Process Sensors MCT Series User manual

Multiple Constituent Transmitter
MCT Series
Installation and Operation Manual
June 15, 2005
Process Sensors Corporation
www.processsensors.com
USA:
Process Sensors Corp
113 Cedar Street, S1
Milford, MA 01757
Tel: [phone]
Fax: [phone]
[email protected]
Europe:
Process Sensors Europe
Adelaide House, Unit 3
Corbygate Business Park
Corby, Northants NN17 5JG UK
Tel: [phone]
Fax: [phone]
[email protected]
Eastern Europe:
Process Sensors Polska
Dr inz. Tomasz Stachowiak
Biuro Informatcyjne Techniki
Pomiarowej 03-980 Warzawa
ul. Znanieckiego 16/23
Tel: [phone]
Fax: [phone]
[email protected]

Table of Contents
1.0 Introduction
2.0 Principle of Operation
3.0 Sensor Components
3. 1 Light Source
3.2 Filter Wheel
3.3 Filter Wheel Motor
3.4 Detector
3.5 Electronics
4.0 Installation
4. 1 Sitting the Sensor
4.2 Vibration
4.3 Strong Light
4.4 Temperature
4.5 Humidity & Dust-Window Air Purge
4.6 Optimum Viewing Distance
4.7 Reflections from Material Surface
5.0 Power and Cable Connections
5. 1 AC Power Connections
5.2 Analog & Serial Cable Connections
5.3 Remote Displays & Operator
Interface
6.0 Operator Interfaces
6. 1 Wall Mounting Interface
6.2 Initial Power-Up
6.3 Key Pad
7.0 Set-Up Instructions-Operator Interface
7. 1 Menu Structure
7. 1. 1 Key Pad Lock
7.1.2 Display Selector
7. 1.3 Product Code Select
7. 1.4 Grab Sampling Averaging
7.2 Main Menu Selections
7.3 On-Line Menu
7.4 Calibration Parameters
7.4.1 Analog Output Channels
7.5 Calibration Routine
7.6 Diagnostics
7.7 Miscellaneous
8.0 Gauge Calibration
8. 1 Approximate Calibration
8.2 Multi-Sample Calibration
8.3 On-Line Off Set Trim Adjustments
8.4 Linear Regression Statistics
8.5 Online Multi-Sample Statistics
9.0 Accessories
9. 1 Window Air Purge Assembly
9.2 Product Loss Sensors
9.3 Network Interfaces
9.4 Cooling Panels
9.4. 1 Air Cooling
9.4.2 Water Cooling
9.5 Maintenance Alarm
9.6 Clean Window Alarm
9.7 Power Sampler
9.8 Local Display Unit (LDC)
10.0 Output Signals
10. 1 Serial Communications
10. 1.1 Serial Requirements
11.0 Customer Wiring Connections
12.0 Maintenance
12.1 Routine Maintenance
12.1.1 Sensor Window
12.2 Self Diagnostic Warnings
12.3 Corrective Maintenance
12.4 Replacement Parts List
Appendix I- Special Features
Appendix II- Power Sampler Accessory
Appendix III- Dry Basis Measurements
Appendix IV- Cal Check Standards
Appendix V- Serial Commands
Appendix VI- PI Controller Output
Appendix VII- Outline Drawings
Appendix VIII Product Temperature Option
1

Warranty, Exclusions and Limitations
The workmanship and the materials of all products manufactured by Process Sensors Corp. are
warranted for a period of one year from the date of shipment. This warranty covers parts and labor
required to correct defects within the scope of the Corporation’s warranty.
Excluded from the warranty coverage are products a) which have been subjected to electrical,
mechanical or other misuse or abuse b) which have been disassembled or repaired, or attempted to be,
by other than PSC or its authorized servicing agents.
The foregoing warranty shall be in lieu of all other warranties, expressed or implied, and the
Corporation expressly disclaims any warranty for merchant ability or fitness for a particular purpose.
Unless otherwise agreed in writing by the Corporation, repairs and replacement parts provided by the
Corporation under its warranty shall be guaranteed only for the non expired portion of the original
warranty on the repaired product.
The liability of PSC to any purchaser or user of its products shall not in any case exceed the cost of
correcting defects in a product as herein provided and, upon expiration of one year from the date of sale,
all such liability shall terminate. In no event shall the Corporation be liable for interruption of
operations, loss of profit, or special or consequential damages.
Software Updates
Future revisions of the software that correct errors will be made available to customers at no charge.
Improvements and enhancements to the software will be available for a nominal fee.

1.0 Introduction
The MCT Series are near infrared photometric analyzers that use fixed infrared wavelengths to measure
one, two or three constituents in a variety of products.
The MCT is a “stand-alone” sensor with all items necessary for continuous monitoring being located in
the sensor. Optional wall-mountable or hand-held operator interfaces are available for setup, calibration
and maintenance.
2.0 Principle of Operation
The molecular bonds O-H, C-H and N-H absorb infrared radiation at several specific wavelengths. The
MCT generates these absorbance wavelengths and several other non-absorbing wavelengths using a
rotating wheel containing up to 6 infrared filters. This chopped light is reflected from the surface of the
product collected by optical components inside the sensor. The resultant electrical pulses from the
reflected light are mathematically treated in ratio-based algorithms to compute raw measurements of the
measured constituents. These raw values are then scaled by offset (zero) and sensitivity (span) factors to
provide direct readings of the constituents.
Compensation for aging of optical components and the variations in the reflectivity of different products
is provided in the algorithm treatment of the filter reflectance values.
3.0 Sensor Components
The MCT is housed in an epoxy painted cast aluminum Nema 4 housing. A rear bracket allows the
sensor to be mounted, ensuring the light beam reflects from the product at all times.
3.1 Light Source
A quartz-halogen light bulb running at reduced voltage generates infrared energy.
3.2 Filter Wheel
Up to six infrared and visible filters are held in a circular disc. A single timing notch is machined in the
edge of the disc.
3.3 Filter Wheel Motor
A precision brushless DC motor is used to accurately rotate the filter disc in front of the infrared light
beam.
3.4 Detector
A thermoelectrically cooled PbS detector is used to convert the infrared light energy into electrical
pulses.
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3.5 Electronics
The MCT contains the following electronic components:
oPower Supply, a 90-260 volt auto selection supply providing DC power to operate the sensor.
oMain PCB, containing pre-amplifiers, detector controller, central processing system, analog and
serial communications.
4.0 Installation
4. 1 Sitting the sensor
The sensor is capable of operating at any orientation provided the light beam can reflect from the
surface of the product.
4.2 Vibration
The sensor mounting support and any items in contact with the sensor should be free from excessive
vibration.
4.3 Strong Light
Strong infrared light or direct sunlight should not be allowed to fall on the sensor window or erroneous
reading may occur.
4.4 Temperature
The sensor is designed to give satisfactory measurements within a temperature range of 32 to 120 deg. F
(0 to 50 deg. C).
4.5 Humidity and Dust – Window Air Purge
The head should be kept clear of excess humidity. It is important to prevent condensation on the sight
window. Normal atmospheric dust will not affect the sensor reading but similar to humidity,
accumulation of dust on the window will impair the sensor’s operation. The air purge attachment fitted
to the sensor window requires a 1/4” (6mm) tube with a supply of clean oil free dry air at a pressure not
exceeding 10 psi. at approximately 2 liters per minute.
4.6 Optimum Viewing Distance
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The optimum viewing distance is 8” (200mm) from the bottom of the sensor but any distance between
6” and 12” (150 - 300mm) is acceptable. Variations in product pass height of +/- 1” (25mm) around the
8’’ (200mm) nominal are permissible.
4.7 Reflections from the Material Surface
It is essential to avoid specular reflections of the transmitted light from the product. Powdered and
granular products cause no problems and the sensor light beam may be mounted at any angle to the top
surface of the product. The closer the beam is to 90º from the surface the better the reflected signal
strengths. Highly reflective and shiny sheet materials require that the sensor be angled so that the light
beam is at approx. 80º-85º to the sheet surface.
8" or 200mm 80-85*
Powdered & Granular
Materials Sheet & Reflective Materials
5.0 Power and Cable Connections
3

Refer to Section 11.0
5. 1 AC Power Connection
The sensor is powered directly using the 6-foot (2mtrs) power cord provided. The input is auto ranging
and accepts 90-260VAC volts, 15 amps. It is recommended that the power be supplied via a breaker or
on/off switch mounted close to the sensor. An optional breaker switch is available from PSC.
5.2 Analog and Serial Cable Connections
Customer data cables connect to the sensor by two 6-way I/O connectors on the rear of the sensor.
Details of the respective terminals in these connectors are given in Section 11.0
5.3 Displays and Operator Interfaces
The MCT may be set-up by using several operator interface and display modules.
Wall Mountable: This display interface is designed to be permanently connected
to the sensor. It connects using a cable up to 500 feet (150
meters) in length.
The interface connects to the sensor using the 9 pin circular socket located on the rear of the sensor
housing.
Detailed descriptions of these interfaces are given in Sections 6.0 & 7.0
Host Computer: This interface is a PC program designed to allow access to
an individual sensors internal setup and calibration settings.
It connects to the serial port of the sensor.
The PC software program has its own Operation Manual.
6.0 Operator Interfaces
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6.1 Wall Mounting Interface
The Wall Operator Interface is a display unit with keypad for user setup, calibration and routine
interaction with the sensor. It is constructed in a cast aluminum housing rated for Nema 12 (IP 55).
The display is a two-line 20 character vacuum fluorescent display. It may be mounted up to 100 feet
from the sensor and obtains both power and communications from the sensor.
6.2 Initial Power-Up
After installation and cable connection is complete, turn the power on at the breaker. The display on the
operator interface will illuminate indicating power-up and the sensor will emit a flashing green light.
6.3 Keypad
The front of the Operator Interface contains eight keys that allow the user to setup, calibrate and check
internal diagnostics of the MCT.
5

Wall Mount Operator Interface
6

Keypad
Keys: Symbol:
UP/DOWN
RIGHT/LEFT
Allows the user to move around the
menu structure and to position the cursor
in the desired place for setting numerical
values.
PRODUCT
CODE
Selects the desired Product Calibration
Code.
ENTER
Confirms changes and commits them to
permanent memory.
HAND
Computes an average value when a
grabbed sample is taken.
DISPLAY
ROTATE
Allows user to select each individual
constituent
7

Operator Interface Panel
2X
8

7.0 Set-Up Instructions - Operator Interface
The wall mountable and handheld operator interfaces both operate in identical ways; the only difference
between the two is the size of the display and the style of enclosure. All the information required to
operate and calibrate the MCT, is given on the 2-line/20 character vacuum fluorescent display.
7.1 Menu Structure
The interface software is organized in a menu “tree” structure. Using the keypad on the front of the
operator interface allows selection of the menu items. The lower half of the display changes as the user
moves through the menu choices.
7.1.1 Keypad Lock
The complete keypad may be ‘locked’ preventing use of any key until the correct key push
sequence is made to unlock the keypad. Contact Process Sensors to obtain the lock and unlock
sequences.
7.1.2 Display Selector
The MCT may be ‘Set-up’ to measure up to three constituents in a product. Depending on this
set-up the MCT’s ‘Home Screen’ will be different.
Home Screen for Single Constituent
Constit : 13.6%
Prod: Prod A (01)
Home Screen for Dual Constituents
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Constit 1 : 3.6% 01
Constit 2 : 25.9% 01
Home Screen for Three Constituents
Constit 1 : 3.6% *
Prod.: Prod A (01)
In the Three Constituent Mode the top line will scroll through the three constituents at 5-second
intervals. An asterisk will be presented in the upper right corner indicating that the sensor is in the Three
Constituent Mode.
The constituents have identical menu structures and access to any of them is gained by selecting the
desired constituent using the Display Rotate key. When in the dual or triple ‘Home Screens’, access to
the menus is denied and only the, Display Rotate, Enter and Prod. Code # key are active.
Display Rotate Key – Single Constituent Mode
When the MCT is measuring a single constituent the Display Rotate Key will act as a ‘Home’ key.
Display Rotate Key – Dual and Triple Constituent Modes
Constit 1: 3.6% 01
Prod: Prod A (01)
Constit 2: 25.9% 01
Prod: Prod A (01)
Pressing the Display
Rotate key
once will
select the first
(constituent) menu
Pressing Display
Rotate a second time
will select the second
constituent menu
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Dual Mode
Constit 1: 3.6% 01
Constit 2: 25.9% 01
Pressing Display
Rotate a third time will
revert the display to the
two constituent 'home
screen'
Triple Mode
Constit 3: 34.5% 01
Prod: Prod A (01)
Constit 1: 3.6% *
Prod: Prod A (01)
Pressing the Display
Rotate a third time will
select the third
constituent menu
Pressing Display
Rotate a fourth time will
revert the display to the
three constituent 'home
screen'
Note: The Display Rotate key will rotate between the constituent menus at any lower level in the
menus, e. g. When the display is on Constituent 1, Prod. Code 1, zero setting, pressing the Display
Rotate will switch the display to Constituent 2, Prod. Code 1, zero setting.
7. 1.3 Prod. Code Select
Both constituents have 9 Calibration codes allowing the MCT to be calibrated for 9 different
products. Each constituent has independent codes, but they are ‘tied’ for each product.
The display will indicate, at the extreme right, the Prod. Code being used at any time.
Changing the Prod. Code is made by pressing the Code Key # until the desired code is presented
and then pressing ENTER to activate that number. Note: Calibrations can be extended to 50,
call PSC for details.
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Moisture: 3.6% 01
Prod: Prod A (01)
Home Screen-Single
Mode
Moisture: 3.6% 01
Prod.: Prod A (09) ???
Press the code # key
will scroll through the
10 product codes
Moisture: 3.6% 01
New Cal Accepted
Press ENTER to accept
the desired Prod. Code
7. 1.4 Grab Sample Averaging
To aid in noting the sensor’s reading while a sample is grabbed from the conveyed product, the
Grab Sample Key will compute an average of the sensors reading between TWO pushes of the
key. To use this feature the display must be in a single constituent mode.
Moisture: 3.6% 01
Prod.: Prod A (01)
Press Display Rotate
to display the
constituent of interest.
Moisture: 3.6% 01
Averaging!!!
Pres the Grab Sample
key. While it shows
AVERAGING take a
sample of the product.
Moisture: 3.6% 01
Average = 3.6%
Press the Grab Sample
Key a second time, to
display the average of
the first constituent.
Oil: 25.9% 01
Average = 25.9%
Press the Display
Rotate Key to show the
average of the second
and third constituent.
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Press the Grab Sample key a third time to exit the routine or wait 10 seconds and it will exit
automatically. Press Display Rotate to return to the ‘Home’ screen.
7.2. Main Menu Selections
The menu selections of each constituent are as follows:
Online (Home)
Calibration Parameters
Calibration Routine
Diagnostics
Miscellaneous
The display will normally start from the Online selection.
Pressing the DOWN/UP arrow key will scroll the display through the menu selections.
Pressing the RIGHT arrow will allow entry to the selected menu.
Pressing the LEFT arrow ONCE will get back to the menu selection, pressing TWICE will get back to
the HOME display.
The following sections give a detailed description of the various menu choices available to set-up and
calibrate the MCT using the operator display and interface.
Press the DOWN arrow to select the desired menu field. To access this selection, press ENTER. All
menus except Diagnostics are protected by a password.
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Main Menu Selections
Home
Moisture: 12.89%
Prod.: Prod A (01) Moisture: 12.89% Damping: 5
Moisture = 5.1% 01
Sample Val: 0.0
Moisture: 12.89%
Password:0000
Moisture: 12.89%
CAL PARAMETERS
Moisture: 12.89%
CAL ROUTINE
Displays Calibration
Parameters
Moisture: 12.89%
Password:0000
Enters Cal Develop
Moisture: 12.89%
First Diagnostic Value
Moisture: 12.89%
DIAGNOSTICS
Moisture: 12.89%
MISCELLANEOUS
Further Values
Moisture: 12.89%
Password:0000
Enters Misc. Menu
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7.3 On-line Menu
The user may make changes to the response time of the sensor and to the zero setting of the selected
Calibration Channel directly from the ‘Home” screen.
When at the ‘home’ screen, pressing the RIGHT arrow will display the Damping Time currently being
used by the sensor.
Press the RIGHT arrow to set the cursor under the digits use the UP/DOWN keys to set the desired
value. Press ENTER to confirm the selection.
From the Damping display press the DOWN arrow to access the Sample Value Trim screen.
This screen allows the sensors reading to be adjusted to agree with the known moisture content of the
sample it is viewing.
Use the RIGHT key to move the cursor under the digits, use the UP/DOWN keys to set the desired
value. Press Enter to confirm the value.
HOME Screen
Moisture: 5.1% 01
Prod.: Prod A (01) Moisture: 5.1% 01
Damping: 1
Moisture = 5.1% 01
Sample Val: 0.0
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7.4 Calibration Parameters
Moisture= 12.89%
CAL Parameters
Move down to display
CAL Parameters
Move right to enter the
menu
Moisture= 12.89%
PASSWORD=0000 Moisture= 12.89% PASSWORD=____
Password: Move
cursor under digits,
move up/down to
set the correct
password, Press
ENTER to accept
Moisture= 12.89%
PARA: PROD. A (01) Moisture= 12.89% PARA: Prod E (05)
Moisture= 12.89%
ZERO = -43.75 Moisture= 12.89% ZERO = -45.78
Moisture= 12.89%
SPAN = 14.56 Moisture= 12.89% SPAN = 18.78
Prod. Code Selection:
To view and adjust the
settings stored in each of
the 9 calibration
channels, move the
cursor under the digits,
move up/down to set the
desired value, then press
Enter to confirm Move
down to the next menu
parameter
Zero Settings: Move
the cursor under the
digits, move up/down
to set the desired
value, then press
Enter to confirm.
Move up or down for
other menu
parameters
Span Settings:
Repeat as per the
offset setting
adjustment
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Moisture= 12.89%
Anout (1) HI: 100.0 Moisture= 12.89% Anout (1) HI: 50.00
Analog Out 1 High
Setting:
Move the
cursor under the
value. Move up/
down to set the
desired value, press
Enter to confirm.
Moisture= 12.89%
Anout (1) LO: 00.00 Moisture= 12.89%
Anout (1) LO:20.0
Analog Out 1 Low
Setting:
Repeat as per
previous parameters.
Move Down to access
Analog #2 settings,
repeat as above.
Analog Out 2
Settings:
Press
DOWN to access
Analog Out 2, then
down again to access
Analog Out 3. Repeat
as per Analog 1 for
different values
compared to the
default values of 0.0
and 100.0
Analog Ranges:
Move down to
access the Analog
Output Ranges.
Moisture= 12.89%
Anout (2) HI: 100.0 Moisture= 12.89% Anout (2) HI: 50.00
Moisture= 12.89%
Anout (2) LO:20.0
Moisture= 12.89%
Anout (2) LO: 00.00
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