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THE ELECTRON MACHINE CORPORATION MPR E-SCAN, Operating And Service Manual

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THE ELECTRON MACHINE CORPORATION MPR E-SCAN Operating And Service Manual Download Page 3

MPR 

E-S

CAN

 

 

INTRODUCTION

 

 

 

Introduction

 

 

The Electron Machine Corporation

 

MPR E-SCAN

 

 

 

 

The  MPR  E-Scan  is  a  microprocessor  driven  critical  angle  refractometer.    It  is  used  to 

measure  the  refractive  index  of  process  fluids  which  directly  correlate  with  customer 

request for dissolved solids, Brix or other meaningful measurement.  The E-Scan may be 

used as an error indicator or an integral part of a complete process control system. 

 

The MPR E-Scan is equipped with a broad range of diagnostics to aid in fault isolation 

without the use of special test equipment.  The instrument is calibrated before leaving the 

factory and should not need recalibration unless some modification is made to the sensing 

head.    Calibration  procedures  are  available  to  change  system  parameters  and  allow  the 

refractometer to measure different process fluids. 

 

Extensive  literature  is  available  for  various  industries  listing  the  correlation  between 

refractive index, degrees Brix, or % solids and specific process parameters. 

 

 

 

 

 

The E-Scan consists of: 

 

•

 

Sensing head 

•

 

Console 

•

 

Interconnecting cable 

 

 

 

 

 

 

 

 

                                                                           MPR E-Scan Overview 

 

 

 

1 

Summary of Contents for MPR E-SCAN

Page 1: ... Refractometer with Color Display Designed and Manufactured by THE ELECTRON MACHINE CORPORATION 15824 CR 450 West 352 669 3101 Post Office Box 2349 FAX 352 669 1373 Umatilla FL 32784 2349 E Mail sales electronmachine com http www electronmachine com Rev A ...

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Page 3: ... is equipped with a broad range of diagnostics to aid in fault isolation without the use of special test equipment The instrument is calibrated before leaving the factory and should not need recalibration unless some modification is made to the sensing head Calibration procedures are available to change system parameters and allow the refractometer to measure different process fluids Extensive lit...

Page 4: ...erly Only trained staff are to use an EMC Isolation Valve Adapter Isolation Valve Adapter must be properly maintained and reconditioned after 10 years of service No pressure should be felt on the head as the mounting nut is being removed See the EMC Isolation Valve Adapter manual for more information ANY PRESSURE FELT WHEN THE NUT IS LOOSENED MUST BE INVESTIGATED BEFORE PROCEEDING Prism cleaning s...

Page 5: ...hing for the MPR E Scan 2 3 2 2 Normal Mode 2 4 2 2 1 What Normal Mode Does 2 4 2 2 2 System Indicators 2 4 2 2 3 The Menu Options in Normal Mode 2 5 2 2 4 Overview of Menu Options 2 6 2 3 Product Selection 2 7 2 4 Calibration Selection 2 10 2 5 Configuration Selection 2 15 2 6 Print Selection 2 20 2 7 Diagnostic Selection 2 21 2 8 Offset Selection 2 24 2 9 Purge Selection 2 25 2 10 Hold Selection...

Page 6: ...s 5 1 5 1 1 2 CCD Linear Array 5 2 5 1 1 3 Signal 5 2 5 1 2 Console 5 3 5 1 2 1 Display 5 3 5 1 2 2 Switch Matrix 5 3 5 1 2 3 Cable entry and mounting 5 4 5 1 2 4 IB interface board for external connection 5 4 5 1 2 5 Power supply 5 4 5 1 2 6 I O card 5 4 5 1 2 7 CPU Card 5 5 5 1 2 8 Supplemental Card Information 5 6 5 2 Refractometer Specifications 5 7 5 3 Available Options 5 7 6 Drawings List 6 ...

Page 7: ...ived may have a calibration cup installed if purchased The sensing head is attached to the process line by an adapter which can be carbon steel stainless steel 316 or a material specified by the customer This adapter must not be placed in an area where vibration is severe or excessive Sensing Head to Adapter Positioning If the sensing head is to be mounted on a horizontal pipe the head should be m...

Page 8: ... head houses optical components which are susceptible to the effects of moisture The cover is moisture proof and contains a desiccant to absorb any moisture remaining in the head after assembly The sight glass on the head allows inspection of the desiccant Light orange indicates that it remains effective Clear indicates it is no longer effective and must be changed The desiccant can be renewed by ...

Page 9: ... the positive output for both the isolated output option and the standard non isolated output module The output for the temperature is located on TB 3 terminals 3 and 4 3 being the positive output in this case The modules on the top of the interface board represent the output modules The one on the left U1 is the output module for the measurement U2 is the output module for the temperature The oth...

Page 10: ... contacts and power must be supplied from an external source as shown on the drawing Contact Electron Machine for specific application information 1 6 1 Steam Pressure The steam pressure must be no less than 50 psi 3 44 bar and preferably no greater than 100 psi 6 89 bar above the process line pressure Both the steam and condensate drain valves should be located as close to the steam purge fitting...

Page 11: ...gate commands 2 1 1 Display The three basic types of messages displayed are Variable These information lines contain either set points that may be altered by the operator or measurement variables that are updated by the CPU Alternate Action Acts much like a two position switch and is used to select various menu options The operator is able to alternate between two states such as ON and OFF Error D...

Page 12: ...to abort to previous operation without saving edited data Menu Used to immediately display the normal mode of operation without saving information or main menu selections if already in normal mode PgUp Displays previous screen of information or mode of operation when indicated on the screen Used to exit graph mode and return to normal mode PgDn Displays the next screen of information or mode of op...

Page 13: ...the graph area as dotted lines The graph time can range from 5 minutes to 9999 minutes and can be accessed via the button on the front panel switch matrix The calibration alarm limits are also displayed graphically within the graph area and are drawn as red dashed lines to differentiate them from the graph span limits The alarm limit lines are drawn 20 pixels apart horizontally which gives the add...

Page 14: ...n will not initiate a prism clean T Below min purge temperature limit No prism clean allowed H Measurement Hold Current readings and analog outputs are maintained until complete Can be invoked by menu selection in normal mode or by external input if configured for on demand hold Measurement Hold can also indicate a cleaning cycle in progress which is indicated by a purge message as well as a curre...

Page 15: ... upon power up To gain access to other system features select the MENU button on the Front Panel Touch Pad Normal Mode Screen with Menu Options When the MENU button is selected the following menu options are displayed on the normal mode screen Normal Mode Screen with Purge and Hold Options If Purge and Hold options are configured the following menu options are displayed on the normal mode screen 2...

Page 16: ...mperature alarms 232 output and associated baud rates measurement title and displayed reading decimal format Other configuration options are selected in advance by EMC and would not normally be changed by the operator Thus access to other system configurations is gained only by entering a correct password PRINT option allows the operator to print all system calibration and configuration settings a...

Page 17: ...uct provided this product has been previously calibrated and configured for on demand use In this example only two products PRODUCT 1 NAME and PRODUCT 2 NAME are available When the Get option is selected the following is displayed The product menu options have been replaced by the Get Mode and Enter Product messages Using the Front Panel buttons the operator can enter a product number and then Get...

Page 18: ... will be the destination of the current calibration and configuration In this example all of product 01 information will be copied to product 03 thus creating a new product The next step would be to assign a meaningful name to the newly created product which can be accomplished by selecting the third product menu option Name The product menu options have been replaced by the Name Mode and Enter Pr...

Page 19: ...ch is updated as characters are selected Using the Front Panel ARROWS and the ENTER button a product name can be selected and then saved The PgDn and PgUp messages at the top right indicate the status of the editing mode Toggling between these modes allows the operator to move the edit cursor to a desired position either in the alphabet or the product name When the Save option is selected the prod...

Page 20: ... changes that are caused by temperature changes 4 Anlg 0 Analog Zero This option is used to adjust or zero in the instrument to match a target value Using the Front Panel buttons the operator can highlight and then select the specified calibration menu options Selecting the Limits menu option would generate the following display Using the Front Panel arrow buttons the operator can scroll through a...

Page 21: ...n seconds for the process temperature that must expire while a limit is exceeded before an error is activated Purge Cycle Time This is the time interval in minutes between automatic purging During purging all system readings and analog outputs are frozen A 0 setting disables automatic purging Condensate Drain Time When the purge cycle is activated this is the time in seconds that elapse before a p...

Page 22: ...for scaling is as follows NEW MEAS Current Meas Base Scale Base Measurement Offset This is the value that is added to the current measurement in order to zero in a target reading Page 3 of calibration limits screen contains Min Purge Temperature This is the value that causes the T indication to come on and limits any further purging Selecting the Meas option from the calibration menu results in th...

Page 23: ... calibration menu results in the following display Circulation bath with temperature adjustment and pump is needed for temperature compensation This is the temperature compensation table The VALUE column represents the compensation values and the DEG C column represents the temperatures at which those compensations occurred Using the Front Panel buttons both columns of data can be edited and saved...

Page 24: ...has been read by the lab the operator can adjust the stored measurement reading to match by pressing the right arrow button entering the desired lab reading using the numeric keys and pressing enter when complete The display will show the change at the bottom of the screen Press enter again to store the changes The adjustment is only capable of changing the measurement voltage plus or minus 1 5 vo...

Page 25: ...cimal place format 4 Meas Title This option allows the operator to assign a meaningful title to the measurement readout such as Brix Solids R I Scale 5 I O This option is used to configure all RS 232 422 communications 6 Alarms This allows the operator to choose the type of alarms for both measurement and temperature readings such as High Low Low Low or High High 7 Special This option allows custo...

Page 26: ...e activated remotely by the configuration of a system input EMC must be notified in all cases that require custom configuration Smart Clean option activates an intelligent prism clean process This will cause the system to automatically initiate another cleaning cycle if the previous cleaning was unsuccessful After three unsuccessful attempts purging will be aborted and a P system indicator will ap...

Page 27: ...is the measurement title alphabet menu It displays the alphabetic characters available for designating a title and the measurement title itself at the bottom which is updated as characters are selected Using the Front Panel ARROW and ENTER buttons a measurement title can be selected and then saved The PgDn and PgUp messages at the top right indicate the status of the editing mode Toggling between ...

Page 28: ... Baud Rate Is the selectable transmission rate for the communications The 232 422 is preset to a default setting displayed However the baud rate is user selectable and is used for all communications configured in the Comm Setup option 3 Unit Num This is used to identify the instrument by a number when configured for PC communications This option is used to identify the MPR E Scan when configured f...

Page 29: ...gh high limit Dev Setpt Meas Alarm An error occurs when the process measurement exceeds above or below a setpoint by a fixed amount The deviation is applied to both sides of the setpoint equally The setpoint can be remotely changed using the Remote Display Panel option This also is the setpoint used in the PID Controller option and can be remotely changed using the Remote Display Panel 2 Temp Alr ...

Page 30: ...l special or custom configurations 2 OnLine This option will automatically print out the online measurement and temperature readings at specified time intervals Selecting the Online option activates the following display This is the Online printer time interval menu Pressing the right arrow button allows the operator to specify an interval time in seconds that will control the printing of online m...

Page 31: ...erator to test system output as well as calibrate the output to work with various chart recorders 4 Time Date This option enables the operator to reset the system clock with a valid time and date Such adjustments may be necessary as a result of time zone differences or when the system clock batteries fail The Voltages option results in the following display Measurement Voltage The voltage produced...

Page 32: ...ltage the operator can test the custom input relays The Anlg Out diagnostic option activates the following display There are two outputs that produce a 0 10 volt or 4 20 mA signals for process measurement and temperature Process measurement is displayed as Analog 1 Out and temperature optional is displayed as Analog 2 Out Using the Front Panel buttons the operator can test the outputs in min mid a...

Page 33: ... Time Date diagnostic option activates the following display This menu enables the operator to set the system time and date System Time This is the time displayed in military format in normal mode System Date This is the date displayed in normal mode 2 23 ...

Page 34: ...e calibration limits menu which is visually highlighted by the edit cursor in the offset value field This enables the operator to make adjustments to the measurement reading in order to zero in a target reading NOTE As the offset is changed the displayed measurement reading at the bottom left will be adjusted to reflect the offset change 2 24 ...

Page 35: ...tem will resume normal operation Following the termination of the purge cycle the H indicator and the information at the bottom is removed When smart cleaning is activated successive purge cycles will be started if the previous purge was unsuccessful This will continue for three entire purge cycles at which time a P system indicator is displayed if all purges were unsuccessful The purging consists...

Page 36: ...system indicator is added to the right of the displayed reading This option allows the operator to freeze system readings and analog output at any time using the Front Panel buttons Selecting the ESC button terminates the hold condition NOTE The hold condition can also be activated on demand remotely by using a custom input 2 26 ...

Page 37: ...Conditions analog voltages for digital microprocessor CPU CPU card Microprocessor plugs into the I O board IB Interface board Most external connections are made to this board Typical display ranges for voltages in test mode are LED voltage 2 5 4 8 vdc Varies slightly with temperature and cable length Measure voltage Varies with process 0 10v range with 1 9 vdc nominal Temperature voltage 0 to 5 vd...

Page 38: ... CPU card NO TEMP VOLTAGE flashing on display If voltage between TB1 3 and TB1 10 on the IB is less than 0 2 volt and the process temperature is above 25 C check 2 5 volt regulator VR 1 in the head Sensing head failed I O card failed NO MEAS VOLTAGE flashing on display If positive voltage does not exist between TB1 12 and TB1 3 on the IB check for process flow across prism Sensing head failed I O ...

Page 39: ...n authorization is necessary Pack defective parts carefully to avoid damage in transit The shipper will be liable if in the opinion of the carrier insufficient packing was used Attach a letter stating the nature of the difficulty encountered the reason for failure if known the date of delivery of original equipment and the approximate number of hours of operation All return shipments must be prepa...

Page 40: ...oration P O Box 2349 Umatilla FL 32784 2349 If the part drawing number is not known give a detailed description including a sketch if possible All orders will receive prompt attention Phone 352 669 3101 Fax 352 669 1373 E Mail sales electronmachine com 4 4 2 Available Spare Parts Description Catalog MPR E Scan Door Assembly w Electronics 511010 Sensing Head E Scan 511002 O Ring 03 030 Viton pkg of...

Page 41: ...the prism is being coated 4 6 Caution CAUTION Close off isolation valve or remove the sensing head and replace with maintenance plug prior to steam cleaning process lines to prevent prism breakage CAUTION When removing the sensing head from an operating line do not assume that the line is empty or that the isolation or bypass means is working properly If an EMC isolation valve is used be sure its ...

Page 42: ...MPR E SCAN SERVICE 4 7 Maintenance Log Sheet Date Time Measurement Voltage Temperature Voltage Lamp Voltage Desiccant Color Initials 4 4 ...

Page 43: ...ses through the prism surface to be reflected off mirror 1 to the prism to process interface The light reaching this interface intersects the same interface over a series of angles chosen to include critical angle for the process being measured Light intersecting the interface at an angle greater than critical angle is refracted into the solution Light intersecting the interface at less than criti...

Page 44: ...e charge per pixel photo site and is reset to ground between each transfer 5 1 1 3 Signal CCD Signal To further increase resolution the signal is rectified and averaged as shown in the following figure This signal is used to control the LED current to eliminate the effects of process color changes suspended solids entrained air and other problems associated with non scanning refractometers The sig...

Page 45: ...l count of 640 by 480 to give very sharp resolution with LED backlighting The display is suitable for both graphics and text information 5 1 2 2 Switch Matrix The switch matrix is located on the outside of the console and allows the operator to make modifications and changes to the operating conditions of the instrument The operation of this switch matrix is further explained in the operations sec...

Page 46: ...rface board for external connection The interface board is located on the back wall of the console Most external connections are made to connectors that plug into this board The only exceptions are optional features that require connections to optional available connectors located on the side of the console 5 1 2 5 Power supply The power supply is located in the top of the console and serves as a ...

Page 47: ...on the above figure for the CPU card layout When the Comm LPT card connection board is supplied cables also run between the parallel printer port and the connector board The optional com ports cable also connects to the CPU core module card as shown in the RS232 Terminal Block Mounting Kit addendum This card is always installed on the I O board and additional cards such as the 422 optional card ar...

Page 48: ...MPR E SCAN INFORMATION 5 1 2 8 Supplemental Card Information Additional cards may be used for special features and options 5 6 ...

Page 49: ...e 40 F to 125 F 40 C to 52 C Console 4 F to 120 F 20 C to 50 C Processor 800 Mhz Vortex86DX Calibration See Engineering Order Sheet Sensing head Wetted materials of Construction 2205 Duplex SS sapphire Teflon Viton other materials available Outputs 4 20ma non isolated 0 10vdc non isolated 5 3 Available Options Optional E Scan Outputs 1 Ethernet Communication 2 Isolated 4 20 ma output for measureme...

Page 50: ...MPR E SCAN INFORMATION N O T E S 5 8 ...

Page 51: ...s Temp and unit configuration Will print out current Meas Temp and product information at interval in seconds selected Will clear any printer errors Used as a zero adjust centered at 2047 Will have a range of 1433 2661 3 00 volts of meas Voltage 409 counts volt Will do a manual prism clean if purge times have been selected Can select Meas Alarms Temp Alarms Purge Cycle times Prism Clean times Meas...

Page 52: ...lamp voltage Can cycle the Meas Temp Drain and Clean relays and see status of custom inputs Used to cycle the 4 20mA output from 4 12 20mA and calibrate for best chart recorder accuracy Used to set system time and date Used to hold present reading Used to select Purge Hold Smart Clean Alarm A Failsafe Alarm B Failsafe Used to name the current measurement units Password protected Used to select PID...

Page 53: ...nt units xx xx x xxx x xx xx x xxxx xxx xx formats available Select desired measurement alarms NONE H L L L or H H using the button Select desired temperature alarms NONE H L L L or H H using the button Used to add or subtract to the current measurement is not true zero shift see Analog O Pressing the PgDn key in the normal mode will bring up a measurement graph The time on the graph can be change...

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Page 55: ...ems Interconnect Diagram B 11365 H Assembly MPR E Scan Interface Board B 11366 C Schematic E Scan Interface Board B 12699 1 Assembly MPR E Scan I O CPLD Card Two Sheets A 12698 H Schematic Diagram MPR E Scan I O CPLD Card Six Sheets B 13024 A Assembly Analog Conditioning Board B 13025 A Schematic Diagram Analog Conditioning Board A 11792 K Assembly Low Power CCD Sensor Board A 11794 I Low Power CC...

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