Cerlic CTXP User manual

2005-07-27 MANE07/05 Ver 2.17
CTXP
Flow-through
Polarized Consistency Transmitter

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TABLE OF CONTENTS
1Introduction ................................................................................................ 3
2A few words about this manual ................................................................ 3
3Design......................................................................................................... 3
4Measuring principle ................................................................................... 3
5Unpacking the CTXP flow-through Sensor.............................................. 4
Optional parts can be ordered:............................................................................................ 4
6Mounting of flow-through sensor............................................................. 5
Automatic flushing ............................................................................................................. 7
7Removing the sensor................................................................................. 7
8Service and maintenance .......................................................................... 7
9Menu for CTXP sensor .............................................................................. 9
Settings................................................................................................................................ 9
Calibrate.............................................................................................................................. 9
Cleaning Press “ENTER” to go to sub menu for Cleaning program............................... 9
Scale / Alarm .................................................................................................................... 10
System............................................................................................................................... 10
10 Calibration ................................................................................................ 11
Multiple Calibration curves.............................................................................................. 11
Calibration points.............................................................................................................. 12
Negative values................................................................................................................. 12
Calibration screen............................................................................................................. 13
Automatic adjustment of the calibration .......................................................................... 14
Getting good measurement ............................................................................................... 14
Zero Calibration................................................................................................................ 15
Sample point Calibration .................................................................................................. 15
Calibration with multiple points....................................................................................... 17
11 Deposit compensation, and alarm.......................................................... 17
12 Scaling ...................................................................................................... 18
13 In-Depth Technical Description .............................................................. 18
14 Technical data .......................................................................................... 20
Certificate of conformity: ................................................................................................. 20
Optional parts can be ordered:.......................................................................................... 20
15 Dimensions............................................................................................... 21
CTXP 03/25...................................................................................................................... 21
Appendix 1. Sample instructions - manual test........................................... 22
Appendix 2. Support information.................................................................. 23
Appendix 3. Setup information ..................................................................... 25

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1Introduction
The CTXP 03/25 consistency transmitter has been developed to measure fiber consistencies
as a function of the ability of fibers to depolarize a polarized beam of light. In conjunction
with the BB2 signal processing unit, fiber consistencies can be measured more or less inde-
pendently of the particle consistencies in applications primarily in the pulp and paper indus-
try. Examples of such applications would be monitoring of ultra filtrate, monitoring of vor-
tex cleaner steps, consistency control prior to the paper machine headbox, and retention con-
trol.
2A few words about this manual
This manual primarily contains information about Cerlic's CTXP 03/25 consistency trans-
mitter. Transmitter functions as well as the measuring principle are discussed, but the man-
ual primarily describes the applications and the starting up of the CTXP 03/25 when it is
connected to the BB2. Menu functions and technical data of the BB2 control box can be
found in the BB2 service manual
3Design
The CTXP 03/25 is made from acid proof stainless steel and is mounted with pipe fittings
(DN25) directly onto a 25 mm (1") pipe. The transmitter has an internal design providing
superior cleaning properties, which permits precise and reliable measurement with the least
amount of maintenance possible, even in critical applications. The measuring window of the
steel cell is made from quartz glass (suprasil). Electronic and optical components are well
protected within the steel shell to handle very demanding environments.
A shielded 10 m (33’) cable is used for signal transmission between the sensor and the BB2
control box. The cable sheath is made of polyurethane and is highly resistant to aggressive
materials and fluids.
4Measuring principle
The CTXP 03/25 measures through the medium. The transmission is made with polarized,
monochromatic light. The measuring principle is based on the ability of fibers to depolarize
the light to a much greater degree than solid particles. The light source consists of a bright,
light-emitting diode which is pulsed with high power. The light is filtered so that only one
plane of polarization is emitted. Two detectors measure the V and H polarization planes. The
detector signals are processed in the BB2 and are presented as fiber consistency. The tem-
perature is measured by the transmitter to be used for temperature compensation of the
measured value. It can be read in the BB2 box, and used as secondary value when a transmit-
ter id configured to use both analog outputs of the BB2. The temperature is not a precision
measurement, but shall be seen as an indication.
Cross section of the CTXP 03/25.

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5Unpacking the CTXP flow-through Sensor
The unit has been tested and approved before delivery from the supplier. Please check to
confirm that no visible damages have occurred during shipment.
Damages
If damages occurred during the shipment, immediately contact the UPS or truck line 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.
Content
Please check that the content corresponds to your order and packing list.
Every shipment should include:
CTXP Sensor, P/N depending on the type of sensor.
Optional parts can be ordered:
•Spare Butt Weld End DN25 - 30x25 mm, for CTXP 03/25 P/N 11203082
•25 mm hose adapter DN25, for CTXP 03/25 P/N 10305122
•33 ft. (10 m) signal cable. The cable can be extended up to P/N 20805510
330 ft. (10x10m).
•Y-splitter, to connect two sensors to one BB2 P/N 21505534
•Connection box for two sensors to one BB2 control box P/N 11505748
with 3 ft. (1m) cable to connect to BB2

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6Mounting of flow-through sensor
The CTX 20/25 is mounted directly in a 1” (25mm) pipe. The sensor shall always be
mounted with its glass windows vertically (the cable connector pointing downwards). With
larger pipes, a 1” by-pass line should be used depending on consistency. Normally, installa-
tion in a by-pass pipe should be done according to the picture below.
There are three possibilities to mount the CTXP sensors, NPT-couplings (standard delivery
in the US), Butt weld end connection (standard delivery except for the US), or Hose connec-
tion. See the Dimension section for more information.
•The inlet of the by-pass pipe should be located where the stock and dilution water are
well mixed and the flow is turbulent. Appropriate distance from a pump discharge or
a pipe elbow is about five pipe diameters downstream (b).
•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 before an
elbow or reduce.
•It should be noted that the distance between the point where the dilution water is
added and the measuring point should be as short as possible, but not less than five
times the pipe diameter. Longer distances can add delay or lag time to your control
loop.
Please carefully observe the information below concerning installation in by-pass pipes.
Incorrect installation can result in measuring problems.

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•Installing the sample or bypass line in a vertical pipe will reduce the influence of en-
trained air in the process liquid and the tendency for laminar flow.
•In order to avoid the water film on pipe walls, the sample or by-pass pipe should ex-
tend at least ¾” (20mm) (a) into the pipe. Horizontal pipes should have the sample
inlet located between 20°-70°on either side of the pipe.
•When measuring pulp stock, the inlet for the by-pass pipe should be inserted with
the stream at an angle of 45°and the end of the by-pass pipe should be cut parallel
to the pipe wall.
•If there is any risk of resin coating, splinters, rags, wires or twigs, then the measur-
ing inlet should be inserted with the flow at an angle of 30°and the discharge should
be to an open tank via a throttling valve.
•The diameter of the by-pass pipe (d) should be 1” (25 mm) and should not have any
throttling valve or pipe bend closer than 20” (0.5 meter) before the sensor (c).
•The by-pass pipe should be made so that dewatering of the pulp stock is avoided at
shutdown. If there is a risk for this, then the valve (V1) upstream the sensor should
be actuated and controlled in sequence, i.e. the valve closes when the pump stops.
•The flow rate (v) of the by-pass pipe should be at least equivalent to the main pipe
but not less than 1.5 f/s (0.5m/s). At slower rates, there is a risk for dewatering and
build up on the glass windows. For pulp stock with resin and printing ink, the flow
rate should double.
•If the flow through the by-pass pipe is so great that there is cavitation in the sensor,
then the valve after the sensor should be throttled back.
•The temperature of the sensor must not exceed 150°F (65°C).
•Install the sensor so that it will not be exposed to considerable and fast changes in
temperature.
•Avoid installation spots where the sensor is exposed to severe cold weather.
•Avoid installation spots where the sensor is exposed to direct sunlight to keep the
temperature within limits.
•Protect the sensor from high pressure spraying during cleaning.
•The sensor should never be submerged under water.
•Always install the cables between sensor and control box in conduit when possible.
•Install the sensor in a way that it is not susceptible to 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, then the cable and the sensor should be
removed.
•Always remount the protective cover on the sensor connector when the cable is re-
moved.

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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 tempera-
ture stress of the sensor. In some applications where dilution of the measured media is al-
lowed, 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 meter must not in any way throttle the flow when open. If
there is a risk of turbulence in the valve, it must be placed more than 20” (0.5 meter) before
the sensor.
Sometimes the sensor may need manual cleaning using a bottle brush and diluted acid. By
mounting a T-pipe and a ball valve with a plug on the outlet, the sensor can be manually
cleaned without first removing the sensor. The media valves are first closed, the sensor is
flushed with water, and finally the plug is removed to let the brush into the sensor.
7Removing the 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.
8Service and maintenance
The sensor does not require much maintenance. In some applications the measure cell may
need to be cleaned. Use warm water and a small bottle brush to clean the measure cell; do
not use a metallic brush or sharp tools. Hydrochloric acid can be used to dissolve coating in
the measure cell. Plug one end of the cell and fill it with 5% HCl. Let the sensor be for a
couple of hours, then flush the cell with plenty of clean water. Repeat the treatment if neces-
sary. If Hydrochloric does not solve the coating other chemicals may be used as long as they
don’t affect the O-rings made of Viton.
Media
in
Waste
Flush wate
r
Media
out
Plug for brush
T
-
pipe

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The sensor housing may not be opend except by Cerlic service personel. Opening the sensor
housing will void all warrenty.

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9Menu for CTXP sensor
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 Curves ”A”-“D”, or “Ext”. Tells BB2 which one of the four calibration
curves to use. “Ext” will allow you to use the three digital inputs to
change curves from a remote location.
I-Time Integration time in seconds, for dampening of output signal
Integrate ”Normal” or “Extra”, Normal integrate the raw values, Extra addi-
tionally integrate the calculated consistansy value
Unit ”%”, ”ppm”, ”g/l”, or ”mg/l”
Analog ”None”, ”Out 1”, ”Out 2”, or ”Both”. Analog output for the sensor
Second ”Temp”, “Clean”, “Raw” or ”=Prim”. If “Both” is chosen above, Out 1 will
always give the primary value. Out 2 will either give the temperature
scaled 0-100°C, the measured value at the last flushing, Raw values (for
test), or the same signal as Out 1. The temperature is additional infor-
mation, not a precision measurement.
Calibrate
Selected Cal The selected curve ”A”-“D”, or “Ext”. Tells BB2 which one of the
four calibration curves to use. “Ext” will allow you to use the three
digital inputs to change curves from a remote location.
Used Cal The currently used curve ”A”-“D”, same as selected except when
“external is selected.
Adjust ”No”, ”Store” or ”Lab”. Stores the reading of the meter when a sam-
ple is taken, and can then automatically adjust the sample value
when the sample analyzed by lab is different to the reading.
Take sample “No”, “Zero”, “# 1”-“# 5”, see section 12 for more information.
Sample # 1 Lab test – consistency/suspended solids value for Sample # 1
Sample # 2 Lab test – consistency/suspended solids value for Sample # 2
Sample # 3 Lab test – consistency/suspended solids value for Sample # 3
Sample # 4 Lab test – consistency/suspended solids value for Sample # 4
Sample # 5 Lab test – consistency/suspended solids value for Sample # 5
Cleaning Press “ENTER” to go to sub menu for Cleaning program
Cleaner ”None”, ”Flush”, or ”Brush”
Interval. min 000- 999 minutes, time between cleaner cycles
Length sec 000 – 999 seconds, duration of cleaning cycle. A brush will do as
many strikes as it can start within this time, always at least one.
Freeze sec 0-999 seconds, freeze time of output after a flushing cycle
Relay ”-”, ”#1”, or ”#2”. Pick relay to send signal to “Brush” or “Flush”
valve. These are the same relays that can be used for “Alarms Re-
lay” above.
Next time The next scheduled cleaning time, Pushing “Enter” on this line will
set the time to current time, and will start a cleaning cycle. Used for
testing the “Brush” or “Flush” system.
Clean The consistency value recorded at the end of the last flush cycle.

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Scale / Alarm
Max 0-99.9 % or 0-99999.9 ppm. mg/l, or g/l (units selected in the “Set-
tings” menu), equal to 20 mA output signal.
Min 0-99.9 % or 0-99999.9 ppm. mg/l, or g/l (units selected in the “Set-
tings” menu), equal to 4 mA output signal.
Hi Alarm 0-99.9 % or 0-99999.9 ppm. mg/l, or g/l (units selected in the “Set-
tings” menu), a value of zero inactivates the alarm
Low Alarm 0-99.9 % or 0-99999.9 ppm. mg/l, or g/l (units selected in the “Set-
tings” menu) , a value of zero inactivates the alarm
Alarm Relay ”-” ”#1”, ”#2”, or ”#1 and #2”. Check that the relay is not used for
cleaning
System
Type Type of sensor, read only
Serial Serial number of the sensor, read only
SoftW Software version of the sensor, read only
Temp Sensor temperature, read only
MaxTemp The highest temperature the sensor has been exposed to, read only
Samples Sub menu to view SA values and consistency or suspended solids
values used for this calibration curve. This is a READ ONLY Section.
Used Cal The currently used calibration curve ”A”-“D”.
SA 0 SA value for zero sample
SA 1 SA value for sample # 1
Cons 1 Lab test - consistency or suspended solids value for Sample # 1
…. SA and Cons repeated for samples 2 to 5
Info This menu is for Cerlic internal use, it may change without notice
MS Linearized light signal, which are SA values in calibration chart
Con Unit value in %, ppm, mg/l, or g/l after MS value has been converted
to units due to sample values. This is displayed on main screen
SA 0 SA value for zero sample
SA 1 SA value for sample # 1
Cons 1 Lab test - consistency or suspended solids value for Sample # 1
Ch1a Raw value for channel 1
Ch2a Raw value for channel 2
Ch1 Raw value for channel 1, compensated for changed intensity
Ch2 Raw value for channel 2, compensated for changed intensity
Ch1/Ch2 Relation between channel 1 and 2
Intensity Currently used intensity
Zero Int Intensity for clear water, set during zero calibration
I-offset Intensity offset, set during zero calibration
Samp/s Number of samples per second
Service Not accessible for users.