K-Patents PR-33-S User manual

PROCESS INSTRUMENTS
SEMICON PROCESS REFRACTOMETER PR-33-S
INSTRUCTION MANUAL
IM-EN-PR33S Rev. 1.4

Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
General safety consideraons
The process medium may be hot or otherwise hazardous. Use shields and
protecve clothing adequate for the process medium - do not rely on avoid-
ance of contact with the process medium.
Precauons when removing a sensor from the process line :
•Check first that the process line is depressurized and drained.
•Loosen the flowcell screws cauously, be prepared to ghten again.
•Ensure you are clear of any possible spillage and you have a clear emer-
gency escape path.
Warranty
K-Patents is rigorous in ensuring that all products manufactured and supplied by
K-Patents shall be free of defects in material and workmanship. K-Patents agrees
to either replace or repair free of charge any product found to be defecve, or parts
thereof when returned to the nearest authorized K-Patents repair facility within two
(2) years of the product’s delivery date.
Important: The warranty is void if the sensor has been taken apart or in any way
tampered with.
Before returning a defecve product for service or replacement, please contact K-Patents
or your nearest K-Patents representave (see hp://www.kpatents.com/ for contact
informaon) for packing and shipping informaon.
Disposal
When wishing to dispose of an obsolete instrument or any parts of an instrument,
please observe local and naonal regulaons and requirements for the disposal of elec-
trical and electronic equipment.

Table of contents
1 Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Ethernet specificaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Connecon sengs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.1 IP sengs for sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.2 IP sengs for stand-alone computer . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.3 Configuring a network of sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Tesng the Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Troubleshoong the connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Instrument homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.1 Main page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4.3 Diagnoscs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Inline refractometer sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Mounng the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 Choosing sensor mounng locaon . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 PR-33-S sensor installaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.3 Check list for pipe mounng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.4 Mounng cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Connecng the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Startup and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.1 Inial check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Calibraon check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Viewing sensor status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Configuraon and calibraon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Configuring the refractometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.1 Signal damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Calibrang the concentraon measurement . . . . . . . . . . . . . . . . . . 23
5.2.1 The chemical curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.2 Direct BIAS adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Prevenve replacement of o-ring in EKC265 applicaon . . . . . . . . 26
7 Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.1 Message HIGH SENSOR HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 Message HIGH SENSOR TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.1 Message OUTSIDE LIGHT ERROR or OUTSIDE LIGHT TO PRISM . . . . . . . . . . 27
7.2.2 Message NO OPTICAL IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.3 Message PRISM COATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.4 Message LOW IMAGE QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.5 Message NO SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.6 Message TEMP MEASUREMENT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.7 Concentraon dri during NORMAL OPERATION . . . . . . . . . . . . . . . . 29
7.3 Diagnosc messages table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Ethernet protocol specificaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1 Communicaon protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1.1 Request format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.1.2 Response format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.3 Request and response errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Request-response pair specificaon . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2.1 NULL message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2.2 Protocol version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2.3 Refractometer informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2.4 Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.3 Error message specificaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EC declaraon of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
PR-33-S refractometer field calibraon form . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1 Introducon 1
© Copyright K-Patents 2015. All rights reserved.
1 Introducon
The inline refractometer sensor PR-33-S (figure 1.1) measures the refracve index nD
and the temperature of the process medium. The concentraon of the process liquid is
calculated from these values when the composion of the process medium is known.
The output values of the sensor are transmied through its Ethernet connecon by
using a UDP/IP protocol (see chapter 2). An oponal mA output unit is also available.
Figure 1.1 PR-33-S sensor
1.1 Principle of measurement
The K-Patents inline refractometer determines the refracve index nDof the process
soluon. It measures the crical angle of refracon using a yellow LED light source
with the same wavelength (589 nm) as the sodium D line (hence nD). Light from the
light source (L) in Figure 1.2 is directed to the interface between the prism (P) and the
process medium (S). Two of the prism surfaces (M) act as mirrors bending the light rays
so that they meet the interface at different angles.
The reflected rays of light form an image (ACB), where (C) is the posion of the crical
angle ray. The rays at (A) are totally internally reflected at the process interface, the rays
at (B) are parally reflected and parally refracted into the process soluon. In this way
the opcal image is divided into a light area (A) and a dark area (B). The posion of the
shadow edge (C) indicates the value of the crical angle. The refracve index nDcan
then be determined from this posion.

2PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
L
P
MM
S
ACB
Figure 1.2 Refractometer principle
The refracve index nDchanges with the process soluon concentraon and temper-
ature. For most soluons the refracve index increases when the concentraon in-
creases. At higher temperatures the refracve index is smaller than at lower tempera-
tures. From this follows that the opcal image changes with the process soluon con-
centraon as shown in Figure 1.3. The color of the soluon, gas bubbles or undissolved
parcles do not affect the posion of the shadow edge (C).
BB
CC
AA
Low concentration High concentration
Figure 1.3 Opcal images
The posion of the shadow edge is measured digitally using a CCD element (Figure 1.4)
and is converted to a refracve index value nDby a processor inside the instrument.
This value is used together with the measured process temperature to calculate the
concentraon.

1 Introducon 3
© Copyright K-Patents 2015. All rights reserved.
a. Optical image
b. CCD element
c. CCD output
V
Figure 1.4 Opcal image detecon

4PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
2 Ethernet connecon
The Ethernet connecon enables data download from a PR-33 sensor to a computer.
Any type of computer (PC, Mac, PDA, mainframe...) with a compable network con-
necon can be configured to view and download data from the sensor. Sensor configu-
raon and monitoring can be carried out without special soware by using a standard
web browser. Secon 8.1 gives all the specificaons necessary to write a data acquisi-
on program.
2.1 Ethernet specificaon
The sensor is designed to be connected to a network with PoE (Power over Ethernet,
IEEE-802.3af) mode A support, as it receives its operang power through the Ethernet.
The sensor is equipped with an integrated Ethernet cable, 10 meter long. The cable
can be connected to any standard RJ45 Ethernet equipment. Addional length can be
gained by using a UTP joint adapter/coupler with a standard Ethernet cable, length up
to 90 meters. The maximum communicaon speed of the sensor is 100 Mbit/s (Ether-
net 100BASE-T).
In the simplest form the network consists of a sensor, a computer, and a PoE switch.
This configuraon is shown in figure 2.1.
PR-33 PoE
switch Laptop
Figure 2.1 Simple network configuraon.
Several sensors can be connected to the same Ethernet network. Also, the sensors have
an automac funcon to detect the polarity of the network so that the network may
ulize either cross-over or straight interconnecng cables.
Figure 2.2 shows an example of how to connect three sensors to an exisng LAN with
no PoE funconality. A single PoE switch will suffice in this case.

2 Ethernet connecon 5
© Copyright K-Patents 2015. All rights reserved.
PR-33
PR-33
PR-33
LAN
PoE
switch
Figure 2.2 Three sensors in the same network.
It is possible to use a WLAN access point to decrease the number of cables (figure 2.3).
PR-33 PoE
switch WLAN
Access
point
Figure 2.3 Connecng sensor(s) via wireless.
The maximum distance of a single Ethernet connecon is 100 m (incl. one joint
adapter/coupler), but if longer distances are required, a fiber link may be used to
extend the range (see figure 2.4).
Fiber
Media
converter Media converter
PR-33 PoE
switch
Figure 2.4 Using fiber link to connect sensor(s).

6PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
2.2 Connecon sengs
2.2.1 IP sengs for sensor
All sensors are shipped with the factory default IP address of 169.254.23.33. This
address belongs to the Zeroconf addresses (as defined in IETF standard RFC 3927) so
that it can easily be reached from a stand-alone computer (figure 2.1), usually without
changing the network sengs of the computer. This address will remain in the sensor
even aer a different IP address has been set. The sensor answers in the address that
is first called up aer startup.
Note: If there are more than one PR-33 in the same network, this address cannot be
used (secon 2.2.3).
The IP address of the sensor can be changed through the instrument homepage (sec-
on 2.4).
2.2.2 IP sengs for stand-alone computer
When you start up a computer with automacal IP sengs (DHCP enabled) in a net-
work with only the PR-33 sensor, the computer should automacally obtain an IP ad-
dress 169.254.x.x. In this case you can connect to the factory default address of the
sensor without any further changes in sengs. If this does not work, please make sure
that your WLAN (Wireless network connecon) is not acve when you connect to the
sensor. If the WLAN is acve, the computer’s Ethernet connecon may not funcon as
expected. Also, obtaining the 169.254.x.x. address may take up to a minute.
If you sll have difficules in connecng to the sensor, you may check the IP address of
the computer by opening the command window (command prompt) and by typing the
command ipconfig at the command prompt (press Enter to give the command), see
figure 2.5 (in Mac OS X and Linux the same command is called ifconfig). The result
will give you your computer’s IP address. If the address does not start by 169.254,
you will have to manually configure the IP address of the computer to 169.254.23.34,
netmask 255.255.0.0.
For further troubleshoong, see secon 2.3.1.

2 Ethernet connecon 7
© Copyright K-Patents 2015. All rights reserved.
Figure 2.5 Typical IP configuraon for a stand-alone laptop when
connected to a sensor; laptop wireless (WLAN) is turned off
Note: The connecon will not work if the computer and the sensor have exactly the
same IP address.
When you have configured the network sengs of the sensor (and/or the computer)
according to the instrucons above, you can proceed to test the connecon as in-
structed below in Secon 2.3.
2.2.3 Configuring a network of sensors
In case you have more than one sensor in a network, the sensor IP addresses have to
be configured, as the factory default will not work.
If you are connecng the sensor to a factory network, please consult the network ad-
ministrator for the correct sengs.
If the network is a stand-alone network with only PR-33’s and one or more computers
with no connecon to any other network, then the IP addresses can be chosen rather
freely. One possibility is to number the instruments so that they all have 192.168.33.x
addresses so that every computer and instrument has a different number x between
1...254. The subnet mask (or netmask) is in this case 255.255.255.0 (see figure 2.6).

8PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
IP = 192.168.33.1 IP = 192.168.33.2 IP = 192.168.33.3
IP = 192.168.33.100
netmask = 255.255.255.0
PoE switch
Figure 2.6 A network of PR-33 sensors.
Note: There are no sengs for subnet mask, default gateway or name servers in PR-33,
as these sengs are not required.
2.3 Tesng the Ethernet connecon
When you connect the sensor to a powered PoE switch, the indicator lights should light
up. The actual posion and funcon of the lights depend on the switch, but figure 2.7
shows the indicators on a typical PoE switch. There’s one indicator showing that the
instrument is drawing power, another indicator (next to the Ethernet connector) shows
the connecon status. In this case a 100 Mbit/s connecon is formed between two
instruments at the switch ports 1 and 3 (a sensor per port), and there is a PoE device
connected in these ports, 1 and 3.
1 2 3 4
PoE
FAULT PWR2
1000M 100M
PWR1
4 2
3 1 5 7
6 8
Figure 2.7 An example of PoE switch indicator lights

2 Ethernet connecon 9
© Copyright K-Patents 2015. All rights reserved.
Note: It is typical that, e.g., 8-port PoE switches only have 4 ports supplying power.
If you keep the sensor in a dimly lit space, you should see the flashing of the processor
indicator lights on the instrument cover (see figure 2.8). If the lights are flashing, the
instrument receives power from the PoE connecon.
Figure 2.8 Process indicator lights in the sensor
Once the sensor is powered up, it should be reachable from any correctly configured
computer connected to the same Ethernet network by typing the IP address of the
instrument to a web browser (see secon 2.4).
Note: The factory-default IP address of the sensor is 169.254.23.33. This address
should always respond (see secon 2.2.1).
2.3.1 Troubleshoong the connecon
In case you are unable to reach the instrument through the network, please check the
following things:

10 PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
•the instrument receives power; there is a faint flashing light on the cover of the
instrument (figure 2.8) or the PoE switch indicates ’power OK’.(see figure 2.7).
•the network sengs of the computer are compable with those of the instrument
(secon 2.2.2)
•if you try to reach the instrument at IP address 169.254.23.33, check that there is
only one PR-33 in the same network, as otherwise there is an address conflict
•check that the soware firewall of the computer does not block the connecons
A useful test to determine whether the problem is in network sengs is to set up a
small network. Perform the following steps:
•set up a network of only one sensor, PoE switch, and a computer (figure 2.1)
•check that the computer has suitable network sengs and that its WLAN connec-
on is turned off (secon 2.2.2)
•use the ping ulity of the computer to try and reach the sensor
The ping ulity menoned above is in Windows systems available by using the Com-
mand Prompt (usually found in the Accessories; or open Run, type cmd in the empty
line and press enter to open Command Prompt). The usage of ping is very simple: go to
the command interface, type the name of the command and the IP address you want to
check and press Enter. If the Ethernet connecon is physically working and the address
given to ping is correct, the sensor will answer to ping and return any data packets sent
to it, see figure 2.9.
2.4 Instrument homepage
Every PR-33 sensor has a built-in web server with the instrument homepage. The home-
page offers facilies to configure, monitor, diagnose and verify the instrument.
Once there is a funconal Ethernet connecon between the instrument and the com-
puter, the homepage can be opened by typing the instrument’s IP address to the ad-
dress bar of a web browser. K-Patents recommends using Firefox 2.0 or newer, but most
funconality is available with any modern web browser.
Opening the instrument homepage:

2 Ethernet connecon 11
© Copyright K-Patents 2015. All rights reserved.
Figure 2.9 Pinging address 169.254.23.33, ping returned fully and connecon ok.
1. Establish a working Ethernet connecon (see above) to the sensor.
2. Start your preferred web browser (for example Mozilla Firefox, Internet Explorer,
Safari, Chrome or Opera).
3. The address (URL) of the instrument homepage is the sensor’s IP address, for a
factory set sensor it is hp://192.168.23.33/. Give the address to the browser just
like you’d enter any other address (for example hp://www.kpatents.com/)
4. Wait unl the homepage is loaded, this may take a few seconds.
The page looks approximately like in Figure 2.10; the exact look of the page depends
on your browser and screen sengs so slight variaon can be expected.
5. Use the links in the link bar on the le side of the page to find more extensive
informaon on the instrument.
Important: In order for the web pages to funcon as designed, the JavaScript support
has to be enabled in the browser.

12 PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
2.4.1 Main page
Once the instrument homepage is loaded, the most important informaon is visible on
the main page (figure 2.10). This page shows the measurement values, serial number
and the tag of the instrument.
Figure 2.10 Main page (sensor not in process)

2 Ethernet connecon 13
© Copyright K-Patents 2015. All rights reserved.
2.4.2 Parameters
All funconal parameters of the instrument can be changed on the Parameters page of
the instrument (figure 2.11). New parameters may be typed into the input fields.
Figure 2.11 Parameter page
Once the parameter eding is done, pressing the Submit changes buon will send
the parameters to the instrument aer asking for a confirmaon. Updang the para-
meters may take a few seconds.
Note: If you change the IP address of the instrument, you will have to enter the new
address to the address bar of the browser, as the sensor will no longer exist in the old
address.

14 PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
2.4.3 Diagnoscs
On the diagnoscs page (figure 2.12) you may see the diagnosc values produced by
the sensor. There is also a link to the opcal image. The diagnosc values are updated
live, but the opcal image is only loaded on request.
Figure 2.12 Diagnoscs page

3 Inline refractometer sensor 15
© Copyright K-Patents 2015. All rights reserved.
3 Inline refractometer sensor
3.1 Mounng the sensor
The sensor mounng locaon should be chosen with care to ensure reliable readings
from the process.
3.1.1 Choosing sensor mounng locaon
The mounng locaon needs to be such that sediments or gas bubbles cannot accu-
mulate by the sensor. Good flow velocity is essenal in keeping the prism clean.
Important: If the process pipe vibrates, support the pipe. A vibrang pipe might dam-
age the in-line sensor mounted on it.
The sensor cover should not be exposed to high temperature radiaon. In most cases,
dra and natural convecon provide sufficient air cooling if the air gets to flow freely
around the sensor head.

16 PR-33-S instrucon manual
Document/Revision No. Rev. 1.4 Effecve: May 15, 2015
3.1.2 PR-33-S sensor installaon
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Cutout in flow cell aperture
to align with temperature
sensor
1/2” thread 1/2” thread
MOUNTING RECOMMENDATIONS
IM-PR33S-IL/C
PR-33-S SENSOR INSTALLATION
SENSOR SUPPORT - VERTICAL FLOW
SENSOR SUPPORT - HORIZONTAL FLOW
FLOW CELL ASSEMBLY/DISASSEMBLY MOUNTING COVER ASSEMBLY
http://www.kpatents.com/
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