Valmet OC2R Installation & Operating Manual Download Page 1

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Valmet Optical Consistency

Measurement - Valmet

OC2R

nstallation & operating

K20798 V1.

Summary of Contents for OC2R

Page 1: ...Valmet Optical Consistency Measurement Valmet OC2R Installation operating K20798 V1 1 EN ...

Page 2: ...titute a warranty or commitment for any purpose nor shall it be considered as part of such contract or giving rise to any liability by Valmet In particular copyright and any other intellectual property rights to software applications described in this publication are vested in Valmet and or its third party licensors as applicable The license to such software is governed exclusively by the terms of...

Page 3: ...ensor 12 5 1 Sensor dimensions 12 5 2 Choosing the mounting location 13 5 3 Installation of process coupling ball valve 15 5 4 Adjusting sensor insertion depth 17 5 5 Installing sensor to process coupling 19 6 Installing the TCU 21 6 1 TCU 21 6 2 Electric connections of TCU 22 6 3 Binary inputs 23 7 Setting up 24 8 Operating 25 8 1 Operating with TCU 26 8 2 Result displays 27 8 3 Operation map 28 ...

Page 4: ... 33 10 3 Calibration methods 34 10 4 Creating a recipe 35 10 5 Sampling for laboratory analysis 36 10 6 Entering lab values 37 10 7 Calibrating 38 10 8 Calibration history 39 11 Diagnostics 41 11 1 Logs 41 11 2 Diag limits 42 11 3 Meas values 42 11 4 Led 42 11 5 Current output 43 11 6 Error messages warnings 44 12 Technical specification 46 13 Spare parts 48 14 Declaration of conformity 49 ...

Page 5: ...ding 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 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 sust...

Page 6: ...ay 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 Caution Before installing the process coupling and ball valve make sure that the process pipeline is empty and depressurized Caution During installation maintenance and service operations remember that the sample line may c...

Page 7: ... to perform compensation calculations that take into account the variation of ash content in the total consistency Multi point calibra tion is also used for ash consistency cali bration 3 1 Operating unit TCU TCU is the user interface power supply and calculation unit of the system The device is operated by using the TCU keypad and four line display The TCU is mounted on a protective cover which p...

Page 8: ...f a TCU with power supply a sensor probe and the connecting cables see chapter 4 TCU installation and cabling has been designed to meet the CE directives and their associated standards as stated in the Declaration of Conformity document delivered with the device In order to meet the EMC directive the following precautions must be taken 1 All wiring must be shielded Power supply electronics shielde...

Page 9: ...ndling the equipment around vessels containing pressurized or hot materials Take the necessary safety precautions when mounting the equipment Use appropriate lifting gear platforms and tools The TCU is powered by hazardous voltages The TCU box is CSA approved Valmet Optical Consistency Measurement Valmet OC2R 9 48 K20798 V1 1 EN 1 12 2019 ...

Page 10: ...ty recommendations apply to a sensor installed with an AC powered TCU Note Always use only parts manufactured or approved by Valmet Automation Follow valid instructions and standards during installation Installing and connecting the sensor Caution Before installing any mounting parts make sure that the process pipeline is empty and depressurized Welding or bolting and the subsequent inspection mus...

Page 11: ...U is properly connected this cable contains the optical fiber Installing the TCU The TCU uses a hazardous voltage Only a qualified electrician may connect the TCU Make sure to connect the earth correctly double check after connecting DANGER High voltage inside the TCU Safety recommendations 11 48 K20798 V1 1 EN 1 12 2019 ...

Page 12: ...n the selected installation site Measured from the pipe surface there must be at least 500 mm 20 of free space to allow the installation of the sensor Make sure to leave sufficient room around the sensor to perform this task Dimensions OC2R Dimensions process coupling Installing the sensor 12 48 K20798 V1 1 EN 1 12 2019 ...

Page 13: ... measurement result The best results are ob tained when the sensor is installed to a pipe section immediately after a pump as the turbu lence is typically the strongest there Measured from the pipe surface there must be at least 500 mm 20 of free space to allow the installation of the sensor Note If there is a globe valve be tween the pump and sensor make sure that the valve is fully open all the ...

Page 14: ...t from a pump not immediately where the pump delivers the pulp Also make sure to install the sensor probe in the downstream direction and adjust the insertion depth see Sensor depth adjustment so that it is flush with the pipe surface Installing the sensor 14 48 K20798 V1 1 EN 1 12 2019 ...

Page 15: ...h otherwise fibers will get snagged to the ragged edges and cause irregularities in the measurement result 3 Center the coupling to the drilled hole and make sure it is in the correct position and weld the coupling to the pipe Screened pulps the notch on the coupling see arrow is on the side facing the pulp flow Unscreened pulps the notch on the coupling is on the downstream side opposite to flow ...

Page 16: ...4 Insert O ring on the welded coupling 5 Screw down the ball valve to the weld ed coupling Installing the sensor 16 48 K20798 V1 1 EN 1 12 2019 ...

Page 17: ...idental opening and closing of the valve 5 4 Adjusting sensor insertion depth As default the insertion depth is adjusted for screened pulps so that the sensor tip is inserted well into the pulp flow When measuring unscreened or unhomogeneous pulps the sensor tip may catch foreign objects contained in the flow Such applications include OCC pulpers measurement points before coarse screens broke pulp...

Page 18: ...n In newer sensor probes the position is marked on the probe If there is no marking on the sensor probe draw a mark 8 mm 0 3 from the front surface of the locking ring step a Push the locking ring towards the probe tip until the rear edge of the ring is aligned with the marking step b Then tighten the 4 locking screws Installing the sensor 18 48 K20798 V1 1 EN 1 12 2019 ...

Page 19: ... tip until it stops at the lock ring 2 Tighten the sealing bushing to the ball valve Do not over tighten 3 Install the locking ring D This ring ensures that the assembly is opened in the correct order the sealing nut must be opened first before the sealing bushing can be unscrewed The locking ring must be on the flat tool surface of the ball valve as shown in the photo Installing the sensor 19 48 ...

Page 20: ... down the sealing nut to the sealing bushing and tighten it Note Before calibration ensure that the optical fiber cable between probe and TCU is properly connected and fastened for example secured to a cable rack with cable ties Installing the sensor 20 48 K20798 V1 1 EN 1 12 2019 ...

Page 21: ... for the TCU remember that the length of the optical fiber cable is either 5 m 16 ft or 10 m 33 ft Sensor electronics box is mounted behind the TCU The cable between TCU and sensor electronics is 0 7 m 2 3 ft long If the TCU and sensor electronics box must be installed separately a 10 m 33 ft extension cable is available as option Maximum total cable length is 30 m 100 ft Installing the TCU 21 48 ...

Page 22: ...the power supply cable 90 260 VAC A 2 In a normal delivery the sensor cable B is already connected to the TCU 3 Insert the output signal cable into the TCU connector casing through an inlet bushing C and connect it to the terminals as shown in the drawing 4 Connect the binary input cable see section Binary inputs on page 23 for more information Installing the TCU 22 48 K20798 V1 1 EN 1 12 2019 ...

Page 23: ... 1 term 13 These inputs share a common ground term 11 The system must sup ply 12 28 VDC 10 mA voltage to the bi nary input Table 1 BIN1 configured for recipe selection BIN0 BIN1 recipe open open recipe 1 selected closed open recipe 2 selected open closed recipe 3 selected closed closed recipe 4 selected Table 2 BIN1 configured for sampler status BIN0 BIN1 recipe sampler status open open recipe 1 s...

Page 24: ...tical fiber Basic set up procedure 1 Make the basic settings Select the temperature unit Celsius Fahrenheit and language see User settings Set the device date and time see Set clock Scale the current output see Output signal1 2 Calibrate the measurement see chapter Calibration on page 33 or Calibration quick guide for detailed instructions Select recipe and pulp type Collect laboratory sample Ente...

Page 25: ...ggle between result display and main menu Edit Save go to edit mode save data after editing Arrows move the cursor move in menus Enter move between result displays in edit mode jump to the next value to edit Table 3 Display symbols value is editable value is read only measured value or entering the next submenu Example of an editing instruction Press Edit Save to start editing a cursor starts to b...

Page 26: ...lt displays to access the Main menu Sample button start and stop sampling Calibration menu is accessed from TCU main menu To access a menu function or submenu press the number key indicated before the name of the function submenu Press Esc to return to the previous level All TCU functions can be accessed from the operations menu You can always return to Main result display by pressing Esc several ...

Page 27: ...mber indicates that remote recipe selection is in use In this case the active recipe is selected by two digital input signals on the TCU unit Cs Consistency in percentage points Cs Ash Ash consistency percentage Elec T Electronics temperature C Status Device status information OK alarm error message Extra result displays mA PV SV Analog output values in milliamps mA Elec T Device electronics tempe...

Page 28: ...8 3 Operation map Operating 28 48 K20798 V1 1 EN 1 12 2019 ...

Page 29: ...t overrides fixed recipe selections by the operator and the active recipe is selected instead by the digital inputs of TCU Re motely selected recipe is indicated in the measurement display with letter R after the recipe number 9 2 Output signal 1 LRV Lower range value The consistency percentage that produces the 4 mA analog out put signal Default 0 5 Cs URV Upper range value The consistency percen...

Page 30: ...D analog output is frozen when alarm goes on and NONE no alarm signal at all Default 3 7 mA 9 3 Output signal 2 Selected variable Ash consistency Other settings same as in Output signal 1 9 4 User settings Tag Device tag is a text describing the installa tion position of the device Max 8 characters letters numbers Temp unit Temperature unit degrees in Cel sius C Fahrenheit F Default C Configuratio...

Page 31: ... of TCU electronics HW Rev Version number of TCU electronics SW Rev Software version of TCU 9 6 Set clock Date and time Enter the date with the number keys To start press Edit Save The first char acter in the field begins to blink Example to enter the date 14 04 2019 April 14 2019 the key sequence is as follows 1 4 ENTER 0 4 ENTER 1 9 ENTER Enter Confirm changes Configuration 31 48 K20798 V1 1 EN ...

Page 32: ... recipe 1 and recipe 2 can be activated through input signals 9 8 Address HART R address of the device Acceptable values are from 0 to 15 Default value is 0 zero i e normal installation with a single sen sor analog output signal 4 20 mA is active Values 1 15 define a fixed 4 mA current output and all communication with the device is performed over the digital HART protocol Caution Do not set value...

Page 33: ...ncy result into the device as instructed below Valmet OC should preferably be calibrated separately for each pulp type it will be measuring Calibrations for up to four pulps can be saved in the TCU memory When the pulp recipe is known the device is able to accurately convert the measured signal into a consistency reading Cs The desired calibration can be activated either directly from the device o...

Page 34: ...hods The measurement signal response to pulp consistency follow the power law function Cs A xB The offset value deviation from zero of the measurement can be adjusted by introducing parameter C to the calculation formula Cs A xB C IMPORTANT Valmet recommends that the measurement should always be calibrated using pulp samples measured in the laboratory in this case the offset C is not required Sing...

Page 35: ...e of the curve The device will alert the operator if the points selected for calibration differ from each other by less than 25 Multi point calibration The data set used for multi point calibration should cover a wide range of ash and consistency variations Only samples for which a laboratory consistency result exists can be used for calibration Multi point calibration requires at least 5 samples ...

Page 36: ...mi thermomechanical pulp SW2 Bleached softwood chemical pulp for example pine HW2 Bleached hardwood chemical pulp for example birch eucalyptus bagasse and other agro fibers RCF2 Recycled pulp Other2 Other pulp types When the settings are done press Edit Save to save them and then return to the main menu with Esc 10 5 Sampling for laboratory analysis In the Main result display press Sample When you...

Page 37: ...ratory Select the correct recipe The number 0 indi cates how many samples have been stored in the recipe The currently active recipe is indi cated by an asterisk at the end of the line Use the arrows up down to scroll the sample data in the display If more than one sample has been stored use the right left arrows to scroll between samples The number indicates which of the saved samples is being sh...

Page 38: ... one sample has been saved scroll them on the display with the up down arrows When the correct sample is shown press En ter to select it for calibration The first calibra tion point is now fixed For two point calibration choose now the sec ond sample up down arrows In single point calibration press now Enter If the values of A and or B look too low or high or if the consistency difference between ...

Page 39: ...ss 2 multipoint cal Press Enter to start calibration Coefficients calculated in total consistency cali bration Coefficients calculated in ash consistency cali bration Note If you want to exclude a sample point from the multi point calibration calculation set its laboratory value to zero 10 8 Calibration history Press 4 Calibration history in the calibration menu This display will appear Calibratio...

Page 40: ...le point calibration has been done Calibration history view when pulp type is RCF2 and multi point calibration for total con sistency has been done Use the left right ar row keys to move from page to page Use the up down arrow keys to move from one history entry to the next Calibration history view for ash calibration Calibration 40 48 K20798 V1 1 EN 1 12 2019 ...

Page 41: ...g time was not detected the ending timestamp is shown as The message Shutdown in the place of the event state end time indicates that the event state was on when power was shut down If the event state is still on when the power is switched on next time the event is reported as a new event Error A text describing the event Config trend The display shows the trend in terval 1 min 2 min 5 min 10 min ...

Page 42: ...play you can set alarm limits for the self diagnostics measurements measurement values compensations channel signal elec tronics temperature and LED current VRfact Factory tuned parameter for reference channel cannot be edited by end user 11 3 Meas values This display shows the measured sample re sults mV and linearized values for the differ ent measurement signals Measured mV Meas1 Meas2 VComp me...

Page 43: ...Increase decrease the analog output value with the Up Down keys Trim mA 1 2 Select Trim Output1 Output2 This function requires that you connect an ammeter to the analog output The device will first send a 4 mA signal to the analog output Measure the actual current value and enter it to the device by changing the Actual value Output1 2 The analog output is frozen to its present value shown here Act...

Page 44: ...orrect the problem ERROR Serious error Output signal set to State fail Safe State can be set in menu Configuration Output signal INFO Informative message no effect on output signal Error messages can be viewed on Diagnostics Event Log display ERROR messages SENSOR COMMUNICATION FAIL Serial communication Error between TCU and sensor LED CURRENT TOO HIGH LED current is over the limit If VComp VRfact...

Page 45: ...Check the LRV and URL values Main menu 1 Configuration 3 Current output2 ANALOG OUTPUT2 FIXED Fixed current value set to current output LED CURRENT WARNING LED current is at the warning limit Check the value Main menu 3 Diagnostics 2 Diag limits Preventive maintenance is recommended MEAS1 OUT OF LIMITS The measured value is outside the measuring limits Check the limits Main menu 3 Diagnostics 2 Di...

Page 46: ...ipe size DN80 80 mm If installation to a smaller pipe is required please contact Valmet Environment Ambient temperature 20 to 60 C 4 to 140 F Temp during storage 50 to 80 C 50 to 176 F EMC test standards Radiated interference IEC 61000 6 2 Interference immunity IEC 61000 6 4 Weight Sensor Optical TCU 3 9 kg 8 6 lbs Valmet OC Optical TCU Connections TCU to Optical Unit length 0 7 m 2 3 ft Optical c...

Page 47: ... OC2R Technical specification Valmet Automation Inc All rights reserved Dimensions TCU 261 10 28 82 3 23 310 12 2 31 1 2 220 8 66 232 9 13 Process coupling Dimensions OC2R 115 4 52 263 10 35 Ø 11 5 0 45 Ø 12 0 47 ...

Page 48: ...1 K19745 Operating unit TCU Valmet OC2R PA 1 Printed circuit boards Y2013 version K19729 TCU board OC2R incl keyboard cable 1 K20719 Keyboard TCU OC2R 1 K11342 Special Tool Kit Qty K16284 Calibration Plate OCR OC2R 1 K11341 Head locking removal Tool 1 K13904 Lock ring pliers 3 10 mm 1 K13905 Pliers 1 Process Mounting Parts Qty K09943 OC Process Mounting Parts 1 Sensor Probes Full Sensor Probe Asse...

Page 49: ...voering van deze richtlijnen Tento produkt vyhovuje požadavkům následujících směrnic a také požadavkům norem a vnitrostátní legislativy kterými se tyto směrnice provádějí Le produit est conforme aux directives et normes suivantes et les dispositions nationales portant mise en œuvre desdites directives Este producto es conforme a los requisitos de las siguientes directivas y normas y legislación na...

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