Flexim PIOX R400 User manual

User Manual
UMPIOXR400V2-7-2EN
Sensor at riser pipe
Sensor
Process Refractometer
PIOX®R400
PIOX®R400B
PIOX®R400C
PIOX®R400A2

PIOX®is a protected trademark of FLEXIM GmbH.
FLEXIM GmbH
Wolfener Straße 36
12681 Berlin
Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.flexim.com
User manual for PIOX R400
UMPIOXR400V2-7-1EN, 2012-07-01
Copyright (©) FLEXIM GmbH 2012
Subject to change without notification.

UMPIOXR400V2-7-1EN, 2012-07-01
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Regarding this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Suitability and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Measuring Principle of PIOX R400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Determining the Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Description of PIOX R400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Transmitter Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Sensor Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1 First Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Type and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Firmware Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Calibration and Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Selecting the Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6 Installation of PIOX R400, R400B, R400C, R400A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.1 Measuring Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 Connection of Sensor PIOX R400 with Transmitter PIOX TR374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Connection of Sensor PIOX R400 with Transmitter PIOX TR379. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.5 Connection of Sensor PIOX R400B, R400C, R400A2 with Transmitter PIOX TR374B, TR374C,
TR374A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.6 Connection of the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.7 Connection of the Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8 Connection of the Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7.1 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
8.1 Selection of the Physical Quantity and of the Unit of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Input of Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.3 Additional Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.1 Installation of an Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.2 Output Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.3 Error Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.4 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10 Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
10.1 Definition of the Storage Rate and of the Physical Quantities to be Output . . . . . . . . . . . . . . . . . . . . . . . 41
10.2 Format of the Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.3 Transmission Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Format Settings of the Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

UMPIOXR400V2-7-1EN, 2012-07-01
11 Output Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.1 Damping Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.2 Activation of the Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.3 Activation of the Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.4 Status Output (Alarms). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.5 Activation of the Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.1 Explanation of the Status Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.2 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.3 Reset of the Status Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.4 Protection against Interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
13 Program RMKoeff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13.1 Create a New Data Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
13.2 Calculation of Characteristics and Coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
13.3 Transmission of a Data Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
13.4 Displaying the Fluid on the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
14 Inputs (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.1 Configuring the Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.2 Assignments of Inputs to Measuring Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
14.3 Activation of the Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
14.4 Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
B Start-Up and Maintenance Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
C Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

UMPIOXR400V2-7-1EN, 2012-07-01 5
1 Introduction
1 Introduction
1.1 Regarding this Manual
This user manual has been written for the personnel operating the process refractometer PIOX R400. It contains
important information about the instrument, how to handle it correctly, how to avoid damages.
Make sure you have read and understood the safety instructions (see document SIPIOX_R400) and the user man-
ual before using the instrument.
All reasonable effort has been made to ensure the correctness of the content of this manual. Should you however
find some erroneous information, please inform us. We will be grateful for any suggestions and comments regard-
ing the concept and your experience working with PIOX R400. This will ensure that we can further develop our
products for the benefit of our customers and in the interest of technological progress. If you have any suggestions
about improving the documentation and particularly this user manual, please let us know so that we can consider
your comments for future reprints.
We also provide special customer solutions and will be pleased to advise you in using PIOX R400 for specific appli-
cations and finding the most appropriate solution for your measurement problem.
The content of this manual may be changed without prior notice. All rights reserved. No part of this manual may be
reproduced in any form without FLEXIM's written permission.
1.2 Safety Instructions
In this user manual, important safety instructions are given. They are marked as follows:
Always observe the safety instructions!
1.3 Suitability and Warranty
We take no responsibility whatsoever concerning the suitability of the PIOX R400 for particular measuring tasks. It
is the duty of the user to ensure that the refractometer is used only for the purpose for which it has been designed
("correct use"). The correct use of the instrument includes the respect of the mounting, commissioning and mainte-
nance instructions.
The material and workmanship of PIOX R400 is guaranteed for the term specified in the sales contract provided
the equipment has been used for the purpose for which it has been designed and operated according to the
instructions given in this user manual.
Misuse of PIOX R400 will immediately revoke any warranty given or implied. This includes:
• replacement of a component of the instrument by a component that was not authorized by FLEXIM
• unsuitable or insufficient maintenance
• repair of the instrument by unauthorized personnel
Attention! Always observe the "Safety Instructions according to Directive 94/9/EC" (see document
SIPIOX_R400).
Note! The notes contain important information which help you use PIOX R400 optimally.
Attention! This text contains important instructions which should be observed to avoid damage or
destruction of PIOX R400.
This text denotes instructions according to directive 94/9/EC.
Attention! The user manual and any complementary instructions you have received with the instrument
have to be read before mounting, commissioning, operating or servicing the instrument.
Attention! Improper installation and operation of the instrument can lead to the revocation of the guaran-
tee.

6UMPIOXR400V2-7-1EN, 2012-07-01
1 Introduction
The manufacturer assumes no responsibility for damages resulting from incorrect use of the instrument.
FLEXIM assumes no responsibility for injury to the customer or third persons proximately caused by the material
owing to defects in the product which were not predictable or for any indirect damages.
PIOX R400 is a very reliable instrument. It is manufactured under strict quality control, using modern production
techniques. If installed as recommended in an appropriate location, used cautiously and taken care of conscien-
tiously, no troubles should appear.
If any problem appears which can not be solved with the help of this user manual, contact our sales office giving a
precise description of the problem. Specify the type, serial number and firmware version of the instrument (see
section 4.2).

UMPIOXR400V2-7-1EN, 2012-07-01 7
2 Measuring Principle of PIOX R400
2 Measuring Principle of PIOX R400
The refractive index n of a solution will be determined by means of transmitted light refractometry. A light beam
propagates through the solution and will be refracted at the interface to a prism. The angle of refraction will be
measured by a detector. The refractive index n of the solution can be calculated from Snell’s law of refraction:
ni.sin i= nt.sin t 
with
ni refractive index of fluid
i angle of incidence
nt refractive index of prism
t angle of refraction
Fig. 2.1: Path of light beam through the sensor
The light source is a special LED with a wave length = 590 nm (sodium D-line) (see Fig. 2.1). The light passes an
aperture, will be parallelized by a lens and reversed by a Dove prism. Then it enters the fluid through a window in
the sensor head. When the light beam re-enters the sensor, it will be split at the vertex of a biprism and refracted at
its inclined edges.
The two resulting measuring beams will be focussed by a lens projecting sharp images of the aperture on the
detector, a CCD sensor with 2048 pixels.
The angle of refraction will be determined from the difference between the two measuring beam projections. The
zero point will be calculated continuously, thus eliminating influences of process pressure and temperature.
Dove prism
pipe
biprism
fluid
window
temperature probe
LED
CCD image CCD sensor
sensor

8UMPIOXR400V2-7-1EN, 2012-07-01
2 Measuring Principle of PIOX R400
2.1 Determining the Concentration
The concentration can be calculated using the refractive index. In solutions, the refractive index varies with con-
centration and temperature (see Fig. 2.2).
If this relationship is known, one-to-one throughout the working area and external effects can be excluded, the
measured refractive index and temperature can be used to determine the concentration according to the character-
istics (see Fig. 2.2).
The characteristics can be determined at the FLEXIM laboratory or directly in the process. Characteristics for vari-
ous sugar solutions have been measured in accordance with ICUMSA1 and have been stored in the internal data-
base.
2.2 Temperature Compensation
The refractive index varies with temperature (see Fig. 2.2). In industrial applications, it is often not necessary to
determine the refractive index at the actual process temperature. Instead, an equivalent value, measured at a ref-
erence temperature, is used. The measured refractive index will be converted by the transmitter accordingly.
The refractive index will be corrected automatically if temperature coefficients are stored for the medium. The refer-
ence temperature is used to calculate the temperature coefficients. This is an integral part of the set of coefficients
for the medium.
1ICUMSA (International Commission for Uniform Methods of Sugar Analysis)
Note! If only the refractive index and temperature are measured, the concentration can only be
determined for two-component liquid systems.
1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0
1 , 3 5 0 0
1 , 4 0 0 0
1 , 4 5 0 0
1 , 5 0 0 0
T e m p e r a t u r :
2 0 ° C
5 0 ° C
8 0 ° C
K o n z e n t r a t i o n ( ° B r i x
B r e c h u n g s i n d e x n
refractive index n
temperature [°C]
concentration [°Brix]
20
50
80
Fig. 2.2: Relationship between refractive index, concentration and temperature
in a saccharose solution

UMPIOXR400V2-7-1EN, 2012-07-01 9
3 Description of PIOX R400
3 Description of PIOX R400
The design of PIOX R400 is shown in Fig. 3.1. Transmitter and sensor are the main components. A junction box
can be mounted between transmitter and sensor.
sensor cable
extension cable
direct connection connection via junction box
sensor cable
Fig. 3.1: Measurement setup for PIOX R400

10 UMPIOXR400V2-7-1EN, 2012-07-01
3 Description of PIOX R400
3.1 Transmitter Design
The command panel and connections for the transmitter PIOX TR374 are shown in Fig. 3.2.
3.2 Sensor Design
For the components of sensor PIOX R400 see Fig. 3.3. The sensor is equipped with a PT1000 temperature probe.
Window and prism are the optical components. LED and CCD are located in the sensor housing.
serial interface RS232
terminal strip KL3:
connection of the power supply
terminal strip KL4:
connection of the outputs
terminal strip KL1:
connection of the sensor
terminal strip KL2:
connection of the inputs
2x16-digit LCD display
keyboard
Fig. 3.2: Design of transmitter PIOX TR374
window
prism
temperature probe
Attention!
Always handle the sensor carefully since
it contains fragile optical components.
Fig. 3.3: Design of sensor PIOX R400

UMPIOXR400V2-7-1EN, 2012-07-01 11
4 Handling
4 Handling
4.1 First Inspection
Upon delivery, check if all parts have been delivered. Please make sure that the specifications of the delivered sen-
sor and transmitter correspond to the specifications given on the purchase order.
4.2 Type and Serial Number
Type and serial number are on the nameplates of the transmitter and of the sensor (see Fig. 4.1 and Fig. 4.2).
4.3 Firmware Version
Select SPECIAL FUNCTION\INSTRUM. INFORM. to obtain informa-
tion about PIOX R400. Press ENTER.
Type and serial number of PIOX R400 will be displayed in the upper
line. Firmware version and its data are given in the lower line. Press
ENTER to return to the program branch SPECIAL FUNCTION.
R E F R A C T O M E T E R T R A N S M I T T E R

I I 3 G E x n A I I T 4
T
a
: - 4 0 . . . + 6 0 ° C
T y p e : P I O X ®T R 3 7 4 A 2 F e x i m G m b H
D - 1 2 6 8 1 B e r i n
S e r . N o :
0 7 4 3 0 1 7 0
B u i t : 2 0 0 8
M a d e i n G e r m a n y
I P 6 5
Fig. 4.1: Nameplate of the transmitter PIOX TR374A2 (example)
P R O C E S S R E F R A C T O M E T E R

I I 3 G E x n A I I T 4
T
a
: - 4 0 . . . + 6 0 ° C
T y p e : P I O X
®
R 4 0 0 A 2
F l e x i G b H
D-12681 B e r l i n
S e r . N o : 22200109
B u i l t : 2 0 0 8
M a d e i n G e r m a n y
T : - 2 0 . . . + 1 3 0 ° C
I P 6 7 P N 1 6
Mode l : M S 4 F KA 2 F
P o we r : 1 2 V / 1 0 0 A
D O N O T O P E N !
Fig. 4.2: Nameplate of the sensor PIOX R400A2 (example)
Special Funct.
Instrum. Inform.
PXTR374-07430147
V1.1 31.03.06

12 UMPIOXR400V2-7-1EN, 2012-07-01
4 Handling
4.4 General Precautions
PIOX R400 is a precision measuring instrument and must be handled with care. To obtain good measurement
results and not to damage the instrument, it is important to pay attention to the instructions given in this user man-
ual, and particularly to the following points:
• protect the instrument from excessive shock
• manipulate the cables cautiously and avoid excessive cable bend
• connect the transmitter correctly to the power supply (voltage, frequency, connection to ground)
4.5 Service
Regular maintenance is normally not required. Always observe the handling precautions and the instructions given
in this manual. If the instrument is installed correctly, in an appropriate location and as recommended, used cau-
tiously and taken care of conscientiously, no troubles should appear.
4.6 Cleaning
Generally, the regular process cleaning and rinsing cycles are sufficient to keep the optical surfaces (prism and
window) clean. However, depending on the liquid to be measured, it might be necessary to clean the measuring
prism regularly to prevent the formation of deposits.
When cleaning with a caustic soda lye or any other aggressive chemical, first make sure that all parts in contact
with the medium are resistant. If a manual cleaning of the prism or of the window is necessary, this can be made
with a small pipe cleaner or with a soft cloth.
4.7 Calibration and Correction
Transmitter and sensor were calibrated by the factory. If the measured values need to be corrected, see
section 8.2.
Attention! Always observe the "Safety Instructions according to Directive 94/9/EC" (see document
SIPIOX_R400).
Attention! The degree of protection IP 65 of the transmitter is only guaranteed if the cables fit firmly and
tightly in the cable glands, the cable glands are firmly tightened and the housing has been
tightly screwed.
Attention! Always handle the sensor carefully since it contains fragile optical components.
Note! Only clean the prism with non-abrasive material!

UMPIOXR400V2-7-1EN, 2012-07-01 13
5 Selecting the Measuring Point
5 Selecting the Measuring Point
The sensor PIOX R400 is designed to be used directly in the process flow. It should be installed at a measuring
point that is representative for the process and relevant to the given application.
If the measurement is integrated in a process control system, the sensor should be installed at a location where it
can react quickly to process changes.
Fasten the sensor to a vertical pipe (rising pipe) that allows the fluid to flow upwards. The pipe is always completely
full and the measurement prism is constantly surrounded by flowing fluid (see Fig. 5.1).
Fig. 5.1: Installation of the sensor with a welding adapter (full section view)
Attention! Always observe the "Safety Instructions according to Directive 94/9/EC" (see document
SIPIOX_R400).
Attention! Make sure that the degree of protection of the transmitter, sensor and junction box is
observed.
Attention! If it is not possible to maintain the operational temperature transmitter, sensor and junction
box have to be cooled.
Attention! If the fluid temperature is > 100 °C and PIOX R400 is used in explosive atmosphere, the sen-
sor must be shielded against heat radiation from the pipe. This ensures that the ambient, fluid
and explosion protection temperatures remain within the specification of the sensor.
Attention! Transmitter, sensor, junction box must not be thermally insulated (i.e., "not wrapped"). Other-
wise, the permissible ambient temperature might be exceeded.
flow direction
sensor

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5 Selecting the Measuring Point
Install the sensor head so that the direction of flow is parallel to the prism edge (see Fig. 5.2).
Fig. 5.2: Orientation of measuring prism in pipe
To prevent deposits from forming on the measuring prism, ensure the following conditions:
• permanent minimum flow in the pipe
• the pipe diameter is relatively small at measurement point, i. e., the smaller the pipe diameter, the larger the
pressure and the larger the self-cleaning effect
• the fluid temperature is relatively high but within the specifications of the sensor, i. e., if the temperature
increases, the fluid solubility increases but the viscosity decreases
• the fluid pressure is relatively high but within the specification of the sensor, i. e., as the pressure increases, the
fluid solubility increases and fewer gas bubbles form
If necessary, clean the measurement prism manually. Therefore, choose a measuring point where the flow can be
interrupted and the sensor can be installed/removed without difficulty.
The selected measuring point should be easily accessible for service work.
Make sure that the transmitter is installed within the range of the cable. The ambient temperature at the installation
site must be within the operating temperature range of the transmitter.
Note! Protect the sensor against direct sunlight, rain and vibrations (pumps).
Note! If the fluid is highly viscous, abrasive or contains solids in suspension, a bypass is recom-
mended.
Attention! Never wrap the cables (extension and sensor cables) around hot pipes.
flow direction

UMPIOXR400V2-7-1EN, 2012-07-01 15
6 Installation of PIOX R400, R400B, R400C, R400A2
6 Installation of PIOX R400, R400B, R400C, R400A2
6.1 Measuring Setups
Direct Connection
The sensor will be connected directly to the transmitter (cable length = 10 m).
Connection via Junction Box
If the distance of sensor and transmitter is > 10 m, the sensor will be connected via a junction box and an extension
cable to the transmitter.
6.1.1 PIOX R400
Fig. 6.1: PIOX R400
6.1.2 PIOX R400B
Fig. 6.2: PIOX R400B
Attention! Always observe the "Safety Instructions according to Directive 94/9/EC" (see document
SIPIOX_R400).
P I O X
transmitter
PIOX TR374 or
PIOX TR379
sensor
PIOX R400
junction box
JB93
extension cable, max. 200 m
connection via junction box
OR
direct connection
10 m
10 m
fluid
outside of explosive
atmosphere
P I O X
10 m
10 m
outside of
explosive
atmosphere
zone 1 zone 0
transmitter
PIOX TR374B
sensor
PIOX R400B
junction
box JB91
connection via junction box
OR
direct connection
fluid
extension cable, max. 100 m

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6 Installation of PIOX R400, R400B, R400C, R400A2
6.1.3 PIOX R400C
Fig. 6.3: PIOX R400C
6.1.4 PIOX R400A2
Fig. 6.4: PIOX R400A2
P I O X
zone 1
10 m
10 m
junction
box JB91
transmitter
PIOX TR374C
sensor
PIOX R400C
extension cable, max. 200 m
connection via junction box
OR
direct connection
outside of
explosive
atmosphere
fluid
P I O X
10 m
10 m
transmitter
PIOX TR374A2
zone 2
junction
box JB92
sensor
PIOX R400A2
extension cable, max. 200 m
connection via junction box
OR
direct connection
fluid

UMPIOXR400V2-7-1EN, 2012-07-01 17
6 Installation of PIOX R400, R400B, R400C, R400A2
6.2 Installation
6.2.1 Installation of Transmitter PIOX TR374, TR374B, TR374C, TR374A2
Wall Installation
The transmitter can be fixed to the wall.
• Remove the cover of the housing.
• At the chosen location, drill 4 holes in the wall (see Fig. 6.5).
• Insert dowels in the holes.
• Fix the housing with screws to the wall.
Fig. 6.5: Assembly dimensions (in mm)
Pipe Installation
The transmitter can be fixed to the pipe. For the assembly, use the supplied pipe mounting kit consisting of a
shackle (1), pipe plate (2) and instrument mounting plate (3) (see Fig. 6.6).
Fig. 6.6: Pipe mounting kit
2 5
3 5
ø 8
3 . 5
163
265
3 0 6
ø
ø
4 x
M 4
M o n t a g e m i t H o l z s c h r a u b e n u n D ü b e l
M o n t a g e m i t L i n s e n k o p f s c h r a u b e n
280
200
163
265
200
280
2
3
1

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6 Installation of PIOX R400, R400B, R400C, R400A2
6.2.2 Installation of Sensor PIOX R400, R400B, R400C, R400A2
The sensor PIOX R400 with FLEXIM flange is fastened to the process connection using a slit ring. The gasket (O-
ring) which is in contact with the medium is placed correctly by a thrust ring (see Fig. 6.7).
Fig. 6.7: Installation of sensor PIOX R400 with FLEXIM flange
6.3 Connection of Sensor PIOX R400 with Transmitter PIOX TR374
Mount the sensor to the pipe at the selected measuring point (see chapter 5). The cable glands for connecting to
the junction box and transmitter are included with the PIOX R400.
6.3.1 Direct Connection
• Remove the blind plug for the connection of the sensor (see Fig. 6.9).
• Open the cable gland of the sensor cable. The compression part remains in the cap nut
(see Fig. 6.8).
Fig. 6.8: Cable gland
Attention! The degree of protection of PIOX TR374 is only guaranteed if the cables fit firmly and tightly in
the cable glands, the cable glands are firmly tightened and the housings have been tightly
screwed.
Note! It is recommended to run the cables from the measuring point to the transmitter before the
connection of the sensor, to avoid load on the connectors.
B
2
1 slit ring
2 thrust ring
3 O-ring
3
B
B
2
1
3
cap nut compression part basic part

UMPIOXR400V2-7-1EN, 2012-07-01 19
6 Installation of PIOX R400, R400B, R400C, R400A2
• Push the sensor cable through the cap nut and the compression part.
• Prepare the sensor cable with the cable gland (see Fig. 6.9).
• Cut the outer shield and brush it back over the compression part.
• Screw the gasket ring side of the basic part in the housing.
• Insert the sensor cable in the housing.
• Fix the cable gland by screwing the cap nut on the basic part.
• Connect the leads to the terminals of the transmitter (see Fig. 6.9).
Fig. 6.9: Direct connection of sensor PIOX R400 with transmitter PIOX TR374
terminal sensor cable 1
measuring
channel A
V+ yellow
V- green
A+ brown
B- white
3a gray
5a pink
measuring
channel B
2V+ yellow
2V- green
2A+ brown
2B- white
6b gray
9b pink
70 mm
10 mm
outer
shield
terminal strip KL1
terminal strip KL1:
sensor
cable
Preparation
of extension cable and
sensor cable:
transmitter
1 No terminals are provided for
connecting the red and blue cables.
Important!
To ensure good high frequency shielding, it is important
to provide good electrical contact between the outer
shield and the cable gland and hence to the housing of
the transmitter. Cut the outer shield and brush it back as
shown in the figure.
Attention!
To connect the sensor cable to the
transmitter, use only metallic cable glands.
outer
shield

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6 Installation of PIOX R400, R400B, R400C, R400A2
6.3.2 Connection via Junction Box
Connection of the Extension Cable with the Transmitter
• Remove the blind plug for the connection of the sensor (see Fig. 6.10).
• Open the cable gland of the extension cable. The compression part remains in the cap nut (see Fig. 6.8).
• Push the extension cable through the cap nut and the compression part.
• Prepare the extension cable with the cable gland (see Fig. 6.10).
• Cut the outer shield and brush it back over the compression part.
• Screw the gasket ring side of the basic part in the housing.
• Insert the extension cable in the housing.
• Fix the cable gland by screwing the cap nut on the basic part.
• Connect the leads to the terminals of the transmitter (see Fig. 6.10).
Connection of the Extension Cable with the Junction Box
• Remove the blind plug from the junction box (see Fig. 6.10).
• Open the cable gland of the extension cable. The compression part remains in the cap nut (see Fig. 6.8).
• Push the extension cable through the cap nut, the compression part and the basic part.
• Insert the extension cable in the junction box.
• Prepare the extension cable with the cable gland.
• Cut the outer shield and brush it back.
• Pull the extension cable back until the brushed back outer shield is below the shield terminal of the junction box
(see Fig. 6.10).
• Screw the gasket ring side of the basic part in the junction box.
• Fix the cable gland by screwing the cap nut on the basic part.
• Fix the extension cable and the outer shield to the shield terminal of the junction box (see Fig. 6.10).
• Connect the leads to the terminals of the junction box (see Fig. 6.10).
Connection of the Sensor Cable with the Junction Box
• Remove the blind plug from the junction box (see Fig. 6.10).
• Open the cable gland of the sensor cable (see Fig. 6.8). The compression part remains in the cap nut.
• Push the sensor cable through the cap nut, the compression part and the basic part.
• Prepare the sensor cable with the cable gland.
• Insert the sensor cable in the junction box.
• Screw the gasket ring side of the basic part in the junction box.
• Fix the cable gland by screwing the cap nut on the basic part.
• Connect the leads to the terminals of the junction box (see Fig. 6.10).
Attention! The outer shield of the extension cable must not have electrical contact to the junction box.
The extension cable has to remain insulated completely up to the shield terminal.
Attention! The outer shield of the sensor cable must not have electrical contact to the junction box.