Valmet K17122 User manual

Valmet Microwave Consistency
Measurement - Valmet MCA
Installation, Operating
& Maintenance
K17122 V1.1 EN

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© 2020 Valmet Automation Inc.
All rights reserved.
Valmet Automation Inc.
P.O. Box 177, FIN-87101 Kajaani, Finland
Tel. [phone]
www.valmet.com/automation
2020

Contents
1 Recycling and disposing............................................................................................ 6
2 Warnings & safety information................................................................................... 7
3 About the sensor........................................................................................................8
3.1 Sensor models.................................................................................................8
3.2 Measurement principle.................................................................................... 8
4 Structure.................................................................................................................. 10
4.1 FT sensor model............................................................................................10
4.2 TB sensor model............................................................................................10
4.3 Sensor electronics......................................................................................... 11
4.4 Valmet BRIDGE............................................................................................. 11
5 Installation................................................................................................................12
5.1 Choosing the sensor model...........................................................................12
5.2 Choosing the installation site.........................................................................12
5.3 Installation check list......................................................................................13
6 Installation, FT model...............................................................................................14
6.1 FT model installation locations...................................................................... 14
6.2 FT sensor dimensions................................................................................... 15
6.3 FT model mounting dimensions.....................................................................17
7 Installation, TB model.............................................................................................. 18
7.1 TB model installation locations...................................................................... 18
7.2 TB sensor dimensions................................................................................... 19
7.3 TB model process coupling........................................................................... 20
7.4 Mounting clamp (TB model)...........................................................................22
8 Operating terminal................................................................................................... 23
8.1 Mechanical installation...................................................................................23
8.2 Electric connections.......................................................................................24
8.3 Current output connections............................................................................26
8.4 Binary input connections................................................................................27

8.5 Binary output connections............................................................................. 27
8.6 Connecting the sensor cable......................................................................... 28
9 Setting up.................................................................................................................29
9.1 Mechanical inspection................................................................................... 29
9.2 Installing sensor and operating terminal........................................................ 29
9.3 Cabling inspection......................................................................................... 29
9.4 Electrical inspection.......................................................................................29
9.5 Quick setup....................................................................................................29
10 Operating................................................................................................................. 32
10.1 Main user interface........................................................................................ 32
10.2 Virtual keyboard.............................................................................................33
10.3 Menu map......................................................................................................34
11 Configuration............................................................................................................35
11.1 General settings.............................................................................................35
11.2 Connection settings....................................................................................... 37
11.3 Sensor settings..............................................................................................40
11.4 User information............................................................................................ 41
11.5 Trend settings................................................................................................ 41
12 Calibration................................................................................................................42
12.1 Recipes..........................................................................................................42
12.2 Sample taking................................................................................................44
12.3 Entering laboratory values.............................................................................46
12.4 Calibration view............................................................................................. 47
12.5 Calibration and sample history...................................................................... 52
13 Advanced calibration................................................................................................53
13.1 When to use advanced calibration.................................................................53
13.2 Chemical compensation................................................................................ 54
13.3 Temperature/Pressure compensation............................................................55
13.4 Manual compensation ...................................................................................56
14 Diagnostics.............................................................................................................. 61
14.1 Trend..............................................................................................................61
14.2 Event log........................................................................................................62

14.3 Diary.............................................................................................................. 63
14.4 Measurement values and limits..................................................................... 64
15 Troubleshooting....................................................................................................... 65
15.1 Detecting the sources of problems................................................................ 65
15.2 Diagnostic messages.....................................................................................67
16 Maintenance............................................................................................................ 71
16.1 Current loop test............................................................................................ 71
16.2 Sensor measurement tuning..........................................................................71
16.3 Sensor self test..............................................................................................72
16.4 Reset functionality......................................................................................... 72
17 Replacing parts........................................................................................................73
17.1 Sensor electronics (TB, FT)...........................................................................73
17.2 Antenna cables (TB)......................................................................................74
17.3 Temperature and pressure sensors (TB).......................................................78
17.4 Measurement head (TB)................................................................................80
17.5 Antenna cables (FT)...................................................................................... 82
17.6 Temperature and pressure sensors (FT)....................................................... 85
17.7 Antennas (FT)................................................................................................86
18 WEEE information....................................................................................................88
19 Technical specification, sensor................................................................................ 89
20 Spare parts, sensor..................................................................................................90
21 Technical specification, Valmet BRIDGE................................................................. 93
22 Spare parts, Valmet BRIDGE...................................................................................94
23 Declaration of conformity......................................................................................... 95

1 Recycling and disposing
Almost all parts of the device are suitable for recycling when sorted by material. The
device may also be returned to the manufacturer, who will recycle and dispose of the
device for a fee.
This device contains the following parts, which must according to EU directive
2012/19/EU be recycled separately:
•printed circuit boards.
Further information about the safe handling and removal of above parts is available
from the manufacturer on request, and from section WEEE information on page 88.
This device can contain some materials considered hazardous under EU Directives
2012/19/EU or 2006/1907/EC. For more information on these materials and their
recycling, see www.valmet.com/sustainability/sustainable-solutions/.
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2 Warnings & safety information
Caution:
During installation, maintenance and service operations, remember
that the sample line may contain hot sample or water – be careful!
DANGER:
Always ensure that the incoming voltage and frequency are correct
before making any electric connections. Wrong connection may
damage the equipment! The applicable safety regulations must be
closely followed in all installation work. All electric connections may
only be made by appropriately trained and authorized persons!
DANGER:
Before any welding works in the vicinity of the devices, make sure that
operating voltage is not connected.
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3 About the sensor
3.1 Sensor models
Valmet Microwave Consistency Measurement (Valmet MCA) includes a sensor unit and
a operating terminal with graphical display and touch screen. There are two different
models of microwave sensors: FT, Flow Through and TB, Twin Blade. These sensors
measure consistency, process temperature and pressure, and they also contain
additional measurement probes for housing humidity, sensor orientation and vibration.
The FT model is available in seven different sizes, ranging from FT-50 to FT-300.The
appropriate model is selected according to the diameter of the process pipe.
Figure 1: FT model sensor. Figure 2: TB model sensor.
3.2 Measurement principle
The operation of sensor is based on the measurement of microwave propagation time.
Microwaves are a form of non-ionizing radiation that is completely safe for the users.
The radiating power in normal conditions is less than 0 dBm; in high conductivity
medium the radiating power is higher, however not exceeding 25 dBm. When the device
is measuring, the microwave radiation is completely contained inside the process
piping.
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The time of flight of microwaves is dependent on the dielectric constant of the medium.
The speed of microwave propagation is calculated as follows:
c = speed of light in a vacuum
er = dielectric constant of media
In water microwaves propagate at a much slower speed than in wood fibers and fillers.
Therefore, consistency can be calculated based on the time it takes the microwaves to
travel through the measured mass. The advantages of this measurement method are its
independence of pulp type, insensitivity to flow rate, and single-point calibration.
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4 Structure
4.1 FT sensor model
The body of the Flow Through sensor is a pipe; when installed, it replaces an identical
length of process pipe. Flush-mounted antennas are installed on opposite sides of the
sensor body, so that the measurement takes place through the pipe. Sensor electronics
casings are installed on the sensor body by means of a base bar, and temperature and
pressure sensors are installed inside the base bar. Antenna cables are located behind
separate protective cover.
4.2 TB sensor model
The Twin Blade sensor is installed via a coupling into the process pipe. The sensor has
two fin shaped blades with flush-mounted antennas, and the measurement takes place
between the blades. This sensor model is suited for high conductivity measurement
locations and for large pipe size installations. A thermoelement sensor that measures
process temperature is installed inside the base bar.
Figure 3: FT model. 1. Sensor electronics
housing, 2. Sensor cable connector, 3.
Pt-100 thermoelement, 4. Pressure sen-
sor, 5. Microwave antennas.
Figure 4: TB model. 1. Sensor electronics
housing, 2. Microwave antennas, 3. Pres-
sure sensor.
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4.3 Sensor electronics
Both FT and TB sensor models use the same sensor electronics. The electronics
assembly includes the microwave transmitter and receiver, as well as control,
measurement and communication electronics. There is also an internal acceleration
sensor for vibration and orientation measurement.
On the right side there are SMA connectors for antenna cable connections. The
mounting screw heads are aligned with the threaded holes on the base plate to guide
the connectors into position. Connectors for power, temperature and pressure are
located around the base plate lead-in assembly.
• X5: Power connector when the board
software is running
• X6: Pressure sensor connector
•X7: Temperature sensor connector
• X8: TX connector (transmitter)
• X9: RX connector (receiver)
• Led: A green LED blinks
4.4 Valmet BRIDGE
The sensor is operated with the Valmet
BRIDGE operating terminal. The terminal is a
user interface for Valmet inline sensors and
contains a 7" capacitive touch screen.
Operating terminal includes10 m (33 ft) long
sensor cable (option: 30 m sensor cable).
Only one sensor can be connected to the ter-
minal at the same time.
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5 Installation
5.1 Choosing the sensor model
The microwave sensor model is selected according to the size of the pipe. On small
pipes with diameter < = 150 mm (6") the Flow Through model sensor is always used.
On larger pipe sizes, 200 mm/8" or larger, both the Twin Blade and Flow Through
sensor types are suitable.
Flow through models are: FT50/2", FT80/3", FT100/4", FT150/6", FT200/8", FT250/10",
and FT300/12". These models are compatible with the following flange standards:
• DIN PN10
• DIN PN16
• ANSI Class 150
• JIS 10k
TB models are compatible with the PN25 flange standard.
For the laboratory analysis of measurement results it is important to use a proper
sampler (for example NOVE) and to install it in accordance with sensor installation
instructions.
Caution:
Before installing the process coupling or sensor, check that the
process pipe is empty and unpressurized and that installation can be
carried out safely.
5.2 Choosing the installation site
When choosing the installation position, consider the following requirements:
•Do not install the sensor on a pipeline where air pockets may form.
•Do not install the sensor on downflow pipes.
• The sensor should not be installed on the suction side of a pump or to a mixing
tank.
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• Make sure there is enough space for the sensor casing. With the Twin Blade
sensor, also remember that there must be enough space to insert and pull out the
sensor.
• The connecting cable between the sensor and its operating terminal BRIDGE is 10
m long. If the distance between sensor and terminal must be longer, an extension
cable can be purchased as option.
Specifications for installation:
• Process temperature under 100 °C (212 °F).
• pH range 2.5–11.5.
• Conductivity maximum according to sensor specifications.
• Sensor pressure rating and recommended minimum process pressure to eliminate
the effect of air bubbles:
• TB model PN25, 1.5–25 bar (21.7–362 psi).
• FT model PN16, 1.5–16 bar (21.7–232 psi).
5.3 Installation check list
• Make sure that the mounting location and position are in accordance with the
installation instructions.
•Check that the flow arrow on the sensor casing is pointing in the direction of flow.
• Protect the sensor and operating terminal from direct heat sources and sunlight.
• TB model: Before operating the sensor, check that the process coupling mounting
clamp is securely tightened.
• FT model: Before operating the sensor, check that the seals between the sensor
and process flanges are properly installed and the mounting nuts are tightened.
• FT model: Make sure that grounding cable is connected to the pipeline.
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6 Installation, FT model
6.1 FT model installation locations
FT model sensor installation to vertical and horizontal pipelines is illustrated in the fol-
lowing picture. The sensor should always be installed as close to dilution water injec-
tion as possible to ensure minimum control delay. The process pressure should be al-
ways > 1.5 bar.
Recommended installation sites are numbered in order of preference, the best one
first:
Figure 5: Installation locations FT model.
1. Directly after a pump.
2. On a vertical pipeline.
3. On a horizontal pipe after a vertical pipe section.
4. On a horizontal pipe after a bend.
5. On a vertical pipe after a horizontal pipe section.
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Sensor installation is not allowed to
the following positions:
6. When the sensor is installed directly
after a pump, align it with the pump main
axle so that the measurement beam is
perpendicular to the motor/pump shaft,
as shown in the previous picture (position
1) and in the photo on the right. One an-
tenna must be on the side where the
pump throws the pulp, the other antenna
on the opposite side, so that the main
pulp stream travels between the anten-
nas. In the incorrect installation (position
6) there will be no steady pulp stream be-
tween the antennas.
7. Air pockets are likely to develop in up-
ward bends in the pipeline, and this will
disrupt the measurement because the
sensor will not always be in contact with
pulp. Figure 6: FT model sensor installed di-
rectly after a pump.
6.2 FT sensor dimensions
208 (8.2”)
FT DN50/2”
245 (9.6”)
210 (8.3”)
102 (4”)
146 (5.7”)
49.4
(1.9”)
55 (2.1”)
100 (3.9”)
Figure 7: Dimensions FT50.
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FT DN80/3” FT DN100/4”
208 (8.2”) 245 (9.6”) 208 (8.2”) 245 (9.6”)
100 (3.9”) 100 (3.9”)
223 (8.8”)
134 (5.3”)
171 (6.7”)
70 (2.8”)
85 (3.3”)
105 (4.1”)
187 (7.4”)
90 (3.5”)
159 (6.3”)
235 (9.3”)
Figure 8: Dimensions FT80 and FT100.
FT DN150/6” FT DN200/8”
208 (8.2”) 245 (9.6”)208 (8.2”) 245 (9.6”)
261 (10.3”)
285 (11.2”)
215 (8.5”)
237 (9.3”)
140 (5.5”) 100 (3.9”)
155 (6.1”)
100 (3.9”)
160 (6.3”)
203 (8”)
270 (10.6”)
Figure 9: Dimensions FT150 and FT200.
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FT DN250/10” FT DN300/12”
208 (8.2”) 245 (9.6”)
208 (8.2”) 245 (9.6”)
168 (6.6”) 120 (4.7”)
255 (10”)
311 (12.2”) 336 (13.2”)
305 (12”)
178 (7”) 120 (4.7”)
370 (14.6”)
320 (12.6”)
Figure 10: Dimensions FT250 and FT300.
6.3 FT model mounting dimensions
When installed, the Flow Through sensor
replaces a corresponding length of proc-
ess pipe. The sensor does not come with
flanges; when installing, it is tightened
with stud bolts between flanges mounted
on the process pipe. Pay attention to
space needed for the gasket when instal-
ling the sensor.
Table 1: FT model mounting dimensions.
MCA L/mm L/" Pipe size
FT-50 100 3.94 DN50 ANSI 2" JIS50
FT-80 100 3.94 DN80 ANSI 3" JIS80
FT-100 100 3.94 DN100 ANSI 4" JIS100
FT-150 100 3.94 DN150 ANSI 6" JIS150
FT-200 100 3.94 DN200 ANSI 8" JIS200
FT-250 120 4.72 DN250 ANSI 10" JIS250
FT-300 120 4.72 DN300 ANSI 12" JIS300
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7 Installation, TB model
7.1 TB model installation locations
TB model sensor installation to vertical and horizontal pipelines is illustrated in the fol-
lowing picture. The sensor should always be installed as close to dilution water injec-
tion as possible to ensure minimum control delay. The process pressure should be al-
ways > 1.5 bar.
Recommended installation sites are numbered in order of preference, the best one
first:
Figure 11: Installation locations TB model.
1. Directly after a pump where pump throws the pulp.
2. On a vertical pipeline.
3. On a horizontal pipe after a vertical pipe section.
4. On a horizontal pipe after a bend.
5. On a vertical pipe after a horizontal pipe section.
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Sensor installation is not allowed to
the following positions:
6. When the sensor is installed directly
after a pump, it must be on the side
where the pump throws the pulp (see po-
sition 1 in the previous picture and the
photo on the right). In position 6 it is on
the opposite side, where the pulp flow is
not steady and cavities may form.
7. Air pockets are likely to develop in up-
ward bends in the pipeline, and this will
disrupt the measurement because the
sensor will not always be in contact with
pulp.
Figure 12: TB model sensor installed di-
rectly after a pump.
7.2 TB sensor dimensions
TWIN BLADE
208 (8.2”) 245 (9.6”)
60
(2.4”)
80
(3.1”)
106
(4.2”)
130
(5.1”)
83 (3.3”)
155 (6.1”)
Min. 219 (8.6”)
(DN200/8”)
180 (7.1”)
L-coupling
114 (4.5”)
Figure 13: Dimensions Twin Blade.
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7.3 TB model process coupling
Note:
Coupling fits to DN200/8" piping without modification.
1. Shape the process coupling according to pipe size. Cutting lines for different pipe
sizes (4) are marked on the coupling.
2. Cut a Ø 118 mm (4.65") hole through the pipe wall.
3. Place the process coupling into the hole so that the alignment marks match with
the axis of the pipeline (2).
4. Check that the coupling limiter flange leans against the pipe and both sides are
equally aligned (3).
5. Weld four spots around the coupling and check the alignment once more.
6. Weld all around the coupling. Welding seam may not exceed the coupling limiter
flange.
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