Cerlic CTX User manual

2019-06-19 C30B5EN19
CTX
Flow-through
Consistency / Suspended Solids Sensor

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TABLE OF CONTENTS
1. Introduction .............................................................................................. 3
2. A few words about this manual .............................................................. 3
3. Design....................................................................................................... 3
4. Measuring principle ................................................................................. 3
5. Unpacking sensor.................................................................................... 4
6. Mounting sensor ...................................................................................... 4
7. Removing sensor..................................................................................... 6
8. Service and maintenance........................................................................ 6
9. Sensor information displays................................................................... 6
10. Sensor menu ............................................................................................ 7
Settings................................................................................................................................ 7
Calibrate.............................................................................................................................. 7
Cleaning .............................................................................................................................. 7
Scale / Alarm ...................................................................................................................... 8
System................................................................................................................................. 8
11. Calibration ................................................................................................ 9
Overview............................................................................................................................. 9
Zero Calibration.................................................................................................................. 9
Calibrating consistency..................................................................................................... 10
Adjusting calibration of consistency ................................................................................ 10
Calibration points.............................................................................................................. 10
Automatic adjustment of the calibration .......................................................................... 11
Calibration with multiple points ....................................................................................... 11
Calibration display............................................................................................................ 11
Multiple Calibration sets .................................................................................................. 12
12. Deposits – alarm and compensation ................................................... 13
13. Scaling .................................................................................................... 13
14. Technical data........................................................................................ 13
15. Dimensions ............................................................................................ 15
Appendix 1. Low suspended solids with brush cleaning........................... 16

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1. Introduction
The CTX flow-through sensor is used to measure suspended solids in liquids. Combined
with the BB2 control box, the sensor is used to measure fiber and particle consistency in the
pulp and paper industry. Examples of applications are consistency control, retention control,
monitoring white water and suspended solids in white and green liquor.
The sensor is also used in waste water treatment plants and other industries to measure
suspended solids and maintain effluent control.
2. A few words about this manual
The manual primarily contains information about the Cerlic CTX sensor. Menu functions
and technical data of the BB2 control box can be found in the BB2 manual.
3. Design
The CTX sensor is made in acid proof stainless steel and is mounted with pipe fittings
(DN25) directly onto a 25 mm (1”) pipe. The sensor has a self cleaning design which permits
precise and reliable measurement with minimum maintenance possible, even in critical
applications. The measuring lenses in the steel cell are made of sapphire glass in order to
withstand abrasive liquids. Electronic and optical components are well protected within the
steel enclosure to handle very demanding environments.
The sensors are available with 50 mm (2” NPT) connections (CTX 20/50) and 25 mm (1”
NPT) connections (CTX 20/25, CTX 20/25 LC, CTX 20/25 K). The LC sensor is a special
type for very low consistencies. The K sensor is a special type for applications with
aggressive media, i.e. white/green liquors, supplied with Kalrez sealings.
A shielded 10 m (33 ft) cable is used for communication between the sensor and the BB2
control box. The cable is made of polyurethane and highly resistant to aggressive substances.
4. Measuring principle
The CTX measures transmitted light through the liquid. The measuring principle is based on
the suspended particles’ ability to absorb and reflect light .The light source is a light emitting
diode (LED) that pulses monochromatic NIR light at high power. The detected measuring
signal is inversely logarithmical proportional to the consistency or suspended solids. Signal
treatment is done by the BB2 control box. The temperature is measured by the transmitter to
be used for temperature compensation of the measured value.

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5. Unpacking sensor
The unit has been tested and approved before shipping.
Content
Please check that the content corresponds to your order and packing list.
Damages
If damages occurred during the shipment, immediately contact the carrier as well as your
Cerlic representative. The shipment can be returned only after contact has been made with
Cerlic.
Packaging
The original packaging is designed to protect the equipment and should be used for storage
or if the goods must be returned.
Optional parts can be ordered P/N
•Butt weld end DN25 - 30x25 mm for CTX 20/25 11203082
•Butt weld end DN50 - 54x50 mm for CTX 20/50 11203320
•25 mm hose adapter DN25 for CTX 20/25 10305122
•10 m (33 ft) signal cable, max 10x10 m (10x33 ft) 20805510
•Connection box for two sensors to one BB2 control box 11505748
with 1 m (3 ft) cable to connect BB2
•Brush cleaning device for CTX 20/25 and CTX 20/25 LC 10603261
•Mounting plate for CTX with brush cleaning device (outside US) 12705528
•Mounting plate for CTX with brush cleaning device (US) 31204066
•Solenoid valve for flushing (outside US) 1705516A
•Solenoid valve for flushing (US) 1705516B
6. Mounting sensor
The CTX 20/25 can be mounted directly in a 25mm (1”) pipe, CTX 20/50 in a 50mm (2”)
pipe. With larger pipes a by-pass line should be used. The sensor shall always be mounted
with the cable connector pointing downwards.
There are three ways to mount the sensors – butt weld end connection, NPT-couplings (US)
or hose connections. See Dimensions section for more information.
For further instructions on white and green liquor applications, please refer to Appendix 1.
In recycled fiber applications the valve after the sensor should be controlled. Regularly it
should open completely in order to purge the sensor. The BB2 control box can control this
using the cleaning relay. With printing ink and resin in the pulp, a higher flow rate through
the sensor than specified below is required to give representative values.
Please carefully study these installation guidelines to reach maximum performance

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•The inlet to the by-pass pipe should be located where the suspension is well mixed and
the flow is turbulent. Appropriate distance from a pump discharge or a pipe elbow is
about five pipe diameters downstream.
•The by-pass pipe should be as short and straight as possible.
•A turbulent flow gives a better representation of the consistency. In order to obtain the
highest possible flow rate in the by-pass pipe, install the by-pass pipe inlet before an
elbow or pipe reduction.
•To avoid the water film on pipe walls, the by-pass pipe should extend at least 20 mm
(¾”) into the pipe.
•For CTX 20/25 and CTX 20/50 the by-pass pipe should be 25 mm (1”) and 50 mm (2”)
respectively.
•The by-pass pipe should not have any throttling valve or pipe bend closer than 0.5 m
(20”) before the sensor.
•The by-pass pipe should be made to avoid dewatering of the pulp stock at shutdown. If
there is a risk for this, then the valve upstream the sensor should be closed automatically
when the pump stops.
•The flow rate in the by-pass pipe should be at least equivalent to the main pipe but not
less than 20 l/min (10 gpm) for CTX20/25 and 60 l/min (30 gpm) for CTX 20/50
sensors. At lower rates, there is a risk for dewatering and build up on the glass windows.
For pulp stock with printing ink and resin, the flow rate should be twice as high. With
automatic flushing, then the flushing water pressure should be at least the same pressure
as the air pressure to the cleaning device.
•The temperature of the sensor must not exceed 95°C (203°F)
•Install the sensor to avoid exposure to considerable and fast changes in temperature
•Avoid installation where the sensor is exposed to severe cold weather or direct sunlight
•Protect the sensor from high pressure water spraying
•The sensor should never be submerged under water
•Always install the cables between sensor and control box in conduit when possible
•Install the sensor to avoid extreme vibrations
•The sensor must not be removed while still under process pressure
•The sensor must not be used as a ground point for welding
•If welding is to be done on the pipe system, the cable and the sensor should be removed
•Always remount the protective cover on the sensor connector when the cable is removed
Automatic flushing
Two three-way valves can be used to automatically flush the sensor with water. The flush
water temperature shall be close to the temperature of the measured media to avoid
temperature stress of the sensor. In some applications where dilution of the measured media

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is allowed, only one three-way valve can be used, and the flush water can go out the same
way as the media. The valves before the sensor must not in any way reduce the flow when
open. If there is a risk of turbulence in the valve, it must be placed more than 0.5 m (20”)
before the sensor.
Sometimes the sensor may need manual cleaning using a bottle brush and diluted acid (5 %
hydrochloric acid or sulphamic acid).
7. Removing sensor
•Close all valves to isolate the sensor.
•Disconnect the sensor from the by-pass pipe by using the couplings on each side of the
sensor. Remove the sensor and save the Teflon gaskets for reassembly.
•Clean the sensor with a clean cloth. Do not use a wire brush!
•Flush through the sensor thoroughly.
Before the sensor is disconnected the valves in the by-pass pipes must be closed. Make
sure that no flow passes through the pipe. If the sensor is disconnected under process
pressure this could cause serious injury or even death. Cerlic does not accept any
responsibility for accidents caused when the sensor is disconnected while still under
line pressure.
8. Service and maintenance
In some applications the measuring cell may need to be cleaned. Use warm water and a
small bottle brush to clean the cell; do not use a metallic brush or sharp tools. An acid
solution can be used to dissolve coating in the measure cell. Plug one end of the cell and fill
it with 5 % hydrochloric acid or sulphamic acid. Leave the sensor for a couple of hours and
then flush the cell with plenty of clean water. Repeat the treatment if necessary. If
hydrochloric acid does not dissolve the coating, other chemicals may be used as long as they
don’t affect the O-rings made of Viton
The sensor housing may not be opened, except by Cerlic service personel. Opening the
sensor housing will void all warrenty.
9. Sensor information displays
Press and ENTER simultaneously to switch between main menu and the sensor display
#1. This first display shows some additional readings to the main values (temperature, the
value measured during last cleaning). Press and ENTER simultaneously again to reach
the display #2 showing the current calibration set graphically. By pressing and ENTER
simultaneously a third time you return to the main display.

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10. Sensor menu
Use or to select the sensor in the main display. Press ENTER for five seconds to
access the menu for the selected sensor.
Settings
Tag Name of the sensor (10 characters) shown in the main display
Calibration Calibration set ”A”-“D” or “Extern”. “Extern” will allow remote selection of
calibration set from DCS.
I-Time(s) Integration time, dampening the output signal
Unit ”%”, ”mg/l”, “g/l” or ””ppm”
Decimals ”Std” or ”Extra”, number of decimals for the reading
Analog ”None”, ”Ch1”, ”Ch2”, ”Ch3”, ”Ch4”, ”Ch1+2” or ”Ch3+4”.
Pick the analog output(s) to be used with sensor. Ch3-4 are optional.
Second ”Temp”, ”=Prim” or “Clean”. If two outputs are chosen, the first will always
give the primary value. The second will either give the temperature (0-
100°C), the same signal as the first or the measured value at the last
flushing.
Calibrate
Selected Cal ”A”-“D” or “Ext”, selection of calibration set
Used Cal Selected calibration set (A-D)
Adjust ”No”, ”Store” or ”Lab”. “Store” stores the present reading of the sensor and
after input of the corresponding lab result through “Lab” the old lab result
under “Sample #1” is automatically adjusted
Take sample “No”, “Zero” or “# 1”-“# 5”, see Calibration section
Cons Actual consistency reading
Sample # 1 Lab test sample # 1
Sample # 2 Lab test sample # 2
Sample # 3 Lab test sample# 3
Sample # 4 Lab test sample # 4
Sample # 5 Lab test sample # 5
Cleaning
Cleaner ”None”, ”Brush” or ”Flush” (“Brush” does not exist for this sensor)
Interval min Time (minutes) between cleaning cycles
Length sec Duration (seconds) of flushing cycle
Freeze sec Extra freeze time of output signal after a flushing cycle
Relay ”-”, ”#1”, ”#2”, “Along #1” or “Along #2”. Select relay to operate solenoid for
flush cycle if this sensor is a master with its own relay, or relay used by
master if this sensor is a slave. These same relays can be used as “Alarm
relay” below.
Next time The next scheduled cleaning time. Pushing “Enter” on this line will set the
time to current time and start a cleaning cycle. This could be used to test
the “Flush” cycle.
Clean Reading in the end of the last flushing cycle

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Scale / Alarm
Max Reading corresponding to 20 mA output signal
Min Reading corresponding to 4 mA output signal
Hi-Alarm Reading to activate high alarm, 0 inactivates the alarm
Low-Alarm Reading to activate low alarm, 0 inactivates the alarm
Alarm Relay ”-”, ”1 and 2”, ”#1” or ”#2”. Check that it is not used for cleaning
System
Type Type of sensor
Serial Serial number of sensor
SoftW Software version of sensor
Temp Sensor temperature
MaxTemp The highest sensor temperature recorded
Samples Sub menu to view SA values and consistency values for this calibration set
Selected Cal ”A”-“D” or “Extern”, selection of calibration set
Used Cal Selected calibration set (A-D)
SA 0 SA value zero sample (clean water)
SA 1 SA value sample #1
Cons 1 Lab test sample #1
..... And so on for sample #2-5
Info Menu for Cerlic internal use
MS Linearized light signal, which are SA values in calibration chart
Con Consistency reading
SA 0 SA value for zero sample on clean water
SA 1 SA value sample #1
Cons 1 Lab test sample #1
Ch1aRaw value channel 1 (1000-40000)
Ch1 Raw value channel 1, compensated for intensity
Intens. Current intensity (150-25000)
Zero Int Intensity for clean water, set during zero calibration
I-offset Intensity offset, set during zero calibration
Temp Calib Temperature compensation constant.
Samp/s Samples per second
Service Not accessible for users

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11. Calibration
Overview
Calibration is made in a number of steps performed in a consecutive order. Each step is
described further down. If one step is redone, all later steps have to be redone:
1. Zero calibration, made on clean water by Cerlic before shipping
2. Calibrating consistency
3. Adjusting calibration of consistency
•It is important that the sensor has been in operation for at least 30 minutes before
calibration to have a stable operation
•Single point calibration is recommended. In case of multiple point calibration, sample
#2-5 can be calibrated when steps 1-4 above are finalized for sample #1
Zero Calibration
The sensor is zero calibrated at the factory, and does normally not need recalibration. Before
doing a zero calibration make sure that it is really needed. The zero point is common for all
four calibration sets. If the zero point is recalibrated it will affect all other calibration points
in all calibration sets of the sensor. The CTX 20/25 LC sensor cannot be zero calibrated in
the mill, it has to be performed by Cerlic.
Make sure the windows are clean, and use clean de-aerated water to check the meter reading.
Tap water is best de-aerated in an open bucket for at least two hours.
To run a zero calibration:
•Remove the sensor from the process and clean it thoroughly
•Plug one end of the sensor and fill the cell with clean de-aerated water
NOTE! The sensor must not be submerged into the bucket!
•Select the sensor to be calibrated in the menu by using or arrows
•Press ENTER for five seconds to enter the sensor menu
•Use and arrows to select “Calibrate” and select ”Take sample”
•Select ”Zero” and press ENTER
•If you really want to destroy the existing calibrations, change “No” to “Yes”, then press
ENTER
•After you have filled the sensor with water, press ENTER again
•Wait for the zero calibration to finish. It will take approximately thirty seconds before
the unit returns to the menu.
For more information concerning use of menu/dialogues, refer to the manual for BB2.

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Calibrating consistency
•Select “Calibrate”, “Take sample”, “#1” and press “ENTER”
•Press ”ENTER” to calibrate and take a lab sample
•Take the sample to the lab for analyzing consistency
•The lab results are entered in “Calibrate” and “Sample #1”
Adjusting calibration of consistency
Statistic adjustment of the lab sample value is a much better way to good measurement than
frequent recalibration. This is done comparing the lab results with the instrument reading
over time. If a systematic discrepancy is detected, the value of the lab sample used in BB2 is
changed accordingly. If for example several lab results for a period of time in average shows
5 % more than the instrument, the sample value in BB2 shall be increased 5 % of its value,
e.g. if the sample value is 1.00 % it shall be changed to 1.05 %. Using statistic adjustment
will gradually improve the accuracy and reliability while a new calibration will restart from
scratch. An Excel sheet to help doing statistical adjustment of the calibration can be
downloaded from http://www.cerlic.com.
Calibration points
The calibration set is built up of the zero calibration point and at least one calibration point.
A calibration point can be disabled by setting the consistency value to zero.
Consistency
0
0
Sensor

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Single point calibration
Multiple point calibration
Automatic adjustment of the calibration
The function ”Adjust” in the calibration menu is used to automatically adjust the calibration
in an easy way. When a sample is taken for the lab, BB2 stores the reading. When the
sample has been analyzed, the result is keyed into the BB2 who will compare it to the stored
reading and calculate a new sample #1 value. Automatic adjustment only works for single
point calibration and is primarily intended as an easy way to get started with a new sensor.
Once the automatic adjustment is done, and the sensor gives a sensible reading, statistical
adjustment is recommended.
•Select sensor in the menu by using or
•Press ENTER for five seconds to enter the sensor menu
•Select “Calibrate”, “Adjust” and then “Store”
•Press ENTER when taking the lab sample
•Get the sample analyzed
•Select “Calibrate”, “Adjust” and then “Lab”
•Press ENTER
•Key in the lab result, then press ENTER
•BB2 will show current and suggested new value for ”Sample #1”, acknowledge the
change by pressing ENTER or abort using or .
Calibration with multiple points
The only cases where multiple calibration point is useful are when the sensor signal is non
linear or when the sensor has to be very accurate at widely separated consistencies.
Use the same procedure described in “Calibrating total consistency and ash content (sample
#1)” but select sample #2, #3, #4 or #5.
Calibration display
Press and ENTER simultaneously to switch between main menu and the sensor display
#1. This first display shows some additional readings to the main value (temperature, the
value measured during last cleaning, raw value of the measurement). Press and ENTER
simultaneously again to reach the display #2 showing the current calibration set graphically.
By pressing and ENTER simultaneously a third time you return to the main display.

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Two samples have probably been
exchanged when entering the lab
results. The Y-value must always
increase with increasing X-value.
A calibration set normally consists of zero point and one consistency sample (single point
calibration). Up to five samples may be used to create a calibration curve (multiple point cal-
ibration). The samples are sorted internally in order of signal intensity. The calibration dis-
play shows the calibration set in a graph:
•X-scale displays consistency, from Min (4 mA) to Max (20 mA)
•Y-scale displays the raw sensor signal
•Actual measuring value is shown in numbers and with the arrow on the Y-axis
•Samples outside the scale are not displayed but still used in the calculations. If you want
to see a point outside the scale, you may temporarily change the scale in the Scale / Alarm
sensor menu.
Multiple Calibration sets
The sensor can handle four independent calibration sets for different types and qualities of
pulp. Each set has up to five calibration points. All four sets have a common zero
calibration. The selection of calibration set is done in the menu for setup and calibration or
from an external device (DCS). At external selection:
•The external selection overrides the manual selection
•If several sensors are connected to one common BB2, all sensors will change
simultaneously to the set selected (A-D)

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12. Deposits – alarm and compensation
BB2 has a choice to output the measured value during the last flushing on its second 4-20
mA output. This is useful in demanding applications where it can be used to trigger an alarm
to manually clean the sensor. The signal can also be used to compensate the reading for
deposits in the sensor, extending the interval between manual cleaning.
13. Scaling
On the "Scale / Alarm" menu the range of the 4-20 mA is selected, as well as alarm limits:
Min sets the 20 mA point output
Max sets the 4 mA point output
Hi-Alarm sets the high alarm set point; a value of zero inactivates the alarm
Low-Alarm sets the how alarm set point; a value of zero inactivates the alarm
14. Technical data
CTX 20/25 P/N 11305503
Process connection DN25, butt weld ends 30x25 mm (outside US) or 1” NPT
connections (US)
Material SIS2343 / 316SS
Pressure rating PN25 / 365 psig
Enclosure IP65 / NEMA4X
Process temperature 0 - 95°C / 32 - 203°F
Set B
Set A
Set C
Set D
A B C D Ex-
000
001
01x
1xx
BB2
digital
inputs

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Process pressure Min 1 bar / 15 psig
Light source GaAs diode, 880 nm monochromatic
Measuring principle Straight transmission, 20 mm measuring gap
Connection cable 5-pin M12 connector
Weight 3.7 kg / 8 lbs
Measuring range Min 0-100 mg/l
Max 2 % consistency or 3 % suspended solids
CTX 20/25 K P/N 11305707, Kalrez®O-rings for white and green liquor
Other technical data Refer to CTX 20/25
CTX 20/25 LC P/N 11305531, low consistency sensor
Process temperature 0 - 50°C / 32 - 122 °F
Flow 15 – 100 l/min / 4 - 25 gpm
Measuring range Min 0 –10 mg/l (resolution 0.1 mg/l)
Max 0 – 200 mg/l (measures up to 2000 mg/l but not fully linear)
Other technical data Refer to CTX 20/25
CTX 20/50 P/N 11305506
Process connection DN50, butt weld ends 54x50 mm (outside US) or 2” NPT
connections (US)
Measuring range Min 0-100 mg/l
Max 5 % in by-pass pipe or 8 % directly in pipe
Other technical data Refer to CTX 20/25
Certificate of conformity
The CTX sensors along with their central unit BB2 are in conformance with the following
EC Directive(s) when installed in accordance with the installation instructions contained in
the product documentation:
73/23/EEC Low Voltage Directive as amended by 93/68/EEC
89/336/EEC EMC Directive as amended by 92/31/EEC and 93/68/EEC
The following standards and/or technical specifications have been applied:
EN 61000-6-4:2001 Electromagnetic compatibility (EMC) Part 6-4
Generic standards – Emission standard for industrial environments

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EN 61000-6-2:2001 Electromagnetic compatibility (EMC) Part 6-2
Generic standards - Immunity for industrial environments
EN 61010-1:2001 Safety requirements for electrical equipment for measurement,
control, and laboratory use
15. Dimensions
CTX 20/25

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Appendix 1. Low suspended solids with brush cleaning
Complete package for measuring of the suspended solids can be delivered on a mounting
plate, ready for installation. The equipment is normally supplied with an automatic brush-
cleaning system to be controlled by the BB2 control box.
Installation
The mounting plate is hung onto a handrail or mounted on a wall. Free space to the right is
necessary for maintenance of the cleaning mechanism.
Cleaning brush
•The cleaning is done by a brush, which is pushed into the sensor cell by a piston,
controlled from the BB2 control box. Typical interval is 45 min.
•During the cleaning the output signal is frozen.
•The brush should be changed depending on the wear caused by the liquid, typically once
per year.
•The compressed air should be about 4-6 bars (60-90 psig).
Changing the brush
1. Close the valves before and after the sensor and the air supply.
2. Loosen the nut that holds the piston assembly to the T-pipe.
3. Pull out the piston assembly from the T-pipe
4. Loosen the locking nut and remove the brush from the piston.
5. Attach the new brush, and tighten the locking nut.
6. Push the assembly back in the T-pipe and tighten the nut.
7. Open the valves and the air supply. Check the function by going to the cleaning menu.
Select “Next time” and push “Enter” to activate a cleaning cycle.
400 mm
16”
625 mm / 25”
215 mm / 8”
Outlet
Compressed air
inlet
Inlet