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4

MAINTENANCE AND DIAGNOSTICS

Faults and actions:

1. SMART-PULP’s consistency reading differs
substantially from laboratory results. However,
SMART-PULP measures in the normal manner and
responds to consistency.
The most common causes for this error:
• A change in pulp type and furnish.
• SMART-PULP has not been installed as instructed, and
turbulent flow occurs at the measuring point.
• Flow velocity is below/above the specified limit.
• The pulp type is not suitable for the installed sensor
type.
• There is a double pipe bend upstream from the
transmitter, and the installation does not include a flow
straightener element that would eliminate the resultant
strong whirling flow.
• A change in fiber properties.
• Accumulations of pulp on the sensor’s surface, on the
taper pin and in the inlet cone.

Remove the transmitter from the process. Then use the
service stand and weights to see whether SMART-PULP
measures the weights correctly with the TRIM-F function.
After initial commissioning calibration you should monitor
the transmitter’s operation regularly with samples and
readjust the Zero when required. All actions should be
recorded in a transmitter-specific log.

2. SMART-PULP does not respond to consistency.

• Remove the transmitter from the process and mount it
on the service stand. Load the sensor blade with different
weights and use the TRIM-F function to determine the
change in output in relation to the applied load.
• Deflect the sensor blade alternately in the plus and
minus directions and see whether the output reading

BCs160VA

Nov. 15, 1997

SMART-PULP

 

Smart Consistency Transmitter

32

3.2  HART® communications

HART® communications is a method of transferring
data between a 2-wire transmitter and hand-held
programming unit without disturbing the actual
measurement signal.

The communications are carried out with theBell 202
FSK technique, where a high-frequency
communication signal is applied to the low-frequency
output signal. Since the communication signal’s DC
level is zero, it does not affect the 4-20 mA output
signal.

The HART® commands are divided to two classes.
Other commands are identical in all HART®
transmitters, while others are transmitter-specific
commands that require software adapted for the
particular transmitter. SMART-PULP supports both
classes. It also permits the sending of transmitter-
specific special commands from a standard
programming unit. For this reason older
programming units can also be used for
comprehensive control of the SMART-PULP
transmitter.

4.1

Troubleshooting

The transmitter monitors its own operation
continuously. Any detected faults are indicated in
error messages which can be read from the
transmitter’s own display or from serial I/Os (HART®
and Modbus)

SMART-PULP does not find all faults by itself. The
user’s actions are required in such cases. The
necessary actions are defined in connection with the
error messages. In this section we discuss faults not
detected by the transmitter, and describe the
measures that should be carried out before
contacting the supplier.

returns to the same value at the same load.
• Measure the output current and compare the reading to
the transmitter’s indication.
• Go to the DIAGNOSTics menu and use the MA- LOCK
function to apply constant current. Measure the output
current and see how it corresponds to the output current
command.
• Open the cover of the electronics housing and ensure
that all wires are firmly attached to the terminal pins.

Rectifying this fault usually requires factory servicing.

3. SMART-PULP operates otherwise in the normal
manner, but does not obey the operator keys or the
display does not respond.

• Check the flat cable connecting the display unit and the
transmitter. Is there any mechanical damage, and does
twisting the cable affect the operation? Does the HART®
interface function in the normal manner? Open the
electronics housing. Are all 8 wires to the junction box
attached to their inlet filters.

4. SMART-PULP operates in the normal manner, but
the HART® interface is inoperative.

• Is the current measuring resistor’s rating at least 250 

W

.

Considering the total load, is the supply voltage
sufficiently high? Also measure the voltage and current
from the transmitter’s terminal blocks. Is the terminal
voltage above 17.5 V at less than 8 mA current and
above 12.7 V at more than 8.5 mA current? Does HART®
operate at any current? Disconnect the transmitter’s
supply, then reconnect it. Did HART® become
operational?

Содержание SMART-PULP

Страница 1: ...s 4 3 Checking the operation of force measurement and current output 4 4 Adjusting the position of the display unit 4 5 Replacing the sensor blade 5 PARTS LIST 6 TECHNICAL SPECIFICATIONS 7 APPLICATIONS 7 1 Applications of different sensors 7 2 Materials for wetted parts WARNING Before disconnecting or installing the transmitter ensure that the process pipe is empty and depressurized Observe the sa...

Страница 2: ...m and flow velocity must be as shown in the APPLICATION chapter If required the pipe diameter can be altered so as to achieve the desired flow velocity Pulp flow must be laminar The pipe should have sufficiently long straight sections of uniform diameter both upstream and downstream from the transmitter Fig 1 1 1a Figure 1 1 1a Determination of coefficient k as a function of pulp consistency and f...

Страница 3: ...ipe is too short for alternative B1 Installation on the top side of the pipe always requires careful consideration because a substantial buildup of air in the pipe may affect the measurement accuracy We do not recommend this installation method C You may consider this option when horizontal and vertical sections before the transmitter are too short The double bend before the measurement point will...

Страница 4: ... will ensure sufficient flow velocity See Figure 1 1 2d This pipe section usually includes other devices such as a flowmeter and control valve Recommended installation order is shown in Fig 1 1 2d To protect the sensor the deflector blade supplied with the transmitter must always be installed in high consistency applications where standard process coupling is used In digester blow line installatio...

Страница 5: ... Consistency Transmitter Figure 1 1 2e Low consistency measurement with bypass line SMART PULP UL ςς5 C P M O S M A L R C L 1 699 MW STEAM POWER M A L FLOW Option DN100 min 1000 min 1500 A B 40 2 Cs DN25 pipe 3 Cs DN32 pipe 3 Cs DN40 pipe ...

Страница 6: ...ting the process The deflectors must be centered exactly in line with the process coupling The deflectors have Ø5 mm holes to facilitate installation for instance you may insert a piece of wire through the holes In exceptional cases when process pressure exceeds 10 bar and or there is exceptionally strong vibartion it is advisable to reinforce the mounting of the process coupling with a reinforcin...

Страница 7: ...astic pipe is illustrated in Figure 1 1 3e First make a bevelled hole in the pipe Then laminate the process coupling carefully on the pipe in accordance with lamination instructions Figure 1 1 3c Installation for SMART PULP WS Figure 1 1 3b Reinforcing the process coupling 7 D pipe s inside diameter s pipe s wall thickness Io width of reinforcing ring h thickness of reinforcing ring NOTE If the pi...

Страница 8: ...th mounting clamp Before tightening the screws ensure that the transmitter s sensor blade is parallel to the direction of flow 1O Use a ruler placed against the bottom of the aligning slot to align the sensor Apply 25 N torque to tighten the screws Note When required the process coupling can be shut with a blind flange Figure 1 1 3d Installation of SMART PULP HL in digester blow line 8 3 1 4 2 3 w...

Страница 9: ...he inlet Use the inlet that points to the side or downwards Leave an extra loop of cable outside the transmitter as reserve and to conduct drain water out Tighten the inlet nut and ensure that the inlet is properly sealed Make the connections as shown in Figures 1 2 1a and b Connect the groundings in accordance with the control system s instructions The remote operator terminal cable shield must b...

Страница 10: ...mA Test Test Figure 1 2 1c SMART PULP electrical connections SMART PULP end of the connection cable wiring for remote operator terminal if the remote operator terminal is used SMART PULP s operator terminal wiring connections remote or local open 0 closed 1 Load Recipe selection Transmitter housing To control system open sampling ON closed sampling OFF To NOVE Sample valve ON OFF 8 7 6 5 1 2 3 4 7...

Страница 11: ...nd the cor responding displays Steps A1 through A6 below describe the actions in more detail More detailed instructions for the menus are found in the chapter Transmitter Functions Menus which gives a detailed description of the Calibration Configuration Diagnostics and Measurement menus PROCEDURE A1 Switch on the transmitter Press MODE and to access the CONFIGURATION menu The text CONFIGUR is dis...

Страница 12: ...efiner mechanical pulp freeness more than 200ml CSF CTMP Chemithermo mechanical pulp RCFU Recycled fiber unscreened contains debris RCFS Recycled fiber screened ROCCU Recycled fiber packing board unscreened OCC ROCCS Recycled fiber packing board OCC screened 12 Even if there is filler you may accept 0 00 as filler content provided that you do not want to change the filler content later without sam...

Страница 13: ...oke ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ESC ESC ENTER ENTER ENTER ENTER Disp text CONFIGUR CALIBRAT NEW RECI RECIPE1 RECIPEn ULIN xxxxx ASH0 0 ASH0 0 P1 1 000 P2 0 000 SAVE OK NEW RECI CALIBRAT MEASURE x xx Cs RECIPE1 RECIPEn SAVE OK NOT CALIB x xxx Cs Description See the NOTE on the page 12 E g recipe number 1 can be accepted Default curve unlinearized shear force signal 0 30 N 0 100 ...

Страница 14: ...boratory Press to display the menu text LABORATO Accept the selection by pressing ENTER Then use the arrow keys to get the correct recipe number i e the same on which the samples were taken and which you want to calibrate The displayed default number should be correct unless the recipe number has been changed since sampling Press ENTER to accept the recipe number The text ASH 0 0 is displayed If y...

Страница 15: ...n completed it is recommendable to write down all recipes pulp type filler P1 and P2 as well as the configuration Standby transmitter can then be made operational with minimum effort Notes Configuration and calibration of standby transmitter used to replace a faulty transmitter B B If the new transmitter s sensor blade has been replaced by the customer or if there is otherwise reason to suspect er...

Страница 16: ...ty is connected to SMART PULP s supply lines it displays the following menu SMARTPULP tag Online 1 Measurement 2 Configuration 3 Calibration 4 Diagnostics With the UP and DOWN keys you can select the desired submenu If you are taking the transmitter into use for the first time you must first select the Configuration menu When the menu is selected you can go there with the RIGHT arrow key This will...

Страница 17: ...tion codes Can be changed by user Final asmbly num Year week in transmitter s serial number Cannot be changed 17 To change an item select the desired line with the cursor and then press the RIGHT arrow key Press the LEFT arrow or ENTER to exit the menu Pressing the RIGHT arrow key at 3 Calibration in the main menu will open the following menu SMARTPULP tag Calibration 1 New recipe 2 Sampling 3 Lab...

Страница 18: ...ce status indicates what faults the transmitter has detected in its own operation These are indicated with the text ON In connection with HART communications the fault are normal and do not require any actions 18 Pressing the RIGHT arrow key at 2 Sampling opens the following two options 1 Start sample 1 2 Start sample 2 With these options you can start average consistency and standard deviation ca...

Страница 19: ...g Device info New recipe Sampling Lab results Special grade Tmpr calib Loop test Device status Low Rnge Upp Rnge LSL USL Min span Damping Alarm current Mounting Blade type Blade material Poll addr Manufacturer Model Sensor ser n o Tag Message Universal rev Fld dev rev Software rev Hardware rev Descriptor Date Device code Final asbly num Recipe 1 Recipe 8 Pulp Ty Filler P1 P2 Start sample 1 Start s...

Страница 20: ...OK enter CS MA G or N S F or C P F or C H F or C RECIPE n ASH MEASURE enter CONFIGUR enter LOWER RA UPPER RA DAMPING LANGUAGE UNITS MOUNTING PASSWORD HART ADD BLADE TY ALRM TYP TAG TMTRTYPE TMTRVERS enter enter CALIBRAT NEW RECI SAMPLING LABORATO SP GRADE DIAGNOST MESSAGES MA LOCK TRIM F TRIM MA DIG INPT COMMUNIC esc enter enter SAVE OK enter esc esc enter Return to previous opti on or menu level ...

Страница 21: ...ith arrow keys Pulp s consistency percentage see note above mA output signal Display in per cents of span Shear force G grammes N Newtons NOTE The displayed shear force is already process temperature corrected shear force Force sensor s temperature C C and F F Pulp temperature C C and F F Electronics temperature C C and F F Recipe selection NOTE When performing calibration the recipe to be calibra...

Страница 22: ...s other than 000 the prompt PASS 0 will be displayed when you change other parameters To answer the prompt give the correct number combination with the arrow keys and then press ENTER Default 000 HART address 0 15 or optionally the next item MODB ADD Default 0 i e normal installation with a single transmitter Sensor blade type LL JL GL etc and material AISI TITANium and HASTElloy Default the suppl...

Страница 23: ...s of consistency samples The tuning is done either as single point calibration to define the zero offset P2 or as two point calibration where you also define the curve s slope correction P1 see Fig 1 3b The original curve s P1 1 and P2 0 In sample based calibration SMART PULP will itself calculate corrections P1 and P2 in accordance with laboratory results and samples You can save 1 8 calibrations...

Страница 24: ...that force measurement has been calibrated in the way described in the DIAGNOSTICS chapter by changing P2 manually For example if you increase the value of P2 by 0 1 the consistency reading will increase by 0 1 Cs at every consistency level In other words you can make the required zero correction without other calibration measures Figure 2 3b SMART PULP Calibration menu esc enter Return to previou...

Страница 25: ...moved in the direction of consistency so as to effect a zero offset at the calibration point to eliminate the difference between measured consistency and sample consistency The slope of the curve does not change The value of P2 changes in accordance with the zero offset while the value of P1 slope factor stays unchanged In single point calibration you can also take two samples and use the one take...

Страница 26: ...open the sampling period will exactly match the consistency measurement period This is indicated by a small square at the bottom of the display the square is open at the moment of sampling and closed when the valve is closed Unconnected input 4 equals 0 V i e valve is open 1 CS X XX Average consistency for the sampling period Press an arrow key to proceed 1 Sd X XX Standard deviation Blinking Sd d...

Страница 27: ...ation or if a new special sensor blade is used with an older transmitter the SPecial GRADE menu offers you the chance to correct the curve of recipe No 1 through a max 16 point offset table Through the table you enter the known consistency offsets relative to the calibrated curve at the desired consistency levels You apply the offset value of the table s minimum non zero consistency level for cons...

Страница 28: ...al times over the sample receptacle The sample flow should be as high as possible but the sample should not splash from the receptacle Too small flow may dilute the sample 5 Representative sample to laboratory Sedimentation will occur if the sample is allowed to remain at standstill even for a short time Always stir the sample with special care when separating a smaller portion from a large sample...

Страница 29: ...ough inlet plugs in the inner cover The electronics housing is fastened with screws to the inner cover The electronics units are attached with screws to the electronics housing at the bottom and supported through an O ring on cover 1 at the top The wiring from the electronics to the terminal board passes through oil resistant radio interference filters The operator unit is locked in position in th...

Страница 30: ...stration s plane Mounting clamps and screws and nuts Process coupling Overload protection Taper pin Sensor mounting nut Cover 1 Electronics Electronics housing Electronics mounting screws 3 Expansion diaphragm Electronics housing mounting screws 2 Lock ring Inner cover Damping oil Inner body Body Lock nut Counter pin Process gasket Process temperature transducer Inlet diaphragm s rim gasket Inlet ...

Страница 31: ...UPPLY 3 W RS485 PROCESSOR BOARD PROCESSING UNIT arithmetics serial communication output control EEPROM Processor data HART MODEM HART signal conditioner OPERATOR UNIT SENSOR BOARD 4 20 mA output EEPROM sensor data ADC DAC FORCE TRANSDUCER force measurement Force transducer temperature measurement Process temperature measurement Electronics temperature measurement ESC MODE ENTER COMM COMM TEST TEST...

Страница 32: ...ll HART transmitters while others are transmitter specific commands that require software adapted for the particular transmitter SMART PULP supports both classes It also permits the sending of transmitter specific special commands from a standard programming unit For this reason older programming units can also be used for comprehensive control of the SMART PULP transmitter 4 1 Troubleshooting The...

Страница 33: ... is provided with the TRIM F and TRIM MA functions for trimming these outputs The need for calibration depends on the individual transmitter Stability in force measurement is better than 0 25 max per 6 months which corresponds to 7 5 g per 6 months in shear force Normal regular consistency calibration will rectify the effect of the force transducer s zero drift on consistency measurement but if yo...

Страница 34: ...d adjusting to zero the unweighted 1 WEIGHT command Then select and confirm the 2 WEIGHT command The weight measured by the transmitter is now displayed Allow the reading to become stable and then use the arrow keys to adjust for the correct reading i e the same as the applied weight Accept this value and then accept SAVE and USE BOTH NOTE Stable reading before usng the arrow keys In both cases SM...

Страница 35: ...1 1 1 3 1 106 112 113 114 115 116 117 118 120 122 123 124 125 126 127 128 129 130 131 132 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Retaining ring HL UL sensor JL sensor LS sensor GL sensor RL sensor WS sensor HL sensor LL sensor Inlet gland Cover with window Remote operator terminal case and cover Mounting clamp assy Coupling WS coupling Blow line coupling JL coupling titanium Plug Gl...

Страница 36: ...y Transmitter MO DE EN TER C OMM C OMM TE S T TE S T 27 124 27 81 122 103 131 96 125 31 94 22 126 90 32 123 82 103 120 81 122 103 131 103 91 105 39 37 129 80 38 36 128 42 76 127 93 130 117 118 106 116 115 114 113 112 Figure 5 SMART PULP Parts list 36 ...

Страница 37: ...0 2000 Hz 0 03 N 6 TECHNICAL SPECIFICATIONS Materials Housing AISI 316L and aluminium alloy Wetted materials AISI 316L Hastelloy C276 or titanium Gaskets wetted PTFE and special material Enclosure class IP66 NEMA 4X Weights SMART PULP WS with local operator unit 6 2 kg SMART PULP WS with remote operator unit 7 4 kg Other SMART PULP types with local operator unit 4 8 kg Other SMART PULP types with ...

Страница 38: ...e system 4 20 mA HART Display and operator unit RD SMART PULP with remote operator unit ID SMART PULP with local operator unit Process coupling and its material NO No process coupling SS Standard AISI316L LL LS UL GL RL HL TI Standard Titanium LL LS UL GL RL HL HC Standard Hastelloy C276 LL LS UL GL RL HL SB Blow line installation for HL sensor AISI316L SW For WS sensor AISI316L TJ For JL sensor T...

Страница 39: ...8 78 140 80 110 Sensor Dimension H from edge of coupling LL 95 LS 70 UL 95 GL 95 RL 95 JL 95 Standard coupling JL 57 Plastic pipe coupling HL 60 Standard coupling HL 38 Blow line coupling WS 75 SMART PULP with local operator terminal SMART PULP without operator unit Used with remote operator terminal SMART PULP s remote operator terminal Length of connecting cable 9 75 m ...

Страница 40: ...ess application deflector is not used with UL and JL sensors SMART PULP s operator unit is mounted either on the transmitter or optionally in a wall box remote operator unit 7 1 Applications of different sensors SMART PULP is supplied with different optional sensor types Fig 7 1a Figures 7 1b show the flow velocity and consistency ranges best suited for the different sensor options and pulp types ...

Страница 41: ... appended table Figure 7 1b Flow velocities consistency ranges pulp types for different sensor options cont on next page SMART PULP UL 1 2 For pulps A B F G and L 1 For pulps C D and J For pulp E and L For pulp K SMART PULP LL SMART PULP LS 1 2 For pulps A and B 2 For pulps C and D 1 For pulp G 1 2 For pulp L For pulps F and G ...

Страница 42: ...low velocities consistency ranges pulp types for different sensor options cont from previous page SMART PULP RL For pulps A and B 1 2 For pulps C and D 1 For pulps E and F 1 2 3 For pulp J 1 3 4 For pulp K 1 2 For pulp L SMART PULP GL SMART PULP WS 1 2 For pulps A and B 1 For pulp G 1 2 For pulps C D E 1 For pulp F 1 2 3 For pulps J and K For pulps H and I ...

Страница 43: ...0 1 2 3 4 5 6 7 8 1 For pulps C D E and K 1 2 For pulps L J and F 1 2 3 For pulps A B and G 4 Also suitable for this zone when flow velocity variation is max 1 2 1 2 For pulps A and B 1 For pulps C and D 0 7 3 0 7 3 1 3 1 3 1 4 0 7 3 0 7 3 1 3 1 5 0 7 3 1 5 6 1 5 6 1 8 5 1 8 5 1 5 4 5 1 5 5 5 1 7 7 1 7 7 1 8 7 5 1 8 7 5 1 8 7 5 1 5 6 5 1 5 5 1 5 8 1 8 8 3 6 3 6 1 5 6 1 5 6 1 7 6 5 1 7 6 5 1 7 5 1 ...

Страница 44: ...et Automation Ges m b H Franzosengraben 12 A 1030 Vienna Austria Tel 431 79 552 0 Telefax 431 79 552 28 FRANCE Valmet Automation France Bordeaux Technowest Les Cinq Chemins B P 34 33186 Le Haillan France Tel 33 57 921040 Telefax 33 57 921042 GERMANY Valmet Automation GmbH Grünwalder Weg 28 b D 82041 Oberhaching Germany Tel 49 89 6138080 Telefax 49 89 61380855 JAPAN Valmet Automation K K Aoyama Kob...

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