione CA o CC a entrambi i relè, ma non collegare mai l'alimentazione CA in un relè e l'alimentazione CC nell'altro relè.

Warning


32

Warning! Multiple power sources. The relays are powered from external circuits.

Varoitus! Useita virtalähteitä. Releet saavat virtaa ulkoisista piireistä.

Varning! Flera strömkällor. Reläerna drivs från externa kretsar.

Advarsel! Flere strømkilder. Relæerne får strøm fra eksterne kredsløb.

Hoiatus! Mitu toiteallikat. Releed saavad toidet välistest vooluahelatest.

Внимание! Несколько источников питания. Реле питаются от внешних цепей.

Įspėjimas! Keli energijos šaltiniai. Relės maitinamos iš išorinių grandinių.

Ostrzeżenie! Więcej niż jedno źródło zasilania. Przekaźniki zasilane są z zewnętrznych obwodów.

Varování! Více zdrojů napájení. Relé jsou napájena z externích obvodů.

Figyelmeztetés! Több áramforrás. A relék táplálása külső áramkörökből történik.

Warnung! Mehrere Stromquellen. Die Relais werden über externe Stromkreise gespeist.

Waarschuwing! Meerdere voedingsbronnen. De relais worden gevoed door externe circuits.

Avertissement! Sources d'alimentation multiples. Les relais sont alimentés à partir de circuits externes.

¡Advertencia! Varias fuentes de alimentación. Los relés se alimentan de circuitos externos.

Avvertimento! Molteplici fonti di alimentazione. I relè sono alimentati da circuiti esterni.

Warning


33

4.2.7 Reset buttonYou can reset and restart both the indicating transmitter DTR and the sensor by pushing thereset button. You can access the button through the cable hole in the front panel shield asshown in the following figure. To reach the reset button, use a thin stick or similar utensil,preferably of non-conducting material. After pushing the reset button, the display blacks outfor a few seconds. The instrument returns to full operation within 30 s.

Resetbutton

Figure 18 Location of reset button


34

5. Prism wash systemsThree alternatives of prism wash systems can be provided:

1. Steam wash with integral nozzle, see Prism wash with integral steam nozzle (page 36)2. High-pressure water with integral nozzle, see Prism wash with integral high-pressure

water nozzle (page 38)3. Steam and water wash for flow cell mounting, see Prism wash with flow through cells

(page 42)

In most of the applications the prism wash is not necessary. However, installing a washnozzle should always be considered. A prism wash nozzle can be useful in cases wherenormally no prism coating occurs, for example to clean the prism after a process stop usinga manual wash valve. Washing can also be used for operational check (output signaldecreases during wash) or as a part of maintenance schedule.

5.1 Prism coatingDeposit build up on the prism surface disturbs measurement. Look out for the followingindications of coating:

• Abnormally high concentration reading or upward CONC.• CCD value is getting higher and QF value drops down.• High LED current, especially LED = 100 (max). See Viewing sensor status (page 51).• Prism wash (see Testing prism wash (page 46)) does not change optical image.

In most of the applications the prism will keep clean, but if coating occurs, check thefollowing:• Sensor mounted correctly in respect to flow direction (arrow on sensor head).• Sufficient flow velocity, see Choosing sensor mounting location (page 14)• A temperature difference between process fluid and sensor probe may cause

coating. This may happen for small flows if the thermal insulation is inadequate. Insome cases it helps to insulate also the connection flange, Figure 7 (page 16).

If there is a coating problem, it is recommended to try to increase the flow velocity, forexample by installing a pipe portion with smaller diameter. If this cannot be done, the prismshould be automatically washed at regular intervals, for example by steam or hot water. Aprism wash nozzle (see Prism wash with integral steam nozzle (page 36)) can be usefulalso in cases without coating problems, for example to clean the prism after a process stopusing a manual wash valve.

Chapter 5 – Prism wash systems

35

5.2 Prism wash with integral steamnozzle

Prism wash with integral steam nozzle is for use in applications where steam can removecoating from pipe lines. For other applications see Prism wash with integral high-pressurewater nozzle (page 38) and Prism wash with flow through cells (page 42). The integralnozzle is mounted on the sensor head (see Figure 19 (page 37)). Integral steam nozzle(HPS) can be equipped for a long probe sensor with standard insertion length (LPS) andwith the following process connections:

• Sandvik L‑clamp, 80 mm• ANSI‑flange 150 lbs• DIN flange 2556, PN25, DN 80• JIS flange, 10 K 80 A

The earlier mentioned sensors are equipped with an integral nozzle connection (HPY) as astandard. An integral steam nozzle can be easily fitted afterwards, if required. Figure 20(page 38) shows recommended components for a prism wash system with integral steamnozzle. The components are provided by Vaisala. The steam line should be equipped with acheck valve (see Figure 20 (page 38)). If the process medium solidifies at ambienttemperature, the check valve should be insulated (see Figure 7 (page 16)). A condensatetrap should be used to keep the steam line hot (see Figure 20 (page 38)). Alternatively, anexternal timer can be used. The timer should be equipped with extra contact which is keptclosed during prism washes.

Do not connect the extra contact to external voltage. For recommendedwash pressures and times see Recommended wash pressures and times (page 43).WARNING!

In intrinsically safe system solenoid valves are mounted in the safe area and the pneumaticvalves in hazardous area.


36

Figure 19 Mounting of integral steam nozzles with DIN, JIS, ANSI and Sandvik connections


37

Figure 20 Mounting summary of integral prism wash system

Part Part specification Supplied by Qty

1 Indicating transmitter DTR Vaisala 1

2 Sensor PR‑21‑S Vaisala 1

3 Cable PR‑8023 between indicating transmitter andsensor

Vaisala 1

4 Shut‑off valve and steam trap PR‑3340‑230/110 Vaisala 1

5 Check valve PR‑3303 Vaisala 1

6 Strainer PR‑3342 Vaisala 1

7 Steam pipe ½ in Customer 1

8 Steam pipe ¼ in Customer 1

9 AC power supply 230/110 V Customer 2

5.3 Prism wash with integral high-pressure water nozzle

Integral high‑pressure water prism wash is recommended to be used in applications whereconventional wash (see Prism wash with integral steam nozzle (page 36)) is insufficient toremove coating. It can be used for example in the measurement of starch, beer worth, greenliquor in the wood pulp industry or directly after the evaporation in the sugar industry.


38

Figure 21 (page 40) describes the recommended components for a prism wash system withintegral high pressure water nozzle. The components can be supplied by Vaisala.

Note the following items in the high pressure wash system:

• Integral water wash nozzle (HPN) is built on a sensor which has a Sandvik clamp or aflange connection.

• For mounting a flow cell see Prism wash with flow through cells (page 42).• Check valve PR‑3303 is recommended to all washing applications.• The high pressure pump should be able to keep a pressure of 100 bar for a 1.25 mm

(0.05 in) diameter nozzle.• For recommended wash pressures and times, see Recommended wash pressures and

times (page 43).

High‑pressure pump

Use Vaisala PR‑3602‑SP‑400 high pressure pump. The recommendation is to use 3 (3phase) pumps with local voltages. Inlet water temperature should be warm, about +60 °C(+140 °F). Vaisala delivers high pressure pump with 8 m rubber high‑pressure hose.Customer can also make high pressure line between pump and nozzle from stainless steelpipes which are suitable for pressures up to 150 bar. With stainless steel pipes it isrecommended to use heat trace and insulation to keep washing water warm at +60 … +70 °C(+140 … +158 °F).

Pressure increase can occur in a closed pipe section when the high pressure pump isoperated. It is recommended to mount a pressure relief valve in the pipe section. Reliefpressure should be according to pipe pressure rating.

The DTR (indicating transmitter) relay is used to drive the power relay unit PR‑3603‑400.The power relay unit drives the high‑pressure pump and the water valve. Pump relay has anoverload relay which will switch off the pump if current goes over the set limit. Theconfiguration of the relay is done through the indicating transmitter keyboard. For thewiring of the high‑pressure components, see Figure 22 (page 41).


39

Figure 21 Mounting drawing for integral high‑pressure wash system

Part Part specification Supplied by Qty

1 Indicating transmitter DTR Vaisala 1

2 Sensor PR‑21‑xxx‑HPN Vaisala 1

3 Cable between indicating transmitter andsensor PR‑8230

Vaisala 1

4 Check valve R ¼ in PR‑3303 Vaisala 1

5 High‑pressure hose 8 m (26.25 ft) Vaisala 1

6 AC power supply 230/110 V Customer 2

7 Power relay unit PR‑3603‑400‑U/M‑230/110/24

Vaisala 1

8 High‑pressure pump PR‑3602‑400‑BR/SS‑230/110 including water valve

Vaisala 1

9 Power supply cable 3 m (9.84 ft) for watervalve

Customer 1

10 Power supply cable 3 m (9.84 ft) forhigh‑pressure pump

Vaisala 1


40

Figure 22 Wiring drawing: High‑pressure wash system for water


41

5.4 Prism wash with flow through cells

Figure 23 Prism wash with flow through cells


42

Figure 24 Flow through cell nozzles

5.5 Recommended wash pressures andtimes

To select the recommended wash pressure and wash time use the following table.


43

Table 2 Recommended wash pressures and times

Nozzle type Wash medium Wash time Min. aboveprocess pressure

Max. aboveprocess pressure

Integral nozzles

‑HPS

‑HPN

steam

pressure water

2 … 3 s

10 … 15 s

2 bar (30 psi)

30 bar (450 psi)

6 bar (85 psi)

50 bar (1000 psi)

When using steam wash, do not use longer wash times than recommended.CAUTION!


44

6. Startup and use

6.1 Startup

6.1.1 Initial check

Main display for two sensors Main display for singlesensor, concentration only

Main display for single sensor,concentration and temperature

Main display for single sensor,concentration and bar graph

Figure 25 Main display alternatives

1. Check the wiring, see Electrical connections (page 23).

2. Connect the power. The power indicator light and the screen light up within a fewseconds.

3. The Main display comes up, as shown in Figure 25 (page 45).

4. In case the display shows a row of dashes, there is no corresponding sensor (forexample in the figure above, upper left, there is no sensor A, only sensor B isconnected). The diagnostic message is NO SENSOR for that sensor.

5. Check the serial number of the sensor at the upper right corner in the display.

Chapter 6 – Startup and use

45

6. For a connected sensor, the diagnostic message at start-up is Normal operation or NOSAMPLE if the process pipe is empty. If another diagnostic message is shown instead,see Diagnostic message priorities (page 94).

7. The TEMP value shows the current process temperature.

8. To check the value and the correct setup of the two mA output signals, selectDESCRIPTION in the Main menu and then mA OUTPUTS in the Description menu, seeViewing system information (page 50).

9. If internal relays or switch inputs are used, you can check their settings through theDescription menu, see Viewing system information (page 50).

6.1.2 Calibration checkWait until normal process conditions occur. The concentration reading is precalibrated atdelivery and a copy of the Sensor calibration certificate is inside the Indicating transmitter. Ifthe diagnostic message is Normal operation but the concentration reading does not agreewith the laboratory results, see Calibrating concentration measurement (page 66).

6.1.3 Testing prism wash

1. Check that the steam or water washing parts are connected.

2. In the Main display, press MENU. Then press 3 (to give the command SENSOR STATUS).In this sensor status display by pressing the soft key WASH. If soft key WASH does notappear, no internal relay is configured for this purpose.

3. Check the nD reading, for a successful wash it must drop below 1.34 during steam washand drop to approximately 1.33 during water wash.

Before testing prism wash, check that there is liquid in the pipe in frontof the refractometer sensor.CAUTION!

More information

‣ Prism wash with integral steam nozzle (page 36)‣ Prism wash with integral high-pressure water nozzle (page 38)

6.2 Using indicating transmitterThe indicating transmitter DTR receives the refractive index value nD and the processtemperature from the sensor. Starting from these values, it calculates the concentration ofthe process media for display and further transmission. The DTR can also be programmed togive alarm for high or low concentration. If the refractometer has a prism wash system, theDTR can control the wash with its built-in timer.


46

More information

‣ Configuration and calibration (page 54)

6.2.1 Keyboard functionsNumber keys: The 10 number keys, minus sign, and decimal point are used to enternumerical parameters. They are also used for menu selections.

ENTER key: The ENTER key is used to implement the selected (highlighted) menu commandor to accept an entered value.

BACK key: The commands are arranged into a decision tree, the BACK key is used to moveone step backward to the preceding display. It is also used to erase or cancel a numericalinput.

Soft keys: The meaning of the soft key is shown on the display immediately above the key.The figure below gives an example the soft key functions, from left to right:

1. SENSOR A: Switch to corresponding menu for Sensor A.2. Arrow down: Move one step down in the menu.3. Arrow up: Move one step up in the menu.4. SELECT: Select the highlighted command (equivalent to pressing ENTER).


47

INSTRUMENTS

P OWE R

Figure 26 DTR keyboard and Main menu for sensor B

Press the key under the display. The display is not touch sensitive.

6.2.2 Display setupSelecting MENU / MENU A / MENU B or SENSOR A or SENSOR B (depending on your Maindisplay format) in the Main display gives the menu display. Choose 4 DISPLAY SETUP tochange the Main display format and bar graph settings, to adjust backlight or contrast andto invert the display. In DTR program version 2.0 or newer you can also switch between theexisting display languages.


48

Figure 27 Display setup menu

Main display format: As shown in Figure 25 (page 45), there are four different Main displayformats: the dual sensor format shows information on both sensors while the three differentsingle sensor formats show selected information on one sensor at a time. Choose 1 MAIN DISPLAY FORMAT in the Display setup menu to change the Main display. The current formatis shown on the display format selection display, as shown in the figure below.

Figure 28 Main display format selection

An automatic 60 s (in verification 5 min) timeout makes backsteps from any display untilthe Main display is reached.


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Display appearance: The 2 DISPLAY BACKLIGHT & CONTRAST can be selected from theDisplay setup menu, see Figure 27 (page 49). The values can be changed by using the arrowsoft keys or alternatively a one digit input, for example 8 designates 80 % when adjustingcontrast.

The 3 DISPLAY INVERSION contains two choices. The default setting of the display is 1 POSITIVE DISPLAY, which is a yellow background and black text. However, in someenvironments the display can be clearer if 2 NEGATIVE DISPLAY, which is a blackbackground and yellow text, is chosen.

Bar graph settings: The command 4 BAR GRAPH allows you to set the bar graph span andzero separately for sensors A and B.

Bar graph is only visible when Main display is in the bar graph format, see above.

Display language: The command 5 DISPLAY LANGUAGE lets you choose the DTR displaylanguage from the existing display languages that are loaded into the DTR. The defaultlanguage is English and it is always available. The order and number of the languages in thelanguage menu varies depending on what languages are loaded into the DTR. Languagechange through this menu is immediate.

6.3 Viewing system informationThe DESCRIPTION selection from the Main menu, see Figure 26 (page 48), opens a path tocomplete information about the system and calibration. This path is risk-free in the sensethat no values can be changed through this menu. To be able to make changes, selectCALIBRATION from the Main menu.

The Description menu, see Figure 29 (page 51), leads to the following information:

1. SYSTEM: See Figure 29 (page 51), right side.2. mA OUTPUTS: See Configuring mA outputs (page 64).3. RELAYS: See Configuring relays (page 60).4. SWITCHES: See Configuring input switches (page 62).5. PRISM WASH: See Configuring relays (page 60) and Configuring prism wash

(page 71).6. PARAMETERS: See Calibrating concentration measurement (page 66).7. NETWORK: The Ethernet address and card ID of the DTR.


50

Figure 29 System description

More information

‣ Ethernet connection specification (page 117)

6.4 Viewing sensor statusSelect SENSOR STATUS from the Main menu.

6.4.1 Optical imageWith the image detection algorithm the Optical image graph (See Figure 5 (page 13) forexplanation) should look like Figure 30 (page 52), right side. The vertical dotted lineindicates the position of the shadow edge. For empty pipe, the optical image looks likeFigure 30 (page 52), left side. The soft key SLOPE leads to a graph (see Figure 31(page 52)) showing the slope (or first differential) of the optical image graph in Figure 30(page 52).

In case there is no signal from the sensor, the image field is crossed over.

The optical image changed slightly with sensor program version 3.13. The optical imagestarts now at origin and the sides of the image are straight and slope slightly. This is doneprogrammatically, it is not a property of the optical module.


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Figure 30 Typical optical images

Figure 31 A slope graph

6.4.2 Diagnostic valuesThe values at the left of the graph are used for diagnostic purposes:

• CONC is the final concentration value including field calibration adjustment, see Figure40 (page 67).

• TEMP, see Temperature measurement (page 53).• CCD gives the position of the shadow edge on CCD in %.• nD is the refractive index value nD from the sensor.• CALC is the calculated concentration value without field calibration adjustment, Field

calibration (page 69).


52

• QF or Quality Factor is a value in the range of 0 to 200. The QF value depends onprocess medium optical properties. A typical good value is 100, but there are processmedia where 50 is acceptable. The QF value should stay constant during the process.Falling QF value may indicate prism coating.

• LED is a measure of the amount of light from the light source in %.• HD TMP is the sensor head temperature, see Temperature measurement (page 53).• HD HUM is the sensor head humidity, see Sensor head humidity (page 53).• I_SNS value shows the current to sensor, the nominal value is 40 mA.• DTR TMP is the indicating transmitter temperature, see Temperature measurement

(page 53).• DTR V1 gives the voltage from the power module, the nominal value is 24 V.• DTR V2 gives the DC supply voltage, the nominal value is 3.3 V.

The slope display also has a soft key SENSOR RESTART which can be used to restart thecurrent sensor (see upper left corner of the display for sensor letter) after a sensorsoftware update.

6.4.3 Temperature measurementThe system contains three different temperature measurements displayed to the left of theoptical image graphs:

TEMP is the process temperature used for automatic temperature compensation in theIndicating transmitter.

HD TMP measures the temperature on the Sensor processor card PR-10100.

DTR TMP measures the temperature on the Motherboard of the Indicating transmitter.

Both sensor head temperature and DTR temperature are monitored by the built-indiagnostics program.

6.4.4 Sensor head humidityThe sensor processor card also contains a humidity sensor. The value HD HUM is the relativehumidity inside the sensor. It is monitored by the diagnostics program.

6.5 Sensor verificationA company that maintains quality systems according to ISO 9000 quality standards musthave defined procedures for controlling and calibrating its measuring equipment. Suchprocedures are needed to demonstrate the conformance of the final product to specifiedrequirements.

More information

‣ Sensor verification (page 133)


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7. Configuration andcalibration

All changes of configuration and calibration are made through the Calibration menuselected from the Main menu by 5 CALIBRATION.

Password: It may be necessary to enter a password before proceeding to the Calibrationmenu. The password is printed on the title page of this manual. The password function isactivated and deactivated with the 6 PASSWORD command in the Calibration menu. Bydefault the password is activated.

7.1 Configuring output signal dampingYou can apply signal damping in the Outputs display to diminish the influence of processnoise. Damping is applied to the CONC value (and therefore the output signal) of theselected sensor (see upper edge of the display to check which sensor is selected). Ifnecessary, you can change the sensor in the Calibration display.

There are three types of signal damping:

• Exponential signal damping• Linear signal damping• Slew rate

You can select the type of signal damping in Calibration > Outputs > Damping type. Thedamping time depends on the damping type.

7.1.1 Exponential dampingExponential (standard) damping works for most processes and is the standard choice forslow and continuous processes. The factory setting is always exponential damping, accessthe 3 DAMPING TYPE command to switch between different damping algorithms. In theexponential damping (standard damping), the damping time is the time it takes for theconcentration measurement to reach half of its final value at a step change. For example, ifthe concentration changes from 50 % to 60 % and damping time is 10 s, it takes 10 s for theDTR to display concentration 55 %. A damping time of 5 … 15 s works best in most cases, thefactory setting is 5 s. Use the 4 DAMPING TIME menu item to set the damping time. Thefollowing figure shows how exponential damping time affects the measurement.


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Figure 32 Exponential damping

7.1.2 Linear dampingIf the process has fast step changes, linear (fast) damping gives shorter settling time. In thelinear damping (fast damping), the output is the running average of the signal during thedamping time. After a step change the signal rises linearly and reaches the final value afterthe damping time. The linear damping gives the best trade-off between random noisesuppression and step change response time. Use the 4 DAMPING TIME menu item to set thedamping time.

For similar noise suppression a longer damping time has to be specified than for theexponential damping.

The following figure shows how linear damping time affects the measurement.

Chapter 7 – Configuration and calibration

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Figure 33 Linear damping

7.1.3 Slew rate limitIf the process signal has short erroneous high or low peaks, the slew rate limiting can beused to cut their effects. The slew rate damping limits the maximum change for the outputsignal in 1 s. The slew rate limit damping is recommended for random noise suppression as itis non-linear.

You can set the slew rate limit in the menu item 5 SLEW RATE. Typical values depend on theconcentration unit but are typically 0.05 % to 1 % when the concentration is measured in %.

The following figure gives an example of different slew rate limits.


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Figure 34 Slew rate damping

Avoid overdamping, the signal should not be made insensitive.

7.2 Configuring output signal holdfunctionality

The refractometer can be configured to temporarily hold its measurement result in threedifferent cases:

1. By using an external hold switch, see Configuring input switches (page 62).2. During prism wash, see Setting prism wash parameters (page 76).3. For a preprogrammed time when there is an intermittent loss of sample on the prism

(due to voids in the process).

When the measurement result is in hold, the displayed concentration value and mA outputdo not change. The diagnostic values (for example, nD) shown on-screen always reflect theactual state of the measurement.

The measurement hold takes place after the CALC value and field corrections have beencalculated but before the signal filtering (damping) takes place, see Calibratingconcentration measurement (page 66). If the hold is on, the output filter remains in itsearlier state, and the output signal is stationary. If the hold is started when there is no outputsignal (for example, no sample on the prism), there will be no measurement signal duringthe hold.


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7.2.1 External holdWhen a switch input is configured for external hold functionality, see Configuring inputswitches (page 62), and the switch contact is closed, the measurement result is in hold. Themeasurement result is kept in hold until the switch contact is opened. A status messageEXTERNAL HOLD is displayed.

7.2.2 Hold during washWhen the setting Hold during wash is configured ACTIVE, the output signal is on hold whenthe instrument is washing. The signal is on hold during all three phases (preconditioning,wash, recovery) of the wash process. This setting can be used to avoid dips in themeasurement signal during the prism wash.

For more information, see Setting prism wash parameters (page 76).

7.2.3 Tolerance timeThe tolerance time setting can be used in processes with intermittent breaks in themeasurement due to non-representative sample on the prism. This typically occurs whenthere are large voids in the process liquid.

If the optical image can be interpreted, the tolerance time setting does not have any effect.When the optical image can no longer be interpreted (status messages, for example, NO SAMPLE, NO OPTICAL IMAGE, PRISM COATED), the measurement is held for the givennumber of seconds.

For example, a setting of 10 s ensures that any NO SAMPLE state which is shorter than 10 sdoes not make a dip into the output signal. The factory setting is 5 s. To se the tolerancetime, access the 6 TOLERANCE TIME menu item.

The tolerance time counter is reset always when there is a representative sample on theprism (for example, the nD can be determined). The following figure shows this behaviorwith an intermittent measurement signal. When the signal drop is shorter than the tolerancetime (for example, at t = 10 s or t = 35 s in the figure), the output signal does not drop. If thesignal drop is so long that the tolerance time counter reaches zero, there is a drop in theoutput signal (at t = 80 s in the figure).


58

Figure 35 Effect of tolerance time on output

7.2.4 QF thresholdThe QF threshold setting can be used to prevent the instrument from measuring when theimage quality is below a certain limiting value. When QF value lower than the defined value,the image status changes to NO OPTICAL IMAGE after the defined tolerance time, seeTolerance time (page 58).

By default the QF threshold value is -1000.

7.2.5 Hold source interactionsThere are three reasons why the measurement signal may be in hold. All three result in thesame behavior, but they also interact with each other.

Wash-related hold, see Hold during wash (page 58), and external hold, see External hold(page 58), are connected in parallel. If at least one of them is active, the measurement resultwill be in hold.

Tolerance time, see Tolerance time (page 58), is independent of these two, but the tolerancetime is reset whenever there is another reason for the measurement hold. For example, if thetolerance time is set to 10 s, and wash hold becomes active after 7 s, the remaining tolerancetime resets to 10 s After the wash is over, there is still 10 s of tolerance time remaining.


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7.2.6 Hold and signal dampingThe signal filtering (damping) is stopped during hold. The last filtered value is shown on thescreen and set to the mA output (if the concentration output is configured). The followingfigure shows this behavior (gray areas represent the periods when the hold is active).

Figure 36 Damping stops during hold

7.3 Configuring refractometer systemThe indicating transmitter has two built-in 4 … 20 mA outputs (mA OUTPUT 1, mA OUTPUT2), two relay contact outputs (RELAY 1, RELAY 2), and four switch inputs (SWITCH 1, SWITCH2, SWITCH 3, SWITCH 4). Each of these resources can be freely assigned to either sensor Aor sensor B.

7.3.1 Configuring relaysFor the electrical properties of the built-in relays, see Connecting indicating transmitter(page 25). You can configure each of the 2 relays individually to either sensor A or sensor B,meaning 0 to 2 relays can be assigned to a sensor. You can also open and close relaysmanually, mainly to test them.


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Figure 37 Relay menu for relay 1

1. Select Menu > 5 CALIBRATION > 3 RELAYS.

2. Select the relay that you want to configure, either 1 RELAY 1 or 2 RELAY 2.

3. To assign the current relay to either sensor A or sensor B, select 1 SENSOR.

The current assignment of the relay is shown at the bottom of the Relay menudisplay. In the figure, relay 1 is assigned to sensor A with function Low limit.

4. To set the relay function, select 2 FUNCTION.

Function name Description

1 NOT DEFINED Factory setting.

2 NORMAL OPERATION Closed contact if diagnostic message isNormal operation during HOLD, seeConfiguring input switches (page 62). Thecontact is also closed when message is NO SAMPLE.

3 INSTRUMENT OK Closed contact if there is no equipmentmalfunction. See also Diagnostic messagepriorities (page 94).

4 LOW LIMIT Used as alarm relay, closing contact ifsource value is below set limit. (See belowfor limit source selection.)

5 HIGH LIMIT Used as alarm relay, closing contact ifsource value is above set limit. (See belowlimit source selection.)

6 PRECONDITION See Wash cycle (page 71).

7 WASH See Configuring prism wash (page 71).

8 PRISM WASH FAILURE Closed contact if diagnostic message isPRISM WASH FAILURE, see Setting prismwash parameters (page 76).


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5. If you choose either low limit or high limit as relay function, you must define a limitsource. To set the limit source, select Relay > 3 LIMIT SOURCE. Limit source selection:



2 CONCENTRATION Measured concentration CONC

3 PROCESS TEMPERATURE Process temperature

6. To set the limit value select Relay > 4 LIMIT VALUE, and enter a numeral limit value.

7. To set the hysteresis value select Relay > 5 HYSTERESIS. The hysteresis value indicateshow soon the relay opens after the process has temporarily gone over the high limit orunder the low limit. For example, if high limit is 50 and hysteresis is 2, the relay opensonly once the process drops to below 48.

8. To change the relay delay time, select Relay > 6 DELAY. The delay is given in seconds,factory setting is 10 s.

9. For manual set, go (back) to the Select relay menu and choose 3 MANUAL SET.In the manual set display you can open and close any relay by pressing the appropriatesoft key. The current status of the relay (open or closed) is displayed next to the relayname.

7.3.2 Configuring input switchesFor the electrical properties of the four input switches, see Electrical connections (page 23).To see which switches are closed, check the Description menu, see Viewing systeminformation (page 50). To configure the switches, follow the instructions below.

1. Select Menu > 5 CALIBRATION > 5 SWITCHES.


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2. Select switch, 1, 2, 3 or 4, to be configured. The Switch menu shows the followingoptions.

3. Select 1 SENSOR to assign the chosen switch to a given sensor.

The selection line automatically goes to the currently valid setting. In the followingfigure, switch 1 has been assigned to sensor A.


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4. To set the switch function, select Switch > 2 FUNCTION.

The current assignment of the switch is shown at the bottom of the Switch menudisplay. For example, in the previous figure, switch 1 is assigned to sensor A withfunction Wash stop.



2 HOLD When used with a built-in wash relay, thisfunction is useful for an intermittentprocess: the prism is washed when theprocess stops (as indicated by contactclosure). The wash is repeated when theprocess restarts (if the stop lasts over 60 s).The signal is on hold betweenwashes.When used with an externalindependent timer, contact closure holdsthe output signal.

3 WASH STOP Switch closure prevents wash cycle. It canbe used to prevent wash action when theprocess pipe is empty. The message WASH STOP displays when a wash cycle isinitiated.

4 REMOTE WASH At switch closure the system waits for anexternal wash command before initiatingwash.

5 SCALE SELECT Any chemical curve and associated fieldcalibration scale can be selected by switchclosure. The scales assigned to each switchindependently.

6 CALIBRATION SEAL Contact closure prevents access tocalibration and configuration ("externalpassword"). Can be used to seal thecalibration.

5. If you chose SCALE SELECT as switch function, select Switch > 3 SCALE CHEMICAL toenter the parameters for the chemical curve assigned to the switch. For moreinformation on chemical curves and chemical curve parameters, see Chemical curve(page 68).

6. If necessary, the chemical curve assigned to a switch can be adjusted by fieldcalibration parameters. Select Switch > 4 SCALE FIELD to enter the parameters. Formore information on field calibration and field calibration parameters, see Fieldcalibration (page 69).

7.3.3 Configuring mA outputsFor the electrical properties of the 2 output signals, see Connecting indicating transmitter(page 25).


64

• Select 5 CALIBRATION in the Main menu and enter password if necessary. Select 2 OUTPUTS in the Calibration menu. In the Outputs menu, select 5 mA OUTPUTS.

• Select the mA output, 1 or 2, to get to the Output menu (as shown in the followingfigure) where the output can be configured.

The line at the bottom of the Output menu display indicates the currentconfiguration of the selected mA output, for example, in the following figure the mAOutput 1 has been configured to send the concentration reading of Sensor B.

Figure 38 Output menu for mA Output 1

• To change the sensor the selected output is assigned to, select 1 SENSOR in the Outputmenu.

• To change output source for the selected output, select 2 SOURCE.

Selecting 1 NOT DEFINED ’turns off’ the selected output.

• The 3 ZERO value sets the value when the signal is 4 mA. The default zero value is 0.00,the unit depends on the source and display unit set for the sensor in question (and canthus be for example 0 BRIX or 0 °F).

• The 4 SPAN sets the range, which is the value given when the signal is 20 mA.Example: If your measurement unit is CONC% and you want to measure the range15 … 25 CONC%, first choose concentration as mA output source. Then set the zerovalue at 15 and span at 10. This means that the output signal is 4 mA at 15 CONC% and20 mA at 15+10=25 CONC%. To change this output to range 10 … 30 CONC%, changezero to 10 and span to 20 (10+20=30).


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• 5 DEFAULT OUTPUT sets a mA default output value that the instrument returns to incertain malfunction situations. The value can be set to a low or high mA value, forexample, 3.0 mA or 22 mA. The factory setting for default output is 3.4 mA. For a list ofmalfunctions that are affected, see Diagnostic message priorities (page 94).

NAMUR is an international association of users of automation in process industries.The association recommendation NE 43 promotes a standardization of the signallevel for failure information. The goal of NE 43 is to set a basis for proactively usingtransmitter failure signals in process control strategies. Using these failure signals,instrument faults are separated from process measurements.

NAMUR NE 43 uses the 3.8 … 20.5 mA signal range for measurement information, with≥21 mA or ≤3.6 mA to indicate diagnostic failures (see the following figure). With thatinformation, it is easier to detect a failure condition on a refractometer, for example, itclearly tells you whether you have an empty pipe or a failed instrument.

0 3.63.8

4 2020.5

21mA

failure OKMeasurement Data

failure

Figure 39 Default mA output values

• 6 SEC DEFAULT MODE and 7 SEC DEFAULT allow you to set a secondary mA outputvalue for empty pipe (message NO SAMPLE) to differentiate it from the othermessages that cause the measurement to revert to default mA. By default thesecondary mA output is disabled.

• 8 MANUAL SET allows you to set different output values to check the output signal.Press the BACK key to return normal output function.

If you want to turn off the mA output, select NOT DEFINED in the Source menu.

7.4 Calibrating concentrationmeasurement

The concentration calibration is organized in six layers.


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mA OUTPUT

FIELD CALIBRATION

CHEMICAL CURVE

nD

CCD

TEMP

Pt-1000

Indicatingtransmitter

DTR

Sensor

CONC

CALC

1.

2.

3.

4.

5.

6.

DAMPING

Figure 40 Concentration calibration layers

1 The information from the CCD element and the Pt-1000 temperature element. Theposition of the shadow edge, see Figure 88 (page 147), is described by a number calledCCD and scaled 0 … 100 %.

2 Sensor calibration: The actual refractive index nD is calculated from the CCD value. Theprocess temperature is calculated from the Pt-1000 resistance. The sensor output is nD

and temperature TEMP in degrees Celsius. The calibrations of all sensors are identical,which makes sensors interchangeable. The calibration of each sensor can be verifiedusing standard refractive index liquids.

3 Chemical curve: The indicating transmitter DTR receives nD and TEMP and calculates theconcentration value according to chemical curves. The result is a temperature-compensated calculated concentration value CALC.


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4 Field calibration: Adjustment of the calculated concentration value CALC may berequired to compensate for some process conditions or to fit the measurement to thelaboratory results. The field calibration procedure, see Field calibration (page 69),determines the appropriate adjustment to CALC. The adjusted concentration is calledCONC. If there is no adjustment, CALC and CONC are equal. Therefore the chemicalcurve is kept intact as a firm base for the calculation, the adjustment is merelyadditional terms.

5 Damping: see Configuring output signal damping (page 54).6 Output signal: The range of the 4 … 20 mA signal is defined by its two endpoints on the

CONC scale, see Configuring mA outputs (page 64).

7.4.1 Chemical curveThe chemical curve is the theoretical concentration curve based on nD and TEMP. It isdefined by a set of 16 parameters.

Table 3 Chemical curve parameters

C00 C01 C02 C03

C10 C11 C12 C13

C20 C21 C22 C23

C30 C31 C32 C33

A chemical curve is specific to the given process medium, for example, sucrose or sodiumhydroxide. The set of parameters is given by Vaisala and should not be altered, except incase of changing to another process medium. The parameters can be changed by selecting5 CALIBRATION from the Main menu, then, in the Calibration menu, 1 CHEMICAL & FIELD PARAMETERS, and finally 1 CHEMICAL CURVE PARAMETERS.

7.4.2 Selecting display units and display decimalsThe display units and display decimals are set separately for each sensor, so first go to theCalibration menu of the correct sensor. Then select 2 OUTPUTS in the Calibration menu andin the Outputs menu choose either 1 DISPLAY UNITS or 2 DISPLAY DECIMALS. For thedisplay units, select either 1 CONCENTRATION or 2 TEMPERATURE and then the unit. Fordisplay decimals, enter the number of decimals you want to see on display by entering anumber in the range of 0 to 5 (0 meaning no decimals are shown).

Change of concentration unit does not change the numerical value of the concentration.Change of temperature unit recalculates the numerical temperature value according toselected scale (°C or °F).


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7.4.3 Field calibrationVaisala provides a field calibration service that adapts the calibration to the factorylaboratory determinations based on the data supplied. The field calibration procedureshould be made under normal process conditions using standard laboratory determinationsof sample concentration.

Record the calibrating data on the field calibration form found in Field calibration form(page 149), also available by emailing a request to [email protected]. Email thecompleted field calibration form to your local Vaisala representative. Vaisala makes acomputer analysis of the data and sends optimal calibration parameters to be entered in theindicating transmitter DTR.

For a complete report, 10 … 15 valid data points (see below) are needed. A data point is ofuse for calibration only when the diagnostic message is Normal operation. If prism wash isemployed, do not take samples during the wash. Each data point consists of

• LAB%: Sample concentration determined by the user.• From DTR display: See Figure 41 (page 70).• CALC: Calculated concentration value.• T: Process temperature measurement in Centigrade.• nD: Actual refractive index nD.• CONC: Measurement in concentration units, the large size number.

In addition to the calibration data, write down the indicating transmitter serial number, thesensor serial number and the sensor position, meaning whether it is installed as Sensor A oras Sensor B.

Accurate calibration is only achieved if the sample is taken correctly. Pay special attention tofollowing details:

• The sampling valve and the refractometer should be installed close to each other in theprocess.

Wear protective clothing appropriate to your process whenoperating the sampling valve and handling the sample.WARNING!

• Run the sample before starting to collect data points to avoid sampling old processliquid that has remained in the sampling valve.


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• Read the values CALC, T, nD and CONC in the DTR’s display at exactly the same timewith sampling.The easiest way of doing this is to use the FIELD SAMPLE soft key available through theSensor status display (DTR program version 2.0 or newer). The value of each sample isthe average of 10 consequent measurements to increase accuracy and reduce possibleprocess noise.

Press the FIELD SAMPLEsoft key

Wait while DTR measures(take sample for lab)

Press REPEAT for nextdata point or BACK to get to

the Sensor status display.

1 2 3

Figure 41 Using FIELD SAMPLE soft key

• Use a tight container for the sample to avoid evaporation.

Offline calibration using process liquid very seldom gives reliable results, as problems arecaused by:

• Low flow which makes sample to form an unrepresentative film on the prism• Sample evaporation at high temperature or undissolved solids at low temperature

giving deviations from laboratory determinations• An ageing sample which is not representative• Outside light reaching the prism

Calibration using the process liquid must always be made in‑line.

7.4.4 Entering field calibration parametersEnter the field calibration parameters supplied by Vaisala by selecting 5 CALIBRATION fromthe Main menu, followed by 1 CHEMICAL & FIELD PARAMETERS and then 2 FIELD CALIBRATION PARAMETERS.

If there is already a previous field calibration, it should be cleared (by settingall values to 0) before entering a new field calibration.CAUTION!

7.4.5 Direct BIAS adjustmentThe concentration measurement value can also be directly adjusted by changing the fieldadjustment parameter f00.


70

The value of the bias parameter f00 is added to the concentration value:

NEW CONC = OLD CONC + f00.

7.5 Configuring prism washIn some applications the process flow does not keep the prism clean because of stickyprocess medium or low flow velocity. In these applications the prism can be automaticallycleaned by installing a wash system.

The prism wash settings for sensors A and B are independent of each other. The washsystem is active if a relay has been configured to be a wash relay, see Configuring relays(page 60), and the wash time is not zero. An automatic wash function can be configured sothat both sensors have different parameters.

More information

‣ Prism wash systems (page 35)

7.5.1 Wash cycleFigure 43 (page 73) shows the wash logic as a flow diagram. The automatic prism washcycle described below consists of three phases: precondition, wash and recovery. Theoptional preconditioning function is used to, for example, blow out the condensate beforewashing. After the preconditioning there is a one-second pause to avoid having bothprecondition and wash relays active at the same time.

The wash cycle is initiated when the wash interval has elapsed. The wash can also be startedby closing an external switch, see Configuring input switches (page 62), or manually fromthe user interface at the Sensor status display, see Testing prism wash (page 46). The orderof priority for these wash triggers is as follows:

1. Manual wash2. Remote wash request3. Wash interval timer

WASH

RECOVERY

INTERVAL

PRECOND.

Figure 42 Automatic prism wash cycle


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For safety reasons two sensors never wash simultaneously. If the manual wash button forsensor A is pressed while sensor B is washing, the wash cycle for sensor A is started afterB has finished. Similarly, if the interval time for sensor B elapses when A is washing, thewash for sensor B is delayed until A has finished.

In case of remote wash request the request is discarded if it arrives when the other sensor iswashing. The request is honored only if the contacts are held closed until the other sensorhas finished.

The wash relay is closed for the wash time specified in the wash settings. If the wash auto-cut functionality is active, the wash may be ended earlier, see Figure 44 (page 75). Thespecified wash time is never exceeded.

After the wash phase is completed, a recovery time is spent. During the wash cycle(precondition, wash, recovery) the measurement result is in hold unless otherwise specified.

Preventing automatic wash

The preconditioning and wash relays are never activated by the automatic wash control:

• Under the diagnostic message NO SAMPLE, as this indicates a clean prism in an emptyprocess line. The diagnostic message is WASH STOP/NO SAMPLE.

• If a wash stop input switch is closed, see Configuring input switches (page 62),indicating, for example, that there is no process flow. The diagnostic message isEXTERNAL WASH STOP.

• If the process temperature limit is activated and the temperature falls below the limit,indicating that the process is not running. The diagnostic message is LOW TEMPWASH STOP.


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sensorwashing?

NO

YES

MANUALWASH been

pressed?

NO

YES

Remotewash

requested? 1

NO

YES

Washinterval

reached?

YES

NO

Templimit

active?

YES

NO

Tempabovelimit?

YES

NO

Message2

NO

YES

Figure 43 Wash logic


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Remote wash is triggered at the closing of the switch. If the switch is held closed, only onewash cycle is carried out.

The wash is inhibited if there is no sample, no sensor or the sensor cannot measurecorrectly.


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Precondition

Start washing

1 s wait

Preconditionenabled?

YES

NO

Washauto-cutenabled?

NO

YES

nD < nD limit?

NO

YES

Wash timereached?

YES NO

Wash timereached?

YES

NO

Stop washing

Recovery

PR

EC

ON

DIT

ION

RE

CO

VE

RY

WA

SH

Figure 44 Wash cycle

More information

‣ Troubleshooting messages (page 89)


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7.5.2 Setting prism wash parametersTo set the prism wash parameters for a given sensor, first select the sensor, then select 5CALIBRATION from the Main menu, and then 4 PRISM WASH. This menu contains thealternatives (factory settings are given in parentheses):

Parameter Value

1 PRECONDITION TIME 0 … 30 s (0 s)

2 WASH TIME 0 … 30 s (3 s)

3 RECOVERY TIME 0 … 30 s (20 s)

4 WASH INTERVAL 0 … 1440 min (20 min)

5 WASH CHECK MODE (Disabled)

6 HOLD DURING WASH (Active)

7 TEMP LIMIT ACTIVATION

8 TEMP LIMIT VALUE °C

9 EMPTY PIPE CHECK (Active)

0 MORE...

1 WASH nD LIMIT

2 WASH TOLERANCE TIME (0 min)

The prism wash cycle: See Figure 44 (page 75) and Wash cycle (page 71). The timing of thewash cycle is controlled by the WASH INTERVAL, PRECONDITION TIME, WASH TIME andRECOVERY TIME settings. If the WASH INTERVAL is set to zero, the wash can be initiatedonly by using the manual wash or remote wash request.

If the PRECONDITION TIME is zero (or there is no relay configured for preconditioning), thepreconditioning phase is skipped. If the WASH TIME is zero (or there is no relay for wash),the wash functionality is completely disabled.

Wash check: The prism wash check monitors automatically that the wash really has aneffect on the prism. In the WASH CHECK STANDARD mode, prism wash is accepted if therefractive index nD either falls below wash nD limit (default 1.34) at Normal operation or NO SAMPLE occurs. This is the indication of a successful wash with water or steam.

If the wash is not accepted, the diagnostic message PRISM WASH WARNING, see Diagnosticmessage priorities (page 94), displays. If no wash is accepted during wash tolerance time,the message becomes PRISM WASH FAILURE. Both messages and the wash tolerancecounter are reset by a successful wash.

The WASH CHECK AUTOMATIC WASH CUT mode differs from the standard mode bystopping the wash 2 s after the nD falls below the limit.

To stop the measurement for the duration of the prism wash, choose 6 HOLD DURING WASH and in that menu activate the hold function. The CONC reading and mA outputareheld in the value they had immediately before starting the wash cycle.


76

To activate (or deactivate) a temperature limit, choose 7 TEMP LIMIT ACTIVATION andthen the appropriate command in the menu.

To set a low temperature limit, choose 8 TEMP LIMIT VALUE °C and enter the temperature(in °C) where the limit should be.

The empty pipe check prevents washing if message is NO SAMPLE, meaning there is noprocess liquid in the pipe. To deactivate (or active) the empty pipe check, choose 9 EMPTY PIPE CHECK and then the appropriate menu command.

To change the wash nD limit, select 0 MORE … and then 1 WASH nD LIMIT to set the nD

value to be used with the wash check functionality.

To set wash tolerance time, select 0 MORE … and then 2 WASH TOLERANCE TIME to setthe time during which a wash must be accepted. If no wash is accepted during washtolerance time, the message becomes PRISM WASH FAILURE. The wash tolerance counter isreset by a successful wash.

More information

‣ Recommended wash pressures and times (page 43)

7.5.3 Mechanical zero adjustmentA mechanical zero adjustment can be made within the limits given in Sensor rangeability(page 78). It is possible to make a zero adjustment with the sensor in-line. For mechanicalzero adjustment, remove the image detector module according to the instructions in sectionsensor disassembly.

Near the tip of the Image detector module (Figure 45 (page 78)) there is a fiber opticsholder (C) and 2 adjustment screws. The 2 screws work against each other in a push and pullconfiguration. The locking screw (A) pushes the holder inwards and the adjusting screw (B)pulls the holder outwards. A combined push-and-pull force locks the holder.

To adjust, first loosen the locking screw (A) carefully. Then adjust the position of the fiberoptics holder. To decrease CCD value and measure higher concentrations, turn the adjustingscrew clockwise. To increase CCD value and measure lower concentrations, turn theadjusting screw counterclockwise. When the position of the fiber optics holder (C) is correct,lock it into place by tightening the locking screw (A) gently. Be careful not to bend the T-shaped holder (C) by forcing the locking screw too far in. The visible part of the holdershould always be in horizontal position.

After the mechanical zero adjustment, check the optical image.

If the sensor cover is removed, ambient light disturbs the CCD signal.


77

C=fiber optics holder

B=adjusting screw A=locking screw

Figure 45 Mechanical zero adjustment

7.6 Sensor rangeabilityThe sensor is made in two versions: Probe tip angle is either 50 degrees or 57 degrees. Thevalue is stamped on the probe tip.

The rangeability of the two sensor versions is described in the following figure. The shadedarea shows the span for a typical mechanical zero setting. By mechanical zero adjustmentthe shaded area can be moved right (holder moved outwards) or left within the borders ofthe rectangle. For example, the 57 degree version can measure up to R.I. 1.530. If the desiredmeasurement range cannot be achieved with the sensor version in use, the sensor has to beexchanged. The standard span in the following figure is based on an objective lens focallength f=10.

0.11

0.1

Figure 46 Sensor rangeability


78

8. Regular maintenanceThe need for regular maintenance is minimal, due to the construction with no moving parts,no mechanical adjustments and with a solid-state light source. The following rules apply:

• Keep the sensor head and the indicating transmitter clean and dry.• Check that the ambient temperature is not above +45 °C (+113 °F). The sensor head

should not be too hot to keep a hand on.• If your refractometer has prism wash, check that it works, see Testing prism wash

(page 46).

8.1 Checking the sensor humidity levelThe sensor head has an internal humidity detector. The humidity reading can be checked onthe indicating transmitter display, select 3 SENSOR STATUS from the Main menu. Check thehumidity reading once in every three months.

Increasing humidity level indicates either condensate forming in the sensor head (if theprocess temperature is below ambient) or prism leakage. If the humidity reading exceeds30 %, replace the dryer. If the reading exceeds 50 %, check the prism seals. Relative humidityexceeding 60 % produces a diagnostic message HIGH SENSOR HUMIDITY (seeTroubleshooting messages (page 89)).

The dryer (desiccant) is two pieces inside the sensor head cover, see Sensor PR-21-S(page 105) (G). The dryer cannot be reactivated, it must be replaced. The spare part numberfor the dryer sachet is PR-9108.

For instructions on how to open the sensor head to replace the dryer, see Disassembling thesensor (page 80).

8.2 Checking the prism and prismgaskets

Once a year check that the prism surface is smooth and clean and free of erosion and smallholes or digs.

8.3 Disassembling and assembling thesensor

Wear appropriate protective clothing and be careful when removing thesensor! Always check that the pipeline is empty before removing a sensor from theprocess line. Never remove the sensor if there is process liquid in the pipe.

WARNING!

Chapter 8 – Regular maintenance

79

8.3.1 Disassembling the sensor

1. To remove the cover, open the clamp using a 11 mm wrench. Lift cover carefully, theO‑ring seal causes some friction.

2. Remove the processor card.

All connectors have latches.

3. Remove the image detector module.

a. Remove screw A.

b. Then the holder can be removed.

c. Gently pull the module out.

Be careful not to pull the CCD card. Pull from the back of the module body. At assemblynote the aligning pin. Do not touch the screw G, because it fixes the CCD card with theCCD element for receiving optical image correctly from the optics inside of the module.


80

4. Remove the light source module.

a. Remove screw B.

b. Pull out the light source module. The hole C should always be empty.

c. Remove the emitter assembly that is locked by screw D.

5. Remove the temperature sensor. Use fingers to turn the temperature sensorcounterclockwise.

8.3.2 Removing electronic cards PR-10301 and PR-10201

Figure 47 Ribbon cable connector

Chapter 8 – Regular maintenance

81

9. Troubleshooting

9.1 Hardware

Warning! Hazardous voltage, contact may cause electric shock or burn. Beware of the live wires in the lower right-hand corner of the H1 interface card.

Varoitus! Vaarallinen jännite – kosketus voi aiheuttaa sähköiskun tai palovammoja. Varo jännitteisiä johtoja H1-liitäntäkortin oikeassa alakulmassa.

Varning! Farlig spänning. Kontakt kan leda till elstöt eller brännskador. Var försiktig med de strömförande kablarna i det nedre högra hörnet på H1-gränssnittskortet.

Advarsel! Farlig spænding, kontakt kan forårsage elektrisk stød eller forbrænding. Vær opmærksom på de strømførende ledninger i nederste højre hjørne af H1-interfacekortet.

Hoiatus! Ohtlik pinge, kokkupuutel võite saada elektrilöögi või põletuse. Ettevaatust voolu all olevate juhtmetega H1-liidesekaardi all paremas nurgas.

Внимание! Опасное напряжение, при контакте можно получить удар электрическим током или ожог. Остерегайтесь проводов под напряжением в правом нижнем углу интерфейсной платы H1.

Įspėjimas! Pavojinga įtampa, kontaktas gali sukelti elektros smūgį arba užsidegimą. Saugokitės įtampos laidų, esančių apatiniame dešiniajame H1 sąsajos kortelės kampe.

Ostrzeżenie! Niebezpieczne napięcie, dotknięcie grozi porażeniem prądem lub oparzeniem. Uważać na przewody pod napięciem w prawym dolnym rogu karty interfejsu H1.

Varování! Nebezpečné napětí, kontakt může způsobit úraz elektrickým proudem nebo popálení. Dejte si pozor na vodiče pod napětím v pravém dolním rohu karty rozhraní H1.

Figyelmeztetés! Veszélyes feszültség, érintése áramütést vagy égési sérülést okozhat. Óvakodjon a feszültség alatt lévő vezetékektől a H1 interfészkártya jobb alsó sarkában.

Warnung! Gefährliche Spannung, Kontakt kann Stromschlag oder Verbrennungen verursachen. Halten Sie sich von den stromführenden Kabeln unten rechts an der H1 Schnittstellenkarte fern.

Waarschuwing! Gevaarlijke spanning, contact kan elektrische schokken of brandwonden veroorzaken. Pas op voor de spanningvoerende draden in de rechterbenedenhoek van de H1-interfacekaart.

Avertissement! Tension dangereuse, un contact peut provoquer un choc électrique ou des brûlures. Prenez garde aux fils sous tension dans le coin inférieur droit de la carte d'interface H1.

¡Advertencia! El contacto con voltaje peligroso puede causar descargas eléctricas o quemaduras. Tenga cuidado con los cables activos en la esquina inferior derecha de la tarjeta de interfaz H1.

Avvertimento! Tensione pericolosa, il contatto può causare scosse elettriche o ustioni. Attenzione ai fili sotto tensione nell'angolo inferiore destro della scheda di interfaccia H1.

Warning


82

To troubleshoot refractometer hardware problems, it is often important to localize thedifferent cards inside the DTR. The Diagnostic LEDs on the cards help solve the problemsand give an indication on whether a connection is good.

1

2

3

4

5

Figure 48 Transmitter card positions

1 Power indicator light2 Transmitter processor card PR‑105003 H1 interface card PR‑107014 Transmitter motherboard PR‑106005 Power module

Chapter 9 – Troubleshooting

83

Figure 49 Motherboard PR‑10600 and H1 interface card PR‑10701


84

9.1.1 Blank display

Is Powerindicatorlight on?

Processorcard LEDsblinking?

Processorcard LEDsblinking?

Yes

No

No

Yes

No

No

Yes

Yes

Power supplyproblem

Processor cardPR-10500 or

Front panel bad.

Processor cardPR-10500 bad.

Reset contrast backlight,check display cable,check backlight cable

Image visible?

Adjust contrastand backlight

(DTR Main menu >Display setup >

Contrast&Backlight)

Power supplyproblem

Front panel faultyProcessor cardPR-10500 faulty

Open F

ront p

anel

See figure on next page totroubleshoot power supply.

Contrast and backlight are reset by pressing . during power-up.Note. This will also temporarily reset the display language.Next normal power reset will bring back to the original displaylanguage if other than English.

Remov

e PR-10

500 c

over

Figure 50 Troubleshooting blank display


85

Power supply OK

MainsOK? Have it fixed

Disconnect +24 V frommotherboard PR-10600

Power supplymodule bad

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No

No

No

No

Reconnect +24 V toMotherboard PR-10600;

Disconnect processor cardPR-10500 cable,

Remove H1 interface cardPR-10701 and (optional

extension card PR-108xx)

MotherboardPR-10600 bad

Reconnect Processor cardPR-10500

Disconnectkeyboard,

display cable andbacklight cable

Processor cardPR-10500 bad

Front panel badReconnect H1 interface

card PR-10701

H1 interface cardPR-10701 bad

Reconnect optional extensioncard PR-108xx

Extension cardPR-108xx bad

Power supply OK

+24 VOK?

+24 VOK?

+24 VOK?

+24 VOK?

+24 VOK?

+24 VOK?

+24 VOK?

No

Yes

Important safety considerations- Always switch off the mains before

disconnecting or reconnectingcables, modules, and similar

- Beware of the high voltageterminals 34 and 35

Measuring instructions- Use a DMM (Digital Multimeter) to

measure the voltage- Measure the +24 V from terminals

41+/42- (except when otherwise indicated)

- The +24 V DC supply is OK if thevoltage is above 21 V

Measure the voltage directly from the power module leads (red & black)

Figure 51 Checking power supply

9.1.2 Diagnostic LEDsFigure 48 (page 83) and Figure 49 (page 84) assist in locating the diagnostic LEDs.


86

Table 4 Diagnostic LEDs

LED Status Indication See section

Front panel

Green LED Lit DTR power is on; processor cardPR‑10500 is active.

Blank display(page 85)

Transmitter processor card PR‑10500

2 yellow LEDs Blinking Processor card OK.

Transmitter motherboard PR‑10600

Yellow LED (D17) Blinking Motherboard processor working.

Green LED (D16) Lit Processor card converts 24 V / 3 V.

Green LED (D26) Lit Isolating DC / DC conversion OK.

2 green LEDs (D23, D25) Lit Corresponding relay (RLY1 / RLY2)has power.

H1 interface card PR‑10701

Green LED (LD1) Lit Sensor A current correct,20 … 60 mA.

Green LED (LD1) blinking Sensor A is being reset.

Red LED (LD2) Blinking Sensor A current is too high andthe card is trying to reconnect withcorrect current.

Troubleshootingmessages(page 89)

Red LED (LD2) Lit Sensor A current is too high andpower supply to Sensor A has beenswitched off.


Green LED (LD3) Lit Sensor B current is correct,20 … 60 mA.

Green LED (LD3) blinking Sensor B is being reset.

Red LED (LD4) Blinking Sensor B current is too high andthe card is trying to reconnect withcorrect current.


Red LED (LD4) Lit Sensor B current is too high andpower supply to Sensor B has beenswitched off.


A lit red LED on PR‑10701 always indicates a problem. Red LEDs are always turned off innormal operation, whether any sensors are connected or not.


87

DISPLAY

KEYBOARD

H1 interface card Transmitter motherboard

Transmitter processor card

mA outputs

A

B

3 V DC

24 V DC~

24 V/3 V

DC/DC

Y

POWER G

D16G

D23 Relay 1G

D17Y

D26G

G

G

R

R

D25 Relay 2G

Y

Power supplymodule

LD1

LD2

LD3

LD4

Figure 52 Diagnostic LED functions

9.1.3 Display unreadableIf the display is unreadable because of extreme display backlight and contrast settings orwrong display language, you can perform a display reset. A display reset temporarilyrestores the display backlight and contrast to their factory settings and returns the displaylanguage to English.

For the display reset, access the DTR keyboard directly. Then perform the following steps.

1. Switch off the DTR power.

2. Press and hold the decimal point key on the keyboard.

3. Switch on the DTR power.


88

4. Hold down the decimal point key until the DTR has started completely and you see themain display.

The reset on the display language is temporary and the language returns to originalnext time the DTR is powered off, except if the language is permanently changedthrough the display settings menu.

9.1.4 Troubleshooting messages

Table 5 Hardware troubleshooting

Problem Cause Corrective action

Message NO SENSOR The current in the cable to thissensor is below 20 mA. Normallythis means that there is no sensorconnected to the cable or thatthere is no cable to the DTR. If thismessage comes up while a sensorproperly is connected, the mostlikely cause of this message is afault in the sensor. It is alsopossible that the cable is totallydead for example if it isaccidentally cut through.

See also Diagnostic LED LD1/LD3,Diagnostic LEDs (page 86). Theconcentration display is a dashedline.

Message NO SIGNAL

Besides the message, theconcentration display is a dashedline although a sensor isconnected.

The current in the cable to thissensor is in the correct range20 … 60 mA, but no data is comingin from the sensor. This indicatesthat the Sensor processor card isfaulty.

See also Diagnostic LED LD1/LD3,Diagnostic LEDs (page 86).

Replace the sensor processor card.


89


Message SHORT-CIRCUIT

The current in the cable to thesensor A/B exceeds 60 mA. First,the DTR attempts fora short timeto reconnect with the sensor inquestion. If the short-circuitpersists, the sensor in question isswitched off completely to protectthe Motherboard from overheating.

See also Diagnostic LED LD2/LD4,Diagnostic LEDs (page 86)

If two sensorsare connectedto the DTR, ashort-circuit inone of thecables maydisturb themeasurement ofboth sensors asDTR attempts toreconnect. Themeasurement ofthe non-affected sensorreturns tonormal as soonas the short-circuited sensoris switched off.

If the DTR detects a short-circuitthat persists, the affected sensor isswitched off to prevent furtherdamage. The message SHORT-CIRCUIT stays on the screen untilthe DTR is powered off and on.

See also Diagnostic LED LD2/LD4,Diagnostic LEDs (page 86)

The most likely cause of thesemessages is a problem in the cableconnecting the sensor in questionto the DTR.

Check that the cable is undamagedand replace it if necessary, thenturn the DTR off and back on.

Message HIGH SENSOR HUMIDITY

Tells that humidity measured at theSensor processor card exceeds60 % relative humidity.

The reason may be moistureleaking in through prism seal or thecover being open.

Check the prism seal and replace itif necessary.

Message HIGH SENSOR TEMP The temperature on the Sensorprocessor card exceeds 65 °C(150 °F). To read this temperature,select 3 SENSOR STATUS from theMain menu.

For action, see Choosing sensormounting location (page 14).


90


Message HIGH TRANSMITTER TEMP

The temperature of themotherboard of the Indicatingtransmitter exceeds 60 °C (140 °F).

To read this temperature, select 3 SENSOR STATUS from the Mainmenu and check DTR TMP. If thewarning persists, move thetransmitter to a cooler place (forexample out of the sun).

Message LOW TRANSMITTER VOLT

The internal DC voltages of thetransmitter are belowspecifications.

Check the power supply inputvoltage. If the supply voltage iswithin specifications, replacepower supply module, Figure 48(page 83).

Relays and switches not working Check configuration, see Viewing system information (page 50), and forpossible correction see Configuring input switches (page 62),Configuring relays (page 60), and Configuring prism wash (page 71).

Relay status is indicated by LEDs D23, D25 on the Motherboard, seeDiagnostic LEDs (page 86). For switches, check also LED D26 on theMotherboard indicating that the 3 V DC supply is correct, see DiagnosticLEDs (page 86).

The wash function can be tested according to Testing prism wash(page 46).

Output signal error during Normal operation

If there is no output signal:

• Check wiring, see Electrical connections (page 23).• Check Diagnostic LED D26, see Diagnostic LEDs (page 86).

If the mA signal does not correspond to the concentration display, checkoutput signal configuration, see Viewing system information (page 50),and for possible correction see Configuring mA outputs (page 64). A lowmA signal can also be caused by high resistance in the external currentloop, see Electrical connections (page 23).

A noisy signal can be damped, see Configuring output signal damping(page 54).

Table 6 Measurement troubleshooting


Message OUTSIDE LIGHT ERROR The measurement is not possiblebecause too much outside lightreaches the camera.

Identify the light source (forexample sun shining into an opentank or a translucent pipe) andblock the light from getting to theprism at the sensor tip.


91


Message NO OPTICAL IMAGE The optical image can be seen from selecting 3 SENSOR STATUS at theMain menu, see Optical image (page 51). There are several possiblecauses:

1. The prism is heavily coated, see Prism coating (page 35). Performprism wash if available, see Testing prism wash (page 46). Removesensor from line and clean prism manually.

2. There is moisture condensation in the sensor head.3. The sensor head temperature is too high.4. The light source is faulty. When the sensor is removed from the

process, the yellow flashing light can be seen through the prism.

The light is only visible at an oblique angle. Alsocheck the LED value in the Sensor status display(select 3 SENSOR STATUS in the Main menu); ifthe value is clearly below 100, LED fault is notlikely.

5. There are negative spikes in the optical image. The probable cause isdust or fingerprints on the CCD window.

6. The CCD card in the sensor is faulty.

Message PRISM COATED The optical surface of the prism iscoated by the process medium orimpurities in the process medium.

Perform prism wash if available,see Testing prism wash (page 46).Remove sensor from line and cleanprism manually.

If the problem is recurrent,consider improving the flowconditions, see Mounting sensor(page 19). If prism wash isavailable, adjust the washparameters, see Configuring prismwash (page 71).

Message OUTSIDE LIGHT TO PRISM

Some light from the outsidereaches the sensor and maydisturb the measurement.

Identify the light source (forexample sun shining into an opentank or a translucent pipe) andblock the light from getting to theprism at the sensor tip.

Message LOW IMAGE QUALITY The most likely cause for thismessage is scaling on the prism.There still is a optical imageavailable, but the measurementquality may not be optimal.

Clean the prism.

Message NO SAMPLE The operation of the equipment is OK but there is no process liquid onthe prism. The optical image looks like the left image in Figure 30(page 52).


92


Message TEMP MEASUREMENT FAULT

Indicates faulty temperatureelement.

Replace the temperature element.

A difference tosome otherprocesstemperaturemeasurement isnot a fault.PR‑23 measuresthe truetemperature ofthe prismsurface.

Concentration drift during Normal operation

For drift upward, suspect prism coating, see Prism coating (page 35).Otherwise check calibration, see Calibrating concentration measurement(page 66), and sensor verification, see Sensor verification (page 133).

Table 7 Wash troubleshooting


Message EXTERNAL HOLD The concentration measurement is on HOLD due to an external switchclosure. For explanation, see Configuring input switches (page 62).

Messages PRECONDITIONING,WASH, RECOVERING

PRECONDITIONING: An optionalpreconditioning relay is closed.

See Configuring prism wash(page 71).

WASH: The internal wash relay isclosed.

Configuring prism wash (page 71).

RECOVERING: The concentrationmeasurement is on HOLD during apreset time.

Message PRISM WASH WARNING No dip of nD value during prism wash. The accepted size of the dip is setas the WASH CHECK function, see Configuring prism wash (page 71). Seealso Testing prism wash (page 46).

Message PRISM WASH FAILURE No dip of nD value during any prism wash during wash tolerance time.The wash tolerance time is set in wash parameters, see Setting prismwash parameters (page 76). See also Testing prism wash (page 46).

Message EXTERNAL WASH STOP Tells that wash action is prevented because an EXTERNAL WASH STOPswitch is closed, see Configuring input switches (page 62).

• NO SAMPLE indicates an empty pipe.

Message LOW TEMP WASH STOP Tells that wash action is preventedbecause of LOW TEMP: lowprocess temperature indicatesempty pipe.

To set the limit, see Configuringprism wash (page 71).

Message NO SAMPLE / WASH STOP

Tells that wash action is prevented because of NO SAMPLE: the processpipe is empty and the prism is clean.


93

More information

‣ Wash cycle (page 71)

9.1.5 Diagnostic message priorities

The messages are listed in descending order of priority. For example, if both NO OPTICAL IMAGE and TEMP MEASUREMENT FAULT are activated, only NO OPTICAL IMAGEdisplays.

When a relay is configured with FUNCTION INSTRUMENT OK, see Configuring relays(page 60), it is closed when there is no equipment malfunction.

Certain malfunctions cause the mA measurement to return to the mA default output value,see Configuring mA outputs (page 64). For more information, see the following table.

Message Instrument OK Returns to default mA

Conc Temp

SHORT-CIRCUIT X X

NO SIGNAL X X

OUTSIDE LIGHT ERROR

NO OPTICAL IMAGE X

TEMP MEASUREMENT FAULT X X

PRECONDITIONING X

WASH X

RECOVERING X

HIGH SENSOR HUMIDITY

HIGH SENSOR TEMP

HIGH TRANSMITTER TEMP

LOW TRANSMITTER VOLT

EXTERNAL WASH STOP X

LOW TEMP WASH STOP X

NO SAMPLE / WASH STOP X

EXTERNAL HOLD X

NO SAMPLE X X

PRISM COATED X X

OUTSIDE LIGHT TO PRISM X

LOW IMAGE QUALITY X


94

Message Instrument OK Returns to default mA

Conc Temp

PRISM WASH FAILURE X

PRISM WASH WARNING X

NO SENSOR X X

NORMAL OPERATION X


95

10. Indicating transmitter DTRspecifications

Model: INDICATING TRANSMITTERProduct code: DTR-U-GP-ACS/N: T06802Tag:100-240 V AC, 50/60 Hz, 30 VAMade by VAISALA Oyj, Vantaa, Finland

www.vaisala.com IP66

DTR STR

Figure 53 Indicating transmitter serial number labels

10.1 CompatibilityThe indicating transmitter DTR is only compatible with the PR-21-S refractometers and thePR-23 range. Any one or two PR-21-S refractometer sensors can be connected to the DTR.PR-01 and PR-03 refractometer sensors are not compatible with an indicating transmitterDTR.

For intrinsically safe installations (see Section 10.4) there is a single-sensor version of thetransmitter (STR). The information given in this chapter applies to STR as well, unlessotherwise indicated.

10.1.1 Transmitter program versionsThe DTR program version can be updated over the Ethernet connection (see Chapter 11).Contact your nearest representative for more information on how to update your DTRprogram version.

The PR-21 sensor is only compatible with transmitter program version 4.07 or newer.


96

10.2 Model code

10.2.1 Indicating transmitter model codes

Table 8 Indicating transmitter DTR and STR model codes

Model Description

DTR Indicating transmitter (connectivity for two sensors)

STR Indicating transmitter (connectivity for one ‑IA/‑IF/‑CI sensor)

Cable connection

-U ½ in NPT type conduit hubs for CSA certified transmitter

-M M20x1.5 metric cable glands for general purpose

Electrical classification

‑GP General purpose

‑CS CSA certified for use in general purpose (ordinary) locations

Applicable to CSA and ANSI/UL standards 1)

Power supply

-AC Power supply 100‑240 V AC 50/60 Hz, fuse with voltage 250 V AC, max. size 10 A andspeed slow

-DC Power supply 24 V DC, fuse with voltage min. 48 V DC, max. size 4 A and fuse speed fast. 2)

1) Available only with cable connection code -U, ½ NPT type conduit hubs and -AC power supply.2) With -GP option only.

10.2.2 Interconnecting cable model code

Table 9 Interconnecting cable model code

Part number Description

PR-8230 Interconnecting cable between transmitter and sensor

Cable length

-010

-_ _ _

• 10 m (33 ft), standard length• Specify cable length in meters with 10 meter increments

Max. length is 200 m (660 ft)

Chapter 10 – Indicating transmitter DTR specifications

97

10.3 Transmitter parts list

2425

2223

2120

26

19 18

18

1713

1412

111 2

3

5

6

8

91015 4,2

4,1 7,1 7,2

15,115,216

27

Figure 54 Indicating transmitter DTR and STR parts (STR-specific parts in italics)

10.4 Specifications

10.4.1 Indicating transmitter specifications

Table 10 Indicating transmitter specifications

Feature Specification

Display 320 x 240 pixel graphical LCD with LED backlight

Keypad 18 membrane keys


98


Current output Two independent current sources, 4 … 20 mA, max.load 1000 Ω, galvanic isolation 1500 V DC or AC(peak), hold function during prism wash.

AC power supply AC input 100 … 240 V AC, ±10%, 50/60 Hz / 30 VA,fuse voltage 250 V AC, fuse max. size 10 A, fuse speedslow.

DC power supply DC input 24 V DC, ±10%, fuse voltage min. 48 V DC,fuse max. size 4 A, fuse speed fast.

Overvoltage category Overvoltage category II

Alarms/Wash relays Two built-in signal relays, max. 240 V/3 A, fuse withvoltage 250 V AC, max. size 10 A and speed slows.

Input switches Four switch inputs

Current outputs Two current outputs configurable independently toindicate process concentration or temperature ofeither sensor.

Sensor connectivity, DTR One or two sensors can be connected to thetransmitter. Sensors independent of each other: ownparameter sets and usable in different applications.

Sensor connectivity, STR Only one sensor can be connected to the transmitter.Used with the Intrinsically safe sensorPR‑23‑…‑IA/‑IF/‑CI.

Transmitter protection class Enclosure IP66, Nema 4X

Pollution degree Pollution degree 2

Installation Indoor

Indicating transmitter weight 4.5 kg (10 lbs)

Altitude Max. altitude 2000 m (6561.68 ft)

Ambient temperature 0 … +45 °C (+32 … +113 °F)

Display operating temperature 0 … +50 °C(+32 … +122 °F), display storage temperature‑20 … +60 °C (‑4 … +140 °F).

Relative humidity 0 … 100 %

Wet location Not applicable

Chapter 10 – Indicating transmitter DTR specifications

99

10.4.2 Interconnecting cable specifications

Table 11 Interconnecting cable specifications


Cable IEC 61158‑2 compliant two-wire cable: two signalwires and shield copper area 0.8 mm2 (18 AWG) cableresistance 24 Ω/km (per wire) cable attenuation3.0 dB/km @ 28 kHz

Cable length Standard 10 m (33 ft), max. total length 200 m(660 ft)

For information on the intrinsically safe cabling for PR‑23‑…‑IA/‑CI, see Intrinsically safemounting.


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11. Sensor specifications

11.1 Model codesTable 12 PR‑21‑S models

Model Description

PR‑21‑S Sensor

Refractive index range limits

50 Low range, R.I. 1.320 … 1.460 (max span = 0.11)

57 High range, R.I. 1.380 … 1.530 (max span = 0.1)

Process connection

‑L Sandvik L‑clamp, 88 mm

‑D DIN‑flange 2656, PN25/40 DN80

‑A ANSI‑flange 150 lbs, 3 in

‑M ANSI‑flange 150 lbs, 4 in

‑J JIS‑flange, 10K 80 A

Sensor wetted parts material

XS SAF 2205 / AISI 316 L



‑FM FM certified Class I, Div.2, Groups A, B, C, D T6 (Tamb −20 … +45 °C)

‑IA ATEX and IECEx certified Ex II 1G, Ex ia IIC T4 Ga (up to zone 0) (Tamb

−20 … +65 °C)1)

Sensor length

‑LPL Long probe, insertion length 302 mm (11.89 in)

‑LPS Long probe, insertion length 150 mm (5.9 in)

Prism wash

‑HPY Integral nozzle mounting connection

‑HPN Integral nozzle for water

‑HPS Integral nozzle for steam

‑YPY Without integral nozzle mounting connection

1) Available with STR‑Indicating Transmitter and IS isolator only

Chapter 11 – Sensor specifications

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Table 13 Transmitter models for 100 … 240 V AC

Model Description


STR Indicating transmitter (connectivity for one ‑IA sensor)

Cable connection

‑U ½ in NPT‑type conduit hubs

‑M M20x1.5 metric cable glands



‑CS CSA certified for use in general purpose (ordinary) locations

Applicable to CSA and ANSI/UL standards 1)

Power supply

‑AC Power supply 100 … 240 V AC 50/60 Hz

1) Available only with Cable connection code ‑U, ½ in NPT‑type conduit hubs only

Table 14 Transmitter models for 24 V DC

Model Description


STR Indicating transmitter (connectivity for one ‑IA/‑IF sensor)

Cable connection

‑U ½ in NPT‑type conduit hubs

‑M M20x1.5 metric cable glands



Power supply

‑DC Power supply 24 V DC

Table 15 Cables

Model Description

PR‑8230 Interconnecting cable between transmitter and sensor (standard black cable)

(for STR transmitter: Interconnecting cable between transmitter and isolator)

Cable length

‑010 10 m (33 ft)


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Model Description

‑_ _ _ Specify cable length in meters with 10 m (33 ft) increments.

Maximum length is 200 m (660 ft)

PR‑8021

PR‑8021‑FMCable connector for PR‑21‑S for ‑GP and ‑IA sensors 1)

Cable connector for PR‑21‑S for FM sensors 1)

1) New cable connector needed for PR‑21‑S new sensor or PR‑21 upgrade

11.2 PR-21-S part list

Figure 55 Probe parts

Item Pcs. Part No. Description

1 1 Probe with Sandvik clamp

PR‑7717 Sensor wetted parts for Sandvik 50 LPL HPY

PR‑7718 Sensor wetted parts for Sandvik 57 LPL HPY

PR‑7719 Sensor wetted parts for Sandvik 50 LPL YPY

PR‑7720 Sensor wetted parts for Sandvik 57 LPL YPY


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PR‑7725 Sensor wetted parts for Sandvik 50 LPS HPY

PR‑7726 Sensor wetted parts for Sandvik 57 LPS HPY

PR‑7727 Sensor wetted parts for Sandvik 50 LPS YPY

PR‑7728 Sensor wetted parts for Sandvik 57 LPS YPY

1.1 1 PR‑3503 Sandvik clamp FCLC‑316L‑99.9‑S‑T PN25

1.2 1 PR‑3504 Sandvik ferrule

1.3 1 PR‑3505 Sandvik O‑ring FCLG‑T‑88.9x3.6 Teflonâ

1.4 1 Earth screw M6 x 10 DIN 933 A 4 (added)

2 1 Probe with flange

PR‑7713 Sensor wetted parts for flange 50 LPL HPY

PR‑7714 Sensor wetted parts for flange 57 LPL HPY

PR‑7715 Sensor wetted parts for flange 50 LPL YPY

PR‑7716 Sensor wetted parts for flange 57 LPL YPY

PR‑7721 Sensor wetted parts for flange 50 LPS HPY

PR‑7722 Sensor wetted parts for flange 57 LPS HPY

PR‑7723 Sensor wetted parts for flange 50 LPS YPY

PR‑7724 Sensor wetted parts for flange 57 LPS YPY

2.1 1 Flange DIN 2656, PN 25, DN 80 (alternatively ANSIB16.5 3 in RF 150 psi or 300 psi or JIS 10 K 3B)

2.2 2 Screw M6 x 30 DIN 912 SS 316L

2.3 2 Washer M6 DIN 125 SS 316L

2.4 1 Earth screw M6 x 10 DIN 933 A 4 (added)

Parts printed in italics for intrinsically safe sensor PR‑21‑S‑…‑IA.


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11.3 Sensor PR-21-S

Figure 56 Sensor


1 1 Probe with Sandvik L‑clamp

2 1 * Prism

2.1 2 PR‑5005 Prism holders AISI 316 L

2.2 2 PR‑5006 Prism holder screws DIN912 M5x12 A4-80

2.3 2 Teflon pads

2.4 2 PR‑5046 Spinel prism + Kalrez 6375 gaskets +support rings + Teflon pads + screwsDIN912 M5x12 A4‑80

3 1 PR‑8101 Sensor base

3.1* 1 PR‑7403 Connector assembly (3.2, 3.2 and 3.3)

3.1 1 PR‑7404 Connector complete with leads

3.2 1 Connector seal

3.3 4 Connector screws DIN 912 M3x8 A2


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3.4 1 PR‑5011 O‑ring seal 108x3 Nitrile

3.5 1 PR‑5013 Thermal insulator 80/90 x 1.7 Teflon

3.6 6 Screws DIN 912 M5 x 30 A2/A4

3.7 4 Metallic standoff screw

4 1 PR‑8110 Sensor cover

4.1 1 PR‑5012 V‑clamp CA 0600/11‑130mm‑S‑40

4.2 2 PR‑9108 Dryer

4.3 1 PR‑9109 Dryer support

4.4 2 Screw

4.5 1 Label

5 1 PR‑10301 Terminator card

5.1 3 Screw

6 1 PR‑10102‑SP Processor card

6.1 4 Plastic stanoff screw

7 1 PR‑10201‑SP Camera card

7.1 1 Camera support

7.2 2 Plastic screw

7.3 1 Screw

7.4 1 Washer

8 1 Fiber optic module

8* 1 PR‑7420 Assembly ‑ LP 10

8.1 1 Module holder

8.2 1 Holder spring

8.3 1 Washer

8.4 1 Screw DIN 912 M2.5 x 10 A2

8.5 1 Mechanical zero adjustment device

8.5* 1 PR‑5010 Mechanical zero adjustment assy

8.6 2 Screw DIN 912 M2.5 x 10 A2

8.7 1 Spring

8.8 1 Screw DIN 916 M3 x 6 A2

8.9* 1 PR‑5019 Objective holder and lens 10 mm

9 1 Temperature sensor module

9* PR‑7402 Temperature sensor module LP


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10 1 Plug‑in light source module

10* PR‑7507 Plug‑in light source module LP 50

10* PR‑7508 Plug‑in light source module LP 57

10.1 1 PR‑5211 O‑ring seal 16x2 FEP / Viton

10.2 1 Screw DIN 912 M3 x 30 A2

10.3 1 Spring

10.4 1 Mirror

10.4* PR‑7514 Mirror assembly 50

10.4* PR‑7515 Mirror assembly 57

10.5 2 Screw DIN 84 M2.5 x 4 A2

10.6 2 Washer DIN 125 M2.5 A2

10.7 1 Plug‑in light source module

10.7* 1 PR‑7507 Plug‑in light source module LP 50

10.7* 1 PR‑7508 Plug‑in light source module LP 57

10.8 2 Washer DIN 125 M3 A2

10.9 2 Screw DIN 912 M3 x 6 A2

11.4 Standard specificationsTable 16 Standard specifications


Refractive index range Low range R.I. 1.320 … 1.460

High range R.I. 1.380 … 1.530

Max. span Low range R.I. 0.11

Accuracy Typically ±0.1% by weight (depending on the process medium).

Repeatability and stability correspond to accuracy

Speed of response 1 s undamped, damping time selectable up to 5 min

Calibration With Cargille standard R.I. liquids

Temperaturecompensation

Automatic, digital compensation

Instrument verification According to ISO 9000 quality system with standard R.I. liquids and transmitter'smenu guided procedure

Process temperature max. +150 °C (+300 °F) (for higher temp. consult factory)


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Ambient temperature −20 °C … +45 °C (−4 °F … +113 °F)

Indicating transmitter: max. +50 °C (+122 °F), min. 0 °C (+32 °F)

Process pressure Flange connections up to 25 bar (350 psi), Sandvik clamp static pressure up to 20 bar(300 psi)/operational pressure up to 10 bar (150 psi)

Sensor protectionclass

IP65, Nema 4X

SENSOR PR‑21‑S‑LPL/LPS (LONG PROBE)

Process connection L‑clamp, 88 mm; DIN‑flange 2656. PN 25, DN80; ANSI‑flange,150 psi, 3 in;ANSI‑flange, 300 psi, 3 in; JIS‑flange, 10K 80 A

Process wetted parts AISI 316L stainless steel, prism gaskets Kalrez (prism pads teflon)

Sensor insertionlength

‑LPL = Long probe 302 mm

‑LPS = Long probe 150 mm

Sensor weight L‑clamp 7 kg (15 lbs)/flange DIN/ANSI/JIS 10.5 kg (23 lbs)

OPTIONS Prism wash, intrinsic safety and hazardous area approvals

11.5 PR-21-S process refractometers inpotentially explosive atmosphere

The PR‑21 refractometer series can be used in locations with potentially explosiveatmosphere with following modifications, made by Vaisala.

The PR‑21‑…‑FM refractometer is certified by Factory Mutual Research Corporation,Certificate No. 3050975. Equipment Ratings: Nonincendive for use in Class I, Division 2,Groups A, B, C & D, Hazardous (Classified) Locations. Temperature identification rating forPR‑21‑…‑FM is T6 (Tamb = +45 °C).

11.5.1 EquipmentThe refractometer system for potentially explosive atmosphere locations consists of amodified refractometer sensor PR‑21‑…‑FM, a standard indicating transmitter DTR, a sensorconnector PR‑8021‑FM and a sensor cable PR‑8230‑…. The connector has to be securedmechanically by the securing clamp.


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Figure 57 Refractometer system PR‑21‑…‑FM

The FM‑certified sensors PR‑21‑S‑…‑FM are identified by the sensor nameplate. Theindicating transmitter is a standard DTR.


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Figure 58 FM nameplate

11.6 Intrinsically safe refractometersPR-21-…-IA

Hazardous locations are places where a possibility of fire or explosion exists because offlammable gases, vapors or fine dust.

Zone0: An area in which an explosive gas-air mixture is continuously present or present forlong periods of time.

Zone1: An area in which an explosive gas-air mixture is likely to occur in normal operation.

Intrinsically Safe Process Refractometer PR‑21‑…‑IA can be used in hazardous locations inZone 0 and Zone 1 areas.

The PR‑21‑…‑IA refractometer has been certified by Eurofins Expert Services under theEuropean ATEX directive 2014/34/EU for ATEX Ex II 1G / Ex ia IIC T4 Ga (Tamb =‑20 … +65 °C) and under the IECEx scheme for Ex ia IIC T4 Ga (Tamb = ‑20 … +65 °C). TheEU‑Type examination Certificate number is EESF 19 ATEX 057X and the IECEx Certificatenumber is IECEx EESF 19.0025X. These certifications cover the following Ex standards: EN60079‑0:2012 / IEC 60079‑0:2011 and EN 60079‑11:2012 / IEC 60079‑11:2011.


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Only trained service personnel of Vaisala and its representatives are permitted to servicethe intrinsically safe PR‑21‑…‑IA refractometer. Servicing must be done according toseparate instructions defined by Vaisala and must be reported to Vaisala.

11.6.1 EquipmentThe intrinsically safe process refractometer consists of the following:

• A modified refractometer sensor PR‑21‑S‑…‑IA• An indicating transmitter STR with single sensor connectivity• IS isolator and cabling between the refractometer sensor and the transmitter

Figure 59 Refractometer system PR‑21‑S‑...‑IA

The equipment is intrinsically safe only if all mounting instructions are followed, seeIntrisincally safe mounting (page 114). If the instrument has been in any way damagedduring transportation, return it to your nearest Vaisala K‑PATENTSâ service point forcheckup before installation. Never install a damaged instrument into the process line.

The intrinsically safe sensor PR‑21‑S‑…‑IA is identified by the nameplate, see the following.The indicating transmitter is of model STR, for single sensor connection.


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Figure 60 IA nameplate

An intrinsically safe sensor has a different processor card and a different terminator cardthan a standard sensor, other parts are as in standard sensor (see earlier in this chapter forfull parts list).


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Figure 61 Intrinsically safe parts

Do not replace any part of an intrinsically safe sensor with a standardsensor part.WARNING!

Contains lightmetalsIgnition hazard!Avoid impact!

Figure 62 Warning sticker


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If the sensor cover is made of aluminum, the refractometer sensor cancause ignition if it hits other metal parts during the installation. An aluminum sensorcover must have a sticker warning about this possibility.

WARNING!

11.6.2 Intrisincally safe mountingChoose the mounting location of the sensor, the isolator/barrier unit and the indicatingtransmitter so that they are protected from sudden impact and friction.

The electrical connections for PR‑21‑S‑…‑IA are described in the following figure.


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Figure 63 Intrinsically safe wiring, PR‑21‑S‑…‑IA

Cables:


115

• 10 m (33 ft) cable, part number PR‑8230‑010, connecting the Indicating transmitter STRand the Isolator unit. The maximum cable length is 100 m (330 ft).

• 10 m (33 ft) power cable, part number PR‑8250‑010, connecting the Indicatingtransmitter STR and the Isolator unit, part number PR‑8250‑010. The maximum lengthis 100 m (330 ft).

• The intrinsically safe cable between Isolator unit and sensor, part PR‑8260‑xxx, wherexxx is the cable length in meters. The maximum length is 100 m (330 ft). For cableconnections, see Figure 63 (page 115) and Figure 64 (page 116).

Isolator/Barrier Unit can also use an optional external +24 V DC power supply instead ofthe +24 V DC power supply from the transmitter. +24 V DC is connected to terminals 13and 14. If +24 V DC is used, the PR‑8250 power cable is not used at all.

11.6.3 Isolator/barriersThe following figure explains the isolator unit wiring.

64 531 2 2101 1197 8

1314

ev- ev+ ev- ev+

-vs

+vs

ISOLATOR UNIT

24 V DC

Power cablePR-8250-xxx

max 100 m (328 ft)

max 100 m (328 ft)max 100 m (328 ft)

CablePR-8230-xxx

12Cable

PR-8260-xxx

Figure 64 Isolator unit wiring

If the power to isolator unit terminals is not correctly connected, +24 V DC to terminal 14(+vs) and zero to terminal 13 (-vs), the transmitter STR displays the message NO SIGNAL.If terminals 11 and 12 are not correctly connected, sensor cable connecting terminal 2 ofthe indicating transmitter STR to the isolator unit terminal 11 (-ve) and terminal 1 of theSTR to isolator unit terminal 12 (+ve) , the message NO SIGNAL displays.


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12. Ethernet connectionspecification

The Ethernet connection enables data download from a DTR to a computer. The connectionworks both directly between DTR and computer or through a hub or switch, local areanetwork (LAN), wireless network (WLAN) or fiber Ethernet.

Any type of computer (for example PC, Mac, PDA, mainframe) with a compatible networkconnection can be configured to download data from the DTR. This document gives all thespecifications necessary to write a communications program for downloading purposes. It isalso possible to get a ready-to-install communications software from Vaisala.

12.1 Cable requirements and connection

12.1.1 Ethernet cable specificationThe DTR uses a standard Ethernet cable (10/100BASE-T Cat 5e UTP cable with RJ45connectors). The maximum cable length is 50 m (164 ft).

Ethernet connection is similar to that of a computer/PC: Use a cross-over Ethernet cable toconnect the DTR directly to a computer, as shown in the figure below. If you are connectingthe DTR to a LAN (Local Area Network) through a wall socket, use straight-through Ethernetcable, as shown in the following figure.

PROCESS INSTRUMENTS

POWER

Ethernet cableCat 5 or Cat 6

Figure 65 Connecting DTR to computer

Chapter 12 – Ethernet connection specification

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PROC ESS INSTRUMENTS

P OWE R

S traight-throughcable

LAN

Figure 66 Connecting DTR to LAN

If you are connecting the DTR to a hub or switch or WLAN access point, please consult theuser guide of your hub/switch/access point for the correct cable type, as shown in thefollowing figures.


P OWE R

Hub/Switch

Check hub/switch manualfor Ethernet cable type

Figure 67 Connecting DTR to hub or switch


P OWE R

WLAN

Accesspoint

Check WLAN manualfor Ethernet cable type

Figure 68 Connecting DTR to WLAN

If you need a longer cable or the environment is electrically noisy, use fiber optics Ethernetwith media converters as shown in the following figure.


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P OWE R

FiberMediaconverter

Mediaconverter

Check mediaconverter manual

for Ethernetcable type

Figure 69 Using fiber optics Ethernet

12.1.2 Connecting Ethernet cableTo connect the Ethernet cable to the DTR, open the DTR’s enclosure cover, loosen the frontpanel screw and open the front panel. The Ethernet connector is behind the front panel, seethe following figure. Plug one end of an appropriate Ethernet cable into the connector. Plugthe other end into your PC/LAN socket/hub/switch/access point.


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Warning! Check that the power is off before opening the front panel. If the green power indicator light is on, there is still power in the system. To completely turn the power off, use the external power switch.

Varoitus! Tarkista, että virta on katkaistu, ennen kuin avaat etupaneelin. Jos vihreä virran merkkivalo palaa, järjestelmässä on edelleen virtaa. Katkaise virta kokonaan ulkoisella virtakytkimellä.

Varning! Kontrollera att strömmen är avstängd innan du öppnar frontpanelen. Om den gröna indikatorlampan lyser är det fortfarande ström i systemet. Använd den externa strömbrytaren för att stänga av strömmen helt.

Advarsel! Kontroller, at strømmen er slukket, før frontpanelet åbnes. Hvis den grønne strømindikatorlampe er tændt, er der stadig strøm i systemet. Brug den eksterne afbryder for at slukke helt for strømmen.

Hoiatus! Enne esipaneeli avamist kontrollige, et süsteem poleks pinge all. Kui roheline toitemärgutuli põleb, on süsteemis endiselt pinge all. Toite täielikuks väljalülitamiseks kasutage välist toitelülitit.

Внимание! Перед открытием передней панели убедитесь, что питание отключено. Если горит зеленый индикатор питания, система находится под напряжением. Чтобы полностью отключить питание, используйте внешний переключатель питания.

Įspėjimas! Prieš atidarydami priekinį skydelį, patikrinkite, ar maitinimas išjungtas. Jei šviečia žalia maitinimo indikatoriaus lemputė, sistemoje vis dar veikia maitinimas. Norėdami visiškai išjungti maitinimą, naudokite išorinį maitinimo jungiklį.

Ostrzeżenie! Przed otwarciem panelu przedniego sprawdzić, czy zasilanie jest wyłączone. Dopóki świeci się zielona kontrolka zasilania, system znajduje się pod napięciem zasilania. W celu całkowitego wyłączenia zasilania należy użyć zewnętrznego wyłącznika zasilania.

Varování! Před otevřením předního panelu zkontrolujte, zda je napájení vypnuto. Pokud svítí zelená kontrolka napájení, je v systému stále přítomno napájení. Chcete-li napájení zcela vypnout, použijte externí vypínač.

Figyelmeztetés! Az előlap kinyitása előtt ellenőrizze, hogy a készülék ki van-e kapcsolva. Ha a zöld tápellátás jelzőfény világít, akkor a rendszer még áram alatt van. A készülék teljes kikapcsolásához használja a külső tápkapcsolót.

Warnung! Prüfen Sie, ob das Gerät ausgeschaltet ist, bevor Sie die Frontblende öffnen. Wenn die grüne Betriebsanzeige leuchtet, liegt noch Spannung an. Verwenden Sie den externen Netzschalter, um das Gerät vollständig auszuschalten.

Waarschuwing! Controleer of de stroom is uitgeschakeld voordat u het voorpaneel opent. Als het groene stroomindicatielampje brandt, staat er nog stroom op het systeem. Gebruik de externe voedingsschakelaar om de stroom volledig uit te schakelen.

Avertissement! Vérifiez que l'alimentation est coupée avant d'ouvrir le panneau avant. Si le voyant d'alimentation vert est allumé, le système est toujours sous tension. Pour mettre l'appareil complètement hors tension, utilisez l'interrupteur d'alimentation externe.

¡Advertencia! Verifique que la alimentación está desconectada antes de abrir el panel frontal. Si la luz indicadora de encendido de color verde está encendida, aún hay energía en el sistema. Para apagar completamente la alimentación, use el interruptor de encendido externo.

Avvertimento! Verificare che l'alimentazione sia spenta prima di aprire il pannello anteriore. Se la spia di alimentazione verde è accesa, il sistema è ancora alimentato. Per spegnere completamente l'alimentazione, utilizzare l'interruttore di alimentazione esterno.

Warning


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Figure 70 Ethernet connector on underside of front panel

The DTR has automatic speed negotiation, and automatically finds out what the optimalspeed for the connection is and chooses accordingly, either 10 Mbit/s or 100 Mbit/s speed.

12.2 Connection settings

12.2.1 IP settings for DTRThe DTR uses the IP protocol to communicate over the Ethernet. The factory setting for theDTR’s IP address is 192.168.23.254 (a private network address).

If you connect the DTR to an existing network, the address must be changed to fit thenetwork before making the connection. To prevent conflicts, consult your networkadministration to find a suitable IP address for the DTR in question.


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The DTR address is changed manually through the Calibration menu through the followingpath:

5 Calibration > 2 Outputs > 6 Network

Type the new IP address and press Enter to change the address.

12.2.2 IP settings for stand-alone computerIf you connect a non-networking (stand-alone) computer directly to a DTR with a cross-overcable, the easiest solution is to check the computer’s network settings and conform theDTR’s settings to it.

If the DTR is in a factory network, contact the system admin on how to connect to theDTR. The stand-alone method may not be the best one in this kind of case.

If you are using Windows (or Mac OS X 10.3 or newer or any recent Linux distribution) andthe computer has the default network settings, change the DTR IP address to169.254.x.y, where x=1–254 and y=1–254, for example 169.254.100.100 or169.254.123.1. This way the DTR address is suitably paired with the address that yourcomputer automatically generates for itself.

If in doubt, you can access your Windows computer’s network settings by opening thecommand window (command prompt) and by typing the command ipconfig at thecommand prompt (press Enter to give the command), see following figure (in Mac OS X andLinux the same command is called ifconfig). The result is your computer’s IP address, soyou can change the DTR to match. The connection should always work if you match the firstthree groups of numbers and just change the last number.

Figure 71 Typical IP configuration for stand-alone laptop when connected to DTR; laptopwireless (WLAN) turned off


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You may have to connect the cross-over cable and power on the DTR before yourcomputer generates an IP address for the Ethernet connection (computer reboot may alsobe required). The connection does not work if the computer and the DTR have exactly thesame IP address.

Please make sure that your WLAN (Wireless network connection) is not active when youconnect to the DTR. If the WLAN is active, the computer’s Ethernet connection may notfunction as expected.

When you have set the DTR (and/or the computer), you can proceed to testing theconnection, see Testing Ethernet connection (page 123).

12.3 Testing Ethernet connectionOn the Ethernet connector inside the DTR there are two diagnostic LEDs.

• The green LED indicates that the physical connection is working. Both ends of theEthernet cable are plugged in, the device in each end is powered and the cable is ofcorrect type.

• The orange LED indicates traffic in the cable, DTR receives data.

You can test the IP address with a ping command after you have set up the physicalEthernet connection and the DTR is powered. To use ping:

1. Go to the command interface (for example, Command Prompt in Windows).2. Type ping and the IP address you want to check.3. Press ENTER.

If the Ethernet connection is good, the DTR is powered on, and the address is correct, theDTR answers to ping and returns any data packets sent to it. If DTR returns and errormessage, see Troubleshooting connection (page 124).


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Figure 72 Ping OK

12.3.1 Troubleshooting connection

Figure 73 Ping error message

If you get a ping error message, check your connections.

Open the DTR cover and front panel and check the diagnostic LEDs of the Ethernetconnector, see Connecting Ethernet cable (page 119).


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Keep both the DTR and your computer powered while you check the diagnostic LEDs.

If both LED lights are turned off, check the following:

• Both the DTR and the device in the other end of the cable are powered on• The Ethernet cable is properly inserted in both ends• The Ethernet cable is of the correct type (cross-over cable for direct DTR-to-computer

connection)

If the green LED is lit, your Ethernet connection is made correctly with the right type ofcable. In this case, try pinging the DTR and check if the orange LED flashes during ping.

If the orange LED does not flash, check that the IP address matches the IP address of theDTR. In case the DTR is not connected directly to the computer, there may be a routingproblem. Please consult your network administrator to solve the problem.

A firewall software with tight settings may stop you from connecting to a DTR. If you areconnecting directly to the DTR and you are not in a network, turn off the firewalltemporarily while working with the DTR. Remember to turn on the firewall beforeconnecting to a network again.

12.4 Instrument homepageFrom DTR program version 2.0 onwards every DTR has its own built-in instrumenthomepage that contains information about the instrument and a remote panel with fullfunctionality. The instrument works like a web server, so you only need a working Ethernetconnection to the DTR and any web browser to access the instrument homepage.


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Figure 74 Instrument homepage open in browser

Opening the instrument homepage

1. Establish a working Ethernet connection to the DTR.2. Start your preferred web browser (for example Firefox, Edge, Safari, Opera or Chrome).3. Type the DTR IP address to the address bar.

The DTR IP address for a factory-set DTR it is http://192.168.23.254/ (the address usedin the figure is not the default).

4. Wait until the homepage is loaded. This may take a few seconds.If the page looks strange, try refreshing the page. The exact look of the page dependson your browser and screen settings, so slight variation can be expected.

5. Use the links in the link bar on the left side of the page to find more extensiveinformation on the instrument.

12.4.1 Remote panelThe instrument remote panel is a fully functional virtual DTR where keys on the keyboard areclicked with a mouse. The DTR does not make any difference between commands comingfrom the actual keyboard and from a remote panel. All commands are executed in the orderthe DTR gets them, independent of where they come from.

The DTR display picture on the remote panel sometimes has a lag of few seconds before itrefreshes. This depends on many factors like the computer and network used. If the DTRseems to ’skip’ displays, it may be that it is executing mouse-click keyboard commandsfaster than your browser updates the picture.


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http://192.168.23.254/

Figure 75 DTR remote panel

12.4.2 Sensor verification certificateA sensor verification certificate can be viewed and printed by following the Verification linkon the link bar.

More information

‣ Sensor verification (page 133)

12.5 Collecting data using EthernetThe main purpose of the Ethernet connection is to collect measurement data from theinstrument. To program a downloading facility, see the specifications in the followingsections.

Vaisala guarantees that the specifications are correct, but cannot assume anyresponsibility or provide support for software.

12.5.1 Communication protocolThe communication protocol is based on UDP/IP to port 50023. It is a client/serverprotocol, where the DTR is the server and therefore only sends information when the client(your computer) requests it. The server answers requests within 5 s (5000 ms), usually theresponse time is below 100 ms.

Request format

The client to server communication (the requests sent from your computer to the DTR), is inbinary format. The request packets contain the following binary data (all integers are in thenetwork order, MSB first):

• 32-bit integer: packet number• 32-bit integer: request ID


127

• (any): request data (depends on the request)• (any): fill-in data

The maximum size of the message is 1472 octets (bytes).

The packet number is echoed back by the DTR, but not processed in any way. The packetnumbers do not have to be sequential, any 32-bit value is valid.

The request ID is a 32-bit value that identifies the requested function, for example sensorinformation. See Request-response pair specification (page 129) for request IDs.

The request data consists of 0 to 1464 octets of additional data associated with the request.

The fill-in data can be used to increase the number of octets in a message. Any number ofNULL characters (0x00) may be added to the end of the request as long as the total size ofthe message does not exceed the maximum of 1472 octets. This may be useful, for example,if the client implementation uses fixed-length packets.

Response format

The response data sent by the DTR is in ASCII format. With the exception of the packetnumber, the data is human-readable. The data structure consists of:

• Packet number (32-bit integer)• Zero or more lines of ASCII (text) keys and values associated with these keys (for

example temperature key and process temperature in Celsius)

The packet number is echoed back without change. The client (software on computer) canuse the packet number to check the response against the packet number of the request.

The message text consists of lines of text, each line a single key (of one word) and its valueor values. The values are separated from the key by an equal sign ( = ) and multiple valuesare separated by a comma. White space (space or tabulator) is allowed anywhere exceptwithin a single value or key name.

If the response consists of a character string, it is enclosed in double quotes ("). For exampleall these are valid message text lines:

ok temp=23.45headhum = 13.32LEDcnt = 8341ChemCurve = 1.234, 3.21, 0.00, 4.37, 1.11, 0.00002, 2.1345StatusMessage = "Normal Operation"

All the key identifiers are case-insensitive, see Request-response pair specification(page 129). However, it is recommended that they are written as in this specification.


128

The server (DTR) may send the response keys in any order. It will send the mandatory keysof the specific request, but it may omit any other keys. The server may also send keys thatare not specified in this document, but the client (computer) may ignore them.

Mandatory keys are marked with an asterisk in Request-response pair specification(page 129).

Request and response errors

When the server (DTR) detects an error, it responds with an error message. For moreinformation see Error message specification (page 131). Error messages can be caused byan unknown request, or inability to collect data for the mandatory keys of a response.

12.5.2 Request-response pair specificationThe list below describes the request-response pairs (query messages), used for datacollection through Ethernet. Mandatory response keys are preceded by an asterisk (*).

When multiple request data options are available, only one can be used at a time. Eachsensor status request must be directed to either sensor A or sensor B, not both.

Table 17 Request-response pair specification

Specification Description Request ID Request data Response key

NULL message The null message is included inthe query messages fordebugging purposes as it isused to check whether theserver is listening. The messagegives a high-level ’ping’functionality.

0x00000000 (none) • IP: IP address• MAC: Ethernet MAC

address

Protocolversion

The version query is respondedwith a value representing theserver (DTR) protocol version.

0x00000001 (none) *Version: integer, theserver protocol version(currently 3)


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DTRinformation

The DTR information querygives the basic information ofthe DTR assembly.

0x00000002 (none) • *DTRserial: string,DTR serial number

• *ProcessorSerial:string, processorcard serial number

• *ProgramVersion:string, mainprogram version

• *MBSerial: string,motherboard serialnumber

• *MBVersion: string,motherboardprogram version

• IFSerial: string,sensor interfaceserial number

• IFVersion: string,sensor interface cardprogram version

IFSerial and IFVersionare only supplied if theinformation is available.

Sensorinformation

The sensor information querygives the basic information ofthe chosen sensor.

0x00000003 0x00000000(sensor A)

• *SensorSerial: string,sensor serial number

• *SProcSerial: string,sensor processorcard serial number

• *SensorVersion:string, softwareversion number

• SensorCurrent:integer, sensorcurrent in milliamps

0x00000001(sensor B)


130


Measurementresults

The measurement result querygives the measured andcalculated measurement valuesfrom the chosen sensor.

0x00000004 0x00000000(sensor A)

• Status: string, sensorstatus message

• Slope: float, imagequality factor (QF)

• PTraw: integer,PT1000 value

• LED: float, sensorled value

• RHsens: float, sensorinternal humidity

• nD: float, calculatednD value

• CONC: float, finalconcentration value

• Tsens: float, sensorinternal temperature

• T: float, processtemperature (withtemperature bias)

• Traw: float, processtemperature(without bias)

• CCD: float, imageshadow edge

• CALC: float,calculatedconcentration value

0x00000001(sensor B)

DTR status 0x00000006 (none) • *Volt1: float, DTRinternal voltage 1

• *Volt2: float, DTRinternal voltage 2

• *DTRtemp: float,DTR internaltemperature

• Out1uA: integer, mAoutput 1 in uA

• Out2uA: integer, mAoutput 2 in uA

• Switches: hex string(for example,"0x00"), switchstatus as a bit field

12.5.3 Error message specificationIf the server (DTR) does not recognize the request or cannot fulfill it, it responds with anerror message. The error message has the following keys:

• *Error : integer, error code 0x00000000 : Unknown request• *Error : integer, error code 0x00000001 : Invalid request (request recognized, invalid

request data)• *Error : integer, error code 0x00000002 : No sensor (sensor(s) not connected to DTR)• ErrorMsg : string, error details


131

There may also be error-dependent extra keys. Other error codes may be returned.0x00000003 is to be handled as unknown request. Codes with higher numbers refer tointernal errors; contact Vaisala for more information on these.


132

13. Sensor verificationA company maintaining quality system according to ISO 9000 quality standards must havedefined procedures for controlling and calibrating its measuring equipment. Suchprocedures are needed to demonstrate the conformance of the final product to specifiedrequirements. The company should:

• Identify the required accuracy and select appropriate equipment for measurements.• Establish calibration procedures including a check method and acceptance criteria.• Calibrate the equipment at prescribed intervals against certified equipment having a

known valid relationship to nationally recognized standards. In cases where no suchstandards exist, the basis used for calibration must be documented.

Vaisala verifies the calibration of all delivered instruments according to a procedure similarto the one described in Refractive index n D verification (page 133).

13.1 Refractive index nD verificationBefore starting the verifications procedures, make sure that you have a PR‑21‑S sampleholder at hand. Check the condition of your standard refractive index liquids. You need acleaning solution (ethanol) to clean the sensor prism and the sample holder.

The sample holder is kept in place by a rubber link.

Figure 76 Sample holder: Part number PR‑5002

Chapter 13 – Sensor verification

133

The verification of the PR‑21‑S sensor calibration is made using a set of standard refractiveindex liquids with the nominal values at +25 °C (+77 °F):

• 1.330• 1.350• 1.360• 1.370• 1.390• 1.410• 1.430• 1.450• 1.460• 1.470• 1.490• 1.500• 1.520

The accuracy of the certified standard refractive index liquids is ±0.0002 and they can betraced back to national standards: N.I.S.T Standards # 1823 and # 1823 II.

The repeatability of PR‑21‑S sensor, that is the deviation from the latest nD calibration, iswithin ±0.0004.

As the specified accuracy of PR‑21‑S is ±0.0004, then the representative level is the rootsum square of the three accuracy specifications, that is ±0.0006.

Vaisala provides a set of standard R.I. liquids, PR‑2000, containing these five liquids. The setcan be ordered directly from Vaisala or through your nearest representative.

13.1.1 Handling R.I. liquidsUse gloves and safety glasses or goggles. Make sure the ventilation is good, local ventilationis preferable. Please review the safety instructions and the MSDS shipped with the liquids(valid inside R.I. range 1.30-1.57, safety markings valid in EU/EEA areas). Do not put tissuesor liquid bottles in household waste, dispose of waste according to local regulations forchemical waste.

13.2 Verification procedureTo start the verification process, select 1 VERIFICATION in the Main menu of your sensor.The first verification display instructs you on the pre-verification procedure:


134

Figure 77 Verification, pre-verificaton checks

When you are finished with the preparations, press CONTINUE (right-most soft key) to startthe verification process.

The verification itself is done by the refractometer system. Follow the instructions on screenand apply one RI liquid at a time on the sensor and press VERIFY (right-most soft key). Seethe following figure.

Figure 78 Verification display

Clean and dry the prism and the sample holder very carefully between the RI liquids. Use asuitable solvent, for example ethanol or IPA (Isopropyl alcohol).

To check that the standard liquid is properly wetting the prism, it is possible to press soft keyOPT. IMAGE. The optical image should show a sharp shadow edge, see the following figure.


135

Figure 79 Typical optical images

A verification data collection method is implemented in the DTR. The instrument measureseach verification data point ten times and uses the average of these measurements.Measuring each verification liquid takes approximately 10 s, during which the measurementprogress display is shown, as shown in the following figure. Wait until the verification step 2display reappears before proceeding to the next verification liquid.

Figure 80 Verification in progress

The sample holder keeps the sample on the prism surface and also blocks the ambient lightfrom reaching the prism.

Press COMPLETE in the verification display finishes the verification procedure and calls upthe verification results.

If verification is successful, meaning that all measurements are within ±0.0004 of thenominal values, you get the message VERIFICATION OK, see the following figure.


136

Figure 81 Verification completed successfully (here only with one RI liquid)

The sensor verification concerns only the refractive index nD measurement. Thecalculation of concentration from nD and process temperature TEMP is not included, seeCalibrating concentration measurement (page 66).

If the verification fails, see Corrective action (page 140).

13.3 Sensor verification certificateThe DTR stores the most recent verification done on the DTR and the results of thatverification can be viewed and printed on the instrument homepage by following theVerification link on the link bar.


137

Figure 82 Instrument verification page open in browser

When you have performed a verification on a sensor, refresh the verification page to viewthe newest results. The date given on the verification page is the page load date, notnecessarily the verification date.

The date and time settings are taken from the computer used to view the verificationcertificate. The DTR does not have timekeeping functionality. To print the verificationcertificate, use your browser’s print function. The page is designed so that with browserdefault settings it normally fits onto a single sheet of A4 or letter sized paper; the navigationbar is omitted for cleaner printout, as shown in the following figure.


138

PROCESS REFRACTOMETER PR-23

Sensor verificationPage loaded on February 2, 2009 at 03:19:28 PM

Sensor information

Serial number: R05676

Test results

Nominal nD Measurement Sensorat 25°C at

actualtemp.

MeasurednD

Accuracy Result Headtemp.°C

Headhum. %

SupplycurrentmA

1 1.3300 1.3297 1.3296 0.0001 pass 30 3 392 1.3700 1.3697 1.3696 0.0001 pass 30 3 393 1.4200 1.4196 1.4197 0.0000 pass 30 3 394 1.4700 1.4697 1.4697 0.0000 pass 30 3 395 1.5200 1.5196 1.5196 0.0000 pass 30 3 39

Verification result: pass

Traceability and conformance

Measurements should be done by using Cargille Refractive Index Liquids withstated in accuracy of ±0.0002 R.I.Cargille Index of Refraction Liquids are manufactured and calibrated usinginstruments whose accuracy is verified by daily comparision to N.I.S.T. (N.B.S.)traceable standards. N.I.S.T. standards are based on angle measurements usinga Wild divided circle spectrometers.

lmths.firev/052.32.861.291//:ptthnoitacifirev rosneS :metsyS retemotcarfeR 32-RP stnetaP-K

1 of 1 2.2.2009 15:21

Figure 83 Instrument verification certificate


139

When verifying two sensors connected to one DTR, verify one sensor and then save orprint the certificate, as the results from the verification of the second sensor overwritesthe results of the first sensor. Check the sensor serial number on the certificate to see thatyou have correct results on screen and refresh if needed.

More information

‣ Ethernet connection specification (page 117)

13.4 Corrective actionIf you get the message VERIFICATION FAILED, see Figure 84 (page 140), check that theprism and the sample holder are clean and the sample holder sits tightly on the sensor tipbefore a standard liquid is applied. Make sure the standard liquids are in good condition andnot past their expiration date. Inspect the prism surface, make sure that it is smooth andglossy without any scratches. Go back to Verification step 2 by pressing REPEAT to theverification procedure.

The following are the most common reasons for verification failure:

• Insufficient cleaning of the prism.• Too old calibration liquids• Bad temperature control (changing temperature)

Figure 84 Verification failed

If verification fails even when repeating the verification procedure, fill in the sensorverification form (available in Appendix C) and send it to your nearest representative oremail the collected information to [email protected] and wait for further instructions.

For the sensor verification form collect data from the Verification step 2 display and theVerification results display. The sensor’s serial number is shown in the upper right corner ofeach display. The measured nD (RI) is given when VERIFY is pressed in Verification step 2.The list of CCD and TEMP values are on the verification results display, see the followingfigure.


140

Figure 85 Finding verification information for sensor verification form


141

14. Regulatory compliance andcertifications

14.1 EC Declaration of Conformity forPR-21 series of refractometers

The following Declaration of Conformity confirms compliance with the applicable EU/EEArequirements and applies to all Vaisala K-PATENTSâ PR‑21 refractometer products:


142

2019-09-01D/JAMO 1 (1)

Vaisala Oyj | PO Box 26, FI-00421 Helsinki, Finland Phone +358 9 894 91 | Fax +358 9 8949 2227 Email [email protected] | www.vaisala.com Domicile Vantaa, Finland | VAT FI01244162 | Business ID 0124416-2

EU DECLARATION OF CONFORMITY

Manufacturer: Vaisala Oyj

Mail address: P.O. Box 26, FI-00421 Helsinki, Finland Street Address: Vanha Nurmijärventie 21, Vantaa, Finland

This declaration of conformity is issued under the sole responsibility of the manufacturer.

Object of the declaration:

K-Patents Process Refractometer PR-21-S with Transmitter DTR / STR

The object of the declaration described above is in conformity with Directives:

RoHS Directive (2011/65/EU) EMC Directive (2014/30/EU) Low Voltage Directive (2014/35/EU)

The conformity is declared using the following standards:

EN 50581:2012 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control and laboratory use – Part 1: General requirements

EN 61326-1:2013 Electrical equipment for measurement, control and laboratory use – EMC requirements – intended for use in industrial locations

Signed for and on behalf of Vaisala Oyj, in Vantaa, on 1st September 2019

______________________________________

Jukka Lyömiö Standards and Approvals Manager

Chapter 14 – Regulatory compliance and certifications

143

14.2 Declaration of Conformity forPR‑21‑…‑IA models (ATEX)

The following Declaration of Conformity confirms compliance with the European ATEXrequirements and applies to Vaisala K-PATENTSâ PR‑21‑…‑IA refractometer products:


144

2019-09-01C/JAMO 1 (1)

Vaisala Oyj | PO Box 26, FI-00421 Helsinki, Finland Phone +358 9 894 91 | Fax +358 9 8949 2227 Email [email protected] | www.vaisala.com Domicile Vantaa, Finland | VAT FI01244162 | Business ID 0124416-2

EU DECLARATION OF CONFORMITY

Manufacturer: Vaisala Oyj

Mail address: P.O. Box 26, FI-00421 Helsinki, Finland Street Address: Vanha Nurmijärventie 21, Vantaa, Finland

This declaration of conformity is issued under the sole responsibility of the manufacturer.

Object of the declaration:

K-Patents Process Refractometer PR-21-S-…-IA

The object of the declaration described above is in conformity with Directives:

RoHS Directive (2011/65/EU) EMC Directive (2014/30/EU) ATEX Directive (2014/34/EU) Low Voltage Directive (2014/35/EU)

The conformity is declared using the following standards:

EN 50581:2012 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances

EN 60079-0:2012 Explosive atmospheres - Part 0: Equipment - General requirements

EN 60079-11:2012 Explosive atmospheres - Part 11: Equipment protection by intrinsic safety "i"

EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control and laboratory use – Part 1: General requirements

EN 61326-1:2013 Electrical equipment for measurement, control and laboratory use – EMC requirements – intended for use in industrial locations

Notified body VTT Expert Services Ltd (number 0537) has issued EU-type examination certificate VTT 13 ATEX 052X for this product.

Signed for and on behalf of Vaisala Oyj, in Vantaa, on 1st September 2019

______________________________________

Jukka Lyömiö Standards and Approvals Manager

Chapter 14 – Regulatory compliance and certifications

145

Appendix A. Principle ofmeasurementThe Vaisala K‑PATENTSâ in‑line refractometer determines the refractive index nD of theprocess solution. It measures the critical angle of refraction using a yellow LED light sourcewith the same wavelength (589 nm) as the sodium D line (hence nD). Light from the lightsource (L) in the figure below is directed to the interface between the prism (P) and theprocess medium (S). Two of the prism surfaces (M) act as mirrors bending the light rays sothat they meet the interface at different angles.

L

P

MM

S

A C B

Figure 86 Refractometer principle

The reflected rays of light form an image (ACB), where (C) is the position of the criticalangle ray. The rays at (A) are totally internally reflected at the process interface, the rays at(B) are partially reflected and partially refracted into the process solution. In this way theoptical image is divided into a light area (A) and a dark area (B). The position of the shadowedge (C) indicates the value of the critical angle. The refractive index nD can then bedetermined from this position.


146

The refractive index nD changes with the process solution concentration and temperature.For most solutions the refractive index increases when the concentration increases. Athigher temperatures the refractive index is smaller than at lower temperatures. From thisfollows that the optical image changes with the process solution concentration as shown inthe figure below. The color of the solution, gas bubbles or undissolved particles do notaffect the position of the shadow edge (C).

B BC CA ALow concentration High concentration

Figure 87 Optical images

The position of the shadow edge is measured digitally using a CCD element and is convertedto a refractive index value nD by a processor inside the instrument. This value is usedtogether with the measured process temperature to calculate the concentration.

a. Optical image

b. CCD element

c. CCD output

V

Figure 88 Optical image detection

Appendix A – Principle of measurement

147

Appendix B. PR-21 sensorverification formFill in this form and email it to [email protected] or to your local service representative.

Sensor serial no:

Customer:

Address:

Email:

Date:

Verification made by:

Table 18 Verification results display

Samplenumber

Nominal nD Measured nD CCD Temp

1 1.3300

2 1.3500

3 1.3600

4 1.3700

5 1.3900

6 1.4100

7 1.4300

8 1.4500

9 1.4600

10 1.4700

11 1.4900

12 1.5000

13 1.5200


148

Appendix C. Field calibrationformFill in this form and email it to [email protected] or to your local service representative.

Refractometer serial no:

Refractometer model:

Customer:

Address:

Email:

Sample description:

Solvent (water/other):

Laboratory method:

Date:

Data collected by:

DTR DISPLAY VALUES

Sample no. LAB% CALC T nD CONC

Appendix C – Field calibration form

149

Appendix D. DTR commandselection tree

CALIBRATION5 NEGATIVE DISPLAY2

SENSOR STATUS3

VERIFICATION1

SENSOR A/B MAIN MENU

RELAYS3

mA OUTPUTS2

SYSTEM1

SWITCHES4

PRISM WASH5

NETWORK7

DESCRIPTION2

PARAMETERS6 FIELD CALIBRATION2

CHEMICAL CURVE1

SENSOR nD CALIBRATION3

FIELD SAMPLES2

SLOPES3

WASHS4

SENSOR RESTARTS2

WASHS4

DUAL SENSOR1

SINGLE SENSOR: CONC2

SINGLE SENSOR: CONC+TEMP3

SINGLE SENS: CONC+BAR GRAPH4

POSITIVE DISPLAY1

MAIN DISPLAY FORMAT1

DISPLAY BACKLIGHT & CONTRAST2

DISPLAY INVERSION3

BAR GRAPH SETTINGS4

DISPLAY LANGUAGE5

DISPLAY SETUP4

CHEMICAL CURVE PARAMETERS1

FIELD CALIBRATION PARAMETERS2


TEMPERATURE BIAS4

CONCENTRATION1

TEMPERATURE2

DAMPING T. EXPONENTIAL (STD)1

DAMPING TYPE LINEAR (FAST)2

mA OUTPUT 11

mA OUTPUT 22

RELAY 11

RELAY 22

RELAYS3

PRISM WASH4

SWITCHES5

PASSWORD6

TEMP LIMIT VALUE °C8 TEMPERATURE LIMIT ACTIVE2

HOLD DURING WASH ACTIVE2

PASSWORD ACTIVE2

TEMP LIMIT ACTIVATION7 TEMPERATURE LIMIT INACTIVE1

HOLD DURING WASH INACTIVE1

PASSWORD INACTIVE1

HOLD DURING WASH6

WASH CHECK MODE5

WASH INTERVAL4

RECOVERY TIME3

WASH TIME2

PRECONDITION TIME1

SCALE FIELD4

SCALE CHEMICAL3

FUNCTION2

SENSOR1

CALIBRATION SEAL6

SWITCH 44

SCALE SELECT5

SWITCH 33

REMOTE WASH4

SWITCH 22

WASH STOP3

SWITCH 11

HOLD2

NOT DEFINED1

WASH CHECK AUTOM. WASH CUT3

WASH CHECK STANDARD2

WASH CHECK DISABLED1

FUNCTION2

SENSOR1

DELAY6

HYSTERESIS5

LIMIT VALUE4

LIMIT SOURCE3

MANUAL SET3

SENSOR B2

SENSOR A1

OUTPUTS2

MANUAL SET8

SPAN4

DEFAULT OUTPUT5

ZERO3

SOURCE2

SENSOR1DISPLAY UNITS1

DISPLAY DECIMALS2

DAMPING TYPE3

DAMPING TIME4

SLEW RATE5

TOLERANCE TIME6

NETWORK8

mA OUTPUTS7

CHEMICAL & FIELD PARAMETERS1

WASH7

PRECONDITION6

HIGH LIMIT5

LOW LIMIT4

INSTRUMENT OK3

NORMAL OPERATION2

NOT DEFINED1

SOURCE PROCESS TEMPERAT.3

SOURCE CONCENTRATION2

SOURCE NOT DEFINED1

SENSOR B2

SENSOR A1

password limit

EMPTY PIPE CHECK ACTIVE2

EMPTY PIPE CHECK INACTIVE1

EMPTY PIPE CHECK9

WASH nD LIMIT1MORE ...0

DAMPING TYPE SLEW RATE3

SEC DEFAULT MODE6

SEC DEFAULT7

PRISM WASH FAILURE8


150

Appendix E. STR/Divert modecommand selection tree

CALIBRATION5 NEGATIVE DISPLAY2

SENSOR STATUS3

VERIFICATION1

MENU

RELAYS3

mA OUTPUTS2

SYSTEM1

SWITCHES4

PRISM WASH5

NETWORK7

DESCRIPTION2

PARAMETERS6 FIELD CALIBRATION2

CHEMICAL CURVE1


FIELD SAMPLES2

SLOPES3

WASHS4

SENSOR RESTARTS2

WASHS4

SINGLE SENSOR: CONC1

SINGLE SENSOR: CONC+TEMP2

SINGLE SENS: CONC+BAR GRAPH3

POSITIVE DISPLAY1

MAIN DISPLAY FORMAT1

DISPLAY BACKLIGHT & CONTRAST2

DISPLAY INVERSION3

BAR GRAPH SETTINGS4

DISPLAY LANGUAGE5

DISPLAY SETUP4

CHEMICAL CURVE PARAMETERS1

FIELD CALIBRATION PARAMETERS2


CONCENTRATION1

TEMPERATURE2

DAMPING T. EXPONENTIAL (STD)1

DAMPING TYPE LINEAR (FAST)2

mA OUTPUT 11

mA OUTPUT 22

RELAY 11

RELAY 22

RELAYS3

PRISM WASH4

SWITCHES5

PASSWORD6

TEMP LIMIT VALUE °C8TEMPERATURE LIMIT ACTIVE2

HOLD DURING WASH ACTIVE2

PASSWORD ACTIVE2

TEMP LIMIT ACTIVATION7TEMPERATURE LIMIT INACTIVE1

HOLD DURING WASH INACTIVE1

PASSWORD INACTIVE1

HOLD DURING WASH6

WASH CHECK MODE5

WASH INTERVAL4

RECOVERY TIME3

WASH TIME2

PRECONDITION TIME1

SCALE FIELD3

SCALE CHEMICAL2

FUNCTION1

CALIBRATION SEAL6SWITCH 44

SCALE SELECT5SWITCH 33

REMOTE WASH4SWITCH 22

WASH STOP3SWITCH 11

HOLD2

NOT DEFINED1

WASH CHECK AUTOM. WASH CUT3

WASH CHECK STANDARD2

WASH CHECK DISABLED1

FUNCTION1

DELAY5

HYSTERESIS4

LIMIT VALUE3

LIMIT SOURCE2

MANUAL SET3

OUTPUTS2

DEFAULT OUTPUT4

SPAN3

ZERO2

SOURCE1

DISPLAY UNITS1

DISPLAY DECIMALS2

DAMPING TYPE3

DAMPING TIME4

TOLERANCE TIME6

SLEW RATE5

CHEMICAL & FIELD PARAMETERS1

WASH7

PRECONDITION6

HIGH LIMIT5

LOW LIMIT4

INSTRUMENT OK3

NORMAL OPERATION2

NOT DEFINED1

SOURCE PROCESS TEMPERAT.3

SOURCE CONCENTRATION2

SOURCE NOT DEFINED1

password limit

EMPTY PIPE CHECK ACTIVE2

EMPTY PIPE CHECK INACTIVE1

EMPTY PIPE CHECK9

WASH nD LIMIT1MORE ...0

mA OUTPUTS7

NETWORK8

DAMPING TYPE SLEW RATE3

MANUAL SET7

TEMPERATURE BIAS4

SEC DEFAULT6

SEC DEFAULT MODE5

PRISM WASH FAILURE8

Appendix E – STR/Divert mode command selection tree

151


152

WarrantyFor standard warranty terms and conditions, see www.vaisala.com/warranty.

Please observe that any such warranty may not be valid in case of damage due to normal wear and tear,exceptional operating conditions, negligent handling or installation, or unauthorized modifications. Pleasesee the applicable supply contract or Conditions of Sale for details of the warranty for each product.

Technical support

Contact Vaisala technical support at [email protected]. Provide at least the followingsupporting information as applicable:

• Product name, model, and serial number• Software/Firmware version• Name and location of the installation site• Name and contact information of a technical person who can provide further

information on the problem

For more information, see www.vaisala.com/support.

Recycling

Recycle all applicable material.

Follow the statutory regulations for disposing of the product and packaging.

153

http://www.vaisala.com/warranty

mailto:[email protected]

http://www.vaisala.com/support

www.vaisala.com

http://www.vaisala.com

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