Valmet TS Installation instructions

Valmet Total Solids Transmitter
– Valmet TS
Installation &
Owner’s manual
OUL00489 V2.3 EN

Table of contents
Warnings & safety information
Recycling and disposal
Introduction 71.
Measurement principle ....................................71.1.
Parts of the device...........................................71.2.
Sensor device plate..........................................81.3.
Construction 92.
Valmet TS-FT...................................................92.1.
Sensor electronics .........................................102.2.
Transmitter Central Unit (TCU) .....................102.3.
Installing 113.
General principles..........................................113.1.
Choosing the installation site.........................113.2.
Installation dimensions...................................133.3.
TCU and its shield..........................................143.4.
Electric connections ......................................143.5.
Setting up 174.
Checking the hardware..................................174.1.
Installing.........................................................174.2.
Checking the cable connections....................174.3.
Checking electric operation............................174.4.
Configuration and calibration.........................174.5.
User interface and operating 195.
Operating unit, TCU.......................................195.1.
Operating diagram.........................................205.2.
Configuration 216.
Configuration menu........................................216.1.
Choosing and scaling the output signal.........216.2.
User settings..................................................216.3.
Device info ....................................................226.4.
Setting date & time.........................................226.5.
Address..........................................................226.6.
Digital inputs ..................................................226.7.
Calibration 237.
About calibration............................................237.1.
Sample taking................................................237.2.
Entering laboratory results.............................247.3.
Offset correction.............................................247.4.
Calibration and sample history ......................247.5.
Diagnostics 258.
Diagnostics menu...........................................258.1.
Error table......................................................258.2.
Diagnostics values.........................................258.3.
Diagnostics limits...........................................268.4.
Special functions 279.
Special functions menu..................................279.1.
Chemical compensation.................................279.2.
Sensitivity correction .....................................309.3.
Recipes .........................................................319.4.
Troubleshooting 3310.
Troubleshooting procedures .........................3310.1.
Effect of process conditions on
measurement.................................................33
10.2.
Self-diagnostics error messages ...................3510.3.
Replacing components 3711.
Pressure test of sensor housing....................3711.1.
Sensor electronics..........................................3811.2.
Antenna cables, FT-sensor............................3911.3.
Antennas, FT-sensor......................................4011.4.
TCU ...............................................................4011.5.
HART user interface 4112.
About the interface.........................................4112.1.
Measurement.................................................4212.2.
Configure........................................................4212.3.
Calibrate.........................................................4312.4.
Diagnostics.....................................................4612.5.
Installation drawings
Technical specifications
Spare parts
Atex certificate
Declaration of conformity
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Valmet Total Solids Transmitter

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Valmet Total Solids Transmitter

Warnings & safety information
Always check input voltage & frequency before making any connections.
Incorrect connections will damage the equipment! Always follow the ap-
plicable electric safety regulations in all installation work!
Before any welding works in the vicinity of the devices, make sure that
operating voltage is not connected!
During installation, maintenance and service operations, remember that
the sample line may contain hot sample or water – be careful!
This equipment (sensor unit) is suitable for use in ATEX ZONE 2 (corres-
ponding to class 1 division 2 group D) or non-hazardous locations only.
Warning! - Operating unit (Valmet TCU) is suitable for use in non-hazard-
ous location only.
Warning! - Explosion Hazard - Substitution of components may impair
suitability for ATEX ZONE 2 area. In the case that components are replaced
into the sensor unit, sensor housing must be pressure tested according
to instructions in the manual to ensure suitability for ATEX ZONE 2.
Warning! - Explosion Hazard - Do not disconnect equipment unless power
has been switched off or the area is known to be non-hazardous.
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Valmet Total Solids Transmitter

Recycling and disposal
When sorted by material, nearly all parts of the device can be recycled.
A materials list is delivered with the device. Upon request, the manufac-
turer will provide more detailed instructions for recycling and disposal.
Used devices may also be returned to the manufacturer for recycling and
disposal against a separate fee.
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Valmet Total Solids Transmitter

1. Introduction
1.1. Measurement principle
The operation of Valmet Total Solids Transmitter (Val-
met TS) is based on the measurement of microwave
propagation time.
Microwaves are a form of electromagnetic radiation,
and their propagation velocity, or flying time, is depend-
ent on the dielectric constant of the medium in which
they travel. The flying time is calculated as follows:
c = speed of light in vacuum
er = dielectric constant of the medium.
In water microwaves travel at a much slower speed
than in sludge. Thus the total solids content 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 on medium, insensitivity to flow rate,
and single-point calibration.
1.2. Parts of the device
The device consists of the sensor unit (Fig. 2 or 3) and
the TCU operating unit (Fig. 1).
Fig. 1. Operating unit, TCU.
Fig. 2. Valmet TS-FT.
Fig. 3. Valmet TS-FT high-pressure model.
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Valmet Total Solids Transmitter

1.3. Sensor device plate
The device plate (Fig. 4) attached to each sensor shows
detailed information of the device: sensor type and
version, serial number and time of manufacture.
Fig. 4. Reading the TS sensor device plate.
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Valmet Total Solids Transmitter

2. Construction
2.1. Valmet TS-FT
The Valmet TS (Fig. 1) consists of the sensor unit and
TCU operating unit. The sensor is available in 7 sizes,
FT50–FT300, with pressure rating PN16.
With pressure rating PN100 the sensor is available
in three sizes in the range FT100 - FT200. The appro-
priate model is selected according to the required
pressure rating and the diameter of the process pipe.
Valmet TS is compliant with ATEX II 3G Ex nR IIA
T6 Gc.
The body of the flow-through sensor consists of a
pipe section that forms part of the process pipeline
once installed. Flush-mounted antennas are installed
on opposite sides of the sensor body, and measure-
ment takes place through the pipe. The sensor electron-
ics housing is installed to the sensor body by means
of a connecting pipe.
A temperature sensor (Pt-100) is installed inside the
connecting pipe. Antenna cables, installed in a protect-
ive tube, run along the outside of the connecting pipe
and connect to the electronics housing.
All wetted sensor and antenna parts are made of
AISI 316/316L. The antenna material is polished
ceramic.
A
B
C
D
E
Fig. 1. Valmet TS-FT: A. sensor electronics, B. sensor
cable connector, C. antenna cable, D. temperature
sensor, E. microwave antennas.
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Valmet Total Solids Transmitter

2.2. Sensor electronics
Sensor electronics of the FT model is shown in Fig. 3.
The sensor electronics board is installed between a
round cover and a base. The electronics contains a
microwave transmitter and receiver, and the electronics
for control, measurement and communciation.
When the electronics board is pressed on the base
plate, its snap-on connectors connect with the antenna
cable connectors on the base plate. Guide pins on the
base plate guide the connectors into position. The
temperature sensor, and the supply power and serial
communication lines from the TCU, are connected to
the connectors on the sensor electronics housing.
2.3. Transmitter Central Unit (TCU)
The TCU is the operating terminal and calculation unit
of the Valmet TS. It is operated by means of the keypad
and a four/line display. The TCU is delivered with a
shield attached to it (Fig. 2).
Connections:
– To sensor unit: operating voltage, RS485 serial
communication.
– To current outputs (2 passive outputs).
– To HART communicator (HART only in current out-
put 1).
– RS232 connection to a PC (for service purposes).
– Mains power.
Fig. 2. Operating unit, TCU.
A
B
C
D
E
Fig. 3. Sensor electronics: 1. power cable connector, 2. fastening screw, 3. temperature sensor connector, 4.
guide hole, 5. antenna cable connectors.
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Valmet Total Solids Transmitter

3. Installing
3.1. General principles
The sensor model is selected according to the size and
pressure rating of the pipeline. Flow-through models
are FT50/2", FT80/3", FT100/4", FT150/6", FT200/8",
FT250/10" and FT300/12". These can be installed to
the following pipe flanges:
Standard model
– DIN PN10
– DIN PN16
– ANSI Class 150
– JIS 10K
High-pressure model
– DIN PN100
– ANSI Class 600
– JIS 63K
For laboratory follow-up, it is important to use a good
sampler (e.g. NOVE) and install it in accordance with
the Valmet TS installation instructions.
NOTE: Before installing the process coupling / sensor,
make sure that the process pipeline is empty and not
pressurized, and that installation work can be carried
out safely!
Fig. 1. Sensor cable shield.
3.2. Choosing the installation site
When choosing the installation point, pay attention to
the following:
– Never install the sensor to the suction side of a
pump, or to a tower.
– Free straight pipe section after any changes in the
pipeline profile.
– Space for the sensor housing.
– TCU must be installed close to the sensor. The
length of the normal sensor cable is 10 m (33 ft), a
30 m (98 ft) cable is available as option.
Also pay attention to the following specifications:
– Process temperature max. 100 °C (212 °F).
– pH 2.5...11.5.
– Recommended process pressure is 1.5…16 bar
(22…232 psi) to eliminate the effect of air bubbles.
– Conductivity according to sensor specifications.
– Pressure rating of the sensor: FT models
PN16/PN100
Inspecting the installation:
– Make sure that the installation point and sensor po-
sition are in accordance with the instructions.
– Make sure that the FLOW arrow on the sensor
housing is aligned with the process flow direction.
– Protect the sensor and TCU from direct heat radi-
ation and direct sunlight.
– Before start-up, make sure that the seals between
the Valmet TS flanges and process flanges are cor-
rectly installed and the mounting bolts tightened.
– Make sure that ground wire is connected under the
flange bolt (Fig. 1).
–Open the shield (Fig. 1 A) to connect the TCU cable.
Close the shield (Fig. 1 B) before connecting power
to the system.
Sensor installation to a vertical and horizontal pipeline
is illustrated in Fig. 2 and 3.
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D
D
A B
Measuring line at a 90° angle
towards the pump axis.
Measuring line parallel to
the previous horizontal pipe.
Fig. 2. Installing the sensor to a vertical pipeline: A. after a pump, B. after a horizontal pipe section.
D
D
A B
Fig. 3. Installing the sensor to a horizontal pipeline: A. after a bend, B. after a vertical pipe section. If the section
of horizontal pipe preceding the sensor is >10xD, then the sensor is installed with its electronics casing on top.
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Valmet Total Solids Transmitter

3.3. Installation dimensions
When installed, the sensor replaces a section of the
process pipeline (Fig. 4 and 5). The installation dimen-
sions are shown in the "Installation drawings" attached
to the end of this manual. A sticker on the electronics
housing indicates the correct installation direction in
relation to the flow in the pipeline.
L
MIN. 500 mm (20")
Fig. 4. Valmet TS-FT installation principle.
min. 500 mm (20")
L
Fig. 5. Valmet TS-FT PN100 installation principle.
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3.4. TCU and its shield
The TCU is delivered with a protective shield attached
to it. Choose an easily accessible location, and mount
the shield on the wall with three screws.
When choosing the TCU installation point, remember
that the sensor cable is 10 m (~ 33 ft) long The dimen-
sions of the shield are shown in Fig. 6.
3.5. Electric connections
NOTE: Before connecting the power supply wires, make
sure that the wires are not powered! Connect power to
the wires only after you have made and checked all
connections.
NOTE: If the TCU has been powered off for some time,
the display will take some time to light up. This delay is
perfectly normal, and the display will start working as
soon as its internal backup battery has recharged.
Sensor cable
NOTE: In normal deliveries the sensor cable is already
connected to TCU.
1. If the sensor cable is not connected, insert its open
end (= cable end without connector) into the TCU
connection box, and connect it as shown in Fig.
8.
2. Lead the other end of the sensor cable to the
sensor unit, and connect it to the connector on the
sensor electronics base plate.
NOTE: Do not put the sensor cable on the same rack with
power cables (motor/pump power cables etc.).
NOTE: Make sure that sensor power is switched off be-
fore opening the sensor cable connector shield or dis-
connecting the cable.
232 (9.13")
70 (2.76")
31 (1.22")
236 (9.29")
133 (5.24")
282 (11.10")
Fig. 6. Installation dimensions of the TCU shield.
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Mains power
Connect the mains power cable (90 - 260 VAC) to TCU
through the left-hand conduit of the connector casing,
and connect it to the terminal strip as shown in Fig. 8.
Current signal cables
The TCU contains two current outputs. Current output
1 (CS+, CSIN) is hardwired to give the total solids
content signal. The user can choose either the process
temperature (°C/°F), process conductivity (mS/cm) or
solids content (TS% / g/l) to current output 2 (CS2+,
CSIN2).
Insert the current output cables to the TCU connector
casing through the inlets and connect them to the ter-
minal strip as shown in Fig. 8.
– Power supply wire to connector 'CS+' or 'CS2+'.
– Current output wire to connector 'CSIN' or 'CSIN2'.
NOTE: The current output of the Valmet TS is a passive
output and it requires an external power source. The
minimum supply voltage is dependent on resistance.
NOTE: Do NOT connect the shield of the current output
cable at the TCU - connect it only at the mill system end!
Fig. 7 shows the resistance as a function of input
voltage. Resistance here means the total sum of all
resistances (measurement, cables, power supply) in
the current loop.
1000
500
250
0612
35 V 2817
Ω
Operating region
Fig. 7. Load on TCU current output.
HART
+ 24 V
250
:
+ 24 V
7
CS+
8
CS IN
9
CS2+
10
CS2 IN
6
SHIELD2
VS IN VS IN
250
:
TCU
TE
HART
INPUT CHANNEL
Passive transmitter
N
90...260 VAC
47...63 Hz
678 9 10 11 12 13 14 15 16
DC output GND RS485+ RS485- SHIELD SHIELD 2 CS+ CS IN CS2+ CS2 IN BINGND BIN0 BIN1 SHIELD2 FIELDB+ FIELDB-
1 2 3 45
Power
Sensor
4...20 mA
Binary
IN
Fieldbus
conn.
Fig. 8. Connections of the TCU.
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Binary inputs
The TCU contains two galvanically isolated binary in-
puts, BIN 0 (connection 12) and BIN 1 (connection 13),
both inputs share a common ground (connector 11).
The switching device must be able to supply 12–28
VDC / 10 mA to the binary input. The connection prin-
ciple of binary inputs is shown in Fig. 9.
BINGND (11)
BIN0 (12)
BIN1 (13)
Fig. 9. Connection principle of binary inputs.
Table 1. BIN1 configured for process running status.
BIN0 BIN1
open open recipe 1 selected Process Stopped
closed open recipe 2 selected Process Stopped
open closed recipe 1 selected Process running
closed closed recipe 2 selected Process running
Table 2. BIN1 configured for recipe selection.
BIN0 BIN1
open open recipe 1 selected
closed open recipe 2 selected
open closed recipe 3 selected
closed closed recipe 4 selected
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4. Setting up
4.1. Checking the hardware
1. Make sure that the delivery is consistent with the
order.
2. Make sure that the device has not suffered any
damage during transport.
4.2. Installing
Install the sensor and TCU as instructed in Chapter 3
of this manual.
4.3. Checking the cable connections
1. Make sure that the power supply cable is correctly
connected.
2. Make sure that the current outputs are correctly
connected.
3. Make sure that the sensor cable is correctly con-
nected.
4.4. Checking electric operation
1. Connect power to the system.
2. Make sure that the TCU display lights up and
shows text. Normally the main display will soon
appear. If a device has been replaced, the program
may ask the user to start calibration. In such cases,
select calibration of the unit (Sensor elec-
ronics/TCU) that was not replaced.
3. Allow the device to warm up for one hour before
starting it up.
4.5. Configuration and calibration
1. Choose the language, temperature unit (Celsi-
us/Fahrenheit) and total solids content unit (TS%
or g/l) as instructed in Chapter 6.2.
2. Set the correct date and time to the device as in-
structed in Chapter 6.4.
3. Scale the current outputs as instructed in Chapter
6.1.
4. Calibrate the total solids content as instructed in
Chapters 7.1 and 7.2.
After these procedures the Valmet TS is ready to
start measurement.
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Notes
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5. User interface and operating
5.1. Operating unit, TCU
The sensor is operated with a TCU (Transmitter Central
Unit).
Number keys: Entering numerical data, selecting from
the menus. In some displays the number keys can also
be used to type letters. To enter letters, press a key
rapidly several times and the letters indicated on the
key will appear one after the other.
Sample: In the "Sample taking" function of the Calibra-
tion menu, pressing this button starts and stops taking
a calibration sample. Pressing this key in the main
menu starts and stops taking a follow-up sample.
Edit/Save: Press this button to go into editing mode.
In editing mode, press this key to save data.
ESC: Exit from editing mode without saving. Toggling
between main display and function menu.
Enter: Toggling between main display and info display.
In editing mode, jumping to the next edit field.
Back arrow: In editing mode, returning to the previous
character inside a field.
Forward arrow: In editing mode, moving to the next
character inside a field.
Down arrow: Scrolling down in a display if there are
more than four lines (a downward-pointing arrow in the
bottom right corner of the display indicates that there
are more lines). Scrolling the alternatives in an editing
field.
Up arrow: Scrolling up in a display if there are more
than four lines (an upward-pointing arrow in the top
right corner of the display indicates that there are more
lines). Scrolling the available alternatives in an editing
field.
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5.2. Operating diagram
The operating diagram is divided into four functions
and their submenus. The main sections are Calibration,
Configuration, Diagnostics, and Special functions.
To access a menu from the main display, press ESC
and then select the number of the desired function.
Press ESC to return to the previous level. If a display
contains more lines than the TCU can show at a time
(i.e. more than four lines), arrows in the top or bottom
right corner of the screen indicate that the lines can be
scrolled up or down with the down arrow or up arrow
keys.
TS Ft200 POS-1234 1=C
2=Tu
4=D
ENTER
3=Lab Values
TS= 3.12%
T= 56.7 C
Status=OK
1=Calibration
2=Configuration
4=Special functions
3=Diagnostics
% Range = 53.00 %
mA = 12.48 mA
Cabin T = 52.3 C
ESC
1
2
3
4
Meas Att= 45.6 dB
Sample taking
Enter lab
Offset Correction
Calibration History
Sample History
Output signal 1
Output signal 2
User Settings
Device Info
Set Clock
Address
Digital inputs
Error Log
Diag. values
Diag. limits
Chemical Compensation
Temperature Compensation
Sensitivity Correction
Recipes
Fig. 1. Operating chart.
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