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Summary of Contents for metso automation kajaaniMCAi
- Page 1 Installation, operating & service manual W4610201 V2.5 EN - for software version 2.5–>...
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Page 2: Table Of Contents
7.A. First Calibration ..........7.1 Introduction 7.B. Modifying the Calibration ........7.2 7.C. Calibration and Sample History ......7.2 1.A. The kajaaniMCAi Consistency Analyzer .... 1.1 1.B. Measurement Principle ........1.1 Data Collection Construction 8.A. Trend Table ............8.1 2.A. -
Page 3: Caution / Warning
Wrong connection may damage the equipment! The applicable electrical safety regulations must be closely followed in all installation work! Before any welding works in the vicinity of the devices, make sure that operating voltage is not connected! kajaaniMCAi – Installation, Operating & Service WARNINGS... -
Page 4: Introduction
In addition, the measure- v = c / e ment is independent of pulp type and flow rate. The kajaaniMCAi is available in two different sen- where c = velocity of light in vacuum; ε sor types: MCAi -F & MCAi-FS (Fork type), and = dielectric constant of the medium. -
Page 5: Construction
2. Construction The kajaaniMCAi consists of the sensor unit and Dis- play Unit. Two sensor types are available: the flow- through MCAi -FT and the fork-type MCAi -F. The sensor type to be used is chosen according to the diameter of the process pipe. -
Page 6: Sensor Electronics
2.C. Sensor Electronics Both sensor types use similar sensor electronics, with 2.C.1. Reset-Abort procedure three units mounted on top of each other: the Micro- NOTE: This will erase all stored configurations from the wave Module, Main Board, and Processor Board. In memory and initialize the device with system defaults! addition, a MIMO Control Board is mounted on top of 1. -
Page 7: Mcai Display Unit + Shield
2.D. MCA i Display Unit + Shield The MCAi Display Unit is used as a fixed display, alongside a Communicator-i or HART communicator. The required information is selected on the 8-digit display using four function keys for operation. One function key is also used for taking samples. The MCAi Display Unit uses mains voltage (90... -
Page 8: Installation
3. Installation NOTE: Before installing the process coupling / sensor, NOTE: The MCAi-F /-FS sensors cannot be used for make sure that the process pipeline is not pressurized measuring unscreened pulps! and installation will be safe! 3.A. General Principles 3.B. MCA i -F /-FS The sensor type is selected according to the diameter of The fork-type sensors MCAi -F and MCAi-FS are the process pipeline at the installation point. -
Page 9: Mcai -Ft
3.C. MCA i -FT When installed, the flow-through sensor forms part of the process pipeline (Fig. 3.2). The sensor must be installed so that the coupling of the Pt-100 temperature sensor (inserted at an angle into the pipe) faces down- stream. -
Page 10: Display Unit + Shield
3.D. Display Unit + Shield 3.E. Shield for Communicator The shield protects the Display Unit from damage. If the Communicator (option) will be used, choose a Choose an easily accessible location, and mount the location close to the Display Unit and mount the shield on the wall with three screws. -
Page 11: Electric Connections
3.F. Electric Connections 3.F.2. Current signals NOTE: Before connecting the mains power wires, make The consistency current signal can be taken either from sure that the wires are not powered! the MCAi Display Unit or from the Field Connection Board (sensor electronics). Current signals for temper- NOTE: First complete all connections and ensure that ature and chemical concentration can only be taken the mains voltage selector is set correctly –... - Page 12 3.F.3. Alarm output 3.F.6. Communicator-i Connect the alarm output to the sensor’s Field Connec- Connect the Communicator-i to the terminal located on tion Board. The alarm output can be either normally- the lower edge of the MCAi Display Unit; Fig. 3.6. closed or normally-open.
- Page 13 Field Connection Board of sensor electronics 2 4 V D C 2 4 V D C I N P U T O U T R E S E T R S - 2 3 2 H A R T A B O R T 2 2 2 3 2 4 2 5 2 6 2 7 3 7 3 8 3 9 4 0 4 1 Display Unit R S - 2 3 2...
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Page 14: Start-Up
4. Start-up 4.A. Mechanics Check 4.D. Checking Electric Operation 1. Make sure that the delivery is consistent with the 1. Plug the Communicator-i to the quick connector on order. the bottom of the Display Unit. 2. Check the equipment for damage that may have 2. -
Page 15: User Interfaces & Operating
5. User Interfaces & Operating 5.A. User Interfaces & Communication 5.B. Communicator-i Three alternative ways can be used to configure the The Communicator-i is shown in Fig. 5.1. sensor and to monitor its measurements: Plug the Communicator-i to the quick connector on the bottom of the Display Unit. -
Page 16: Communicator-I Setup Menu
5.C. Communicator-i Setup Menu If the Communicator-i main menu does not appear on the screen when the terminal is connected to the Display SETUP: Unit, the basic setup is probably incorrect. To check the setup press [ENTER] while switching F1: BAUDRATE: 9600 BD F2: EMULATION: TVI-925... -
Page 17: Main Menu
MAIN MENU Selfdiagnostics Take sample Enter lab (Error Table) Start Stop Special Settings Erase functions Chemical compensation Trend Temp.e compensation curve Latest Cal. in table Filler content: analog input sample Sample taking: binary input Recipes * Calibr. Sensitivity coefficient* History * password 0 Sample History... -
Page 18: Operating With Display Unit
5.F. Operating with Display Unit The Display Unit functions as a fixed display for MCAi measurements. The Display Unit can also be used for M C A some operations – sample taking, reading measured values, self-diagnostics, and device information – so C S = 3 . -
Page 19: Configuration
5. User Interfaces & Operating 6. Configuration 6.A. Initial Configuration of Sensor When the sensor has been installed to the process, it can 6.A.2. Sensor type be powered up. The sensor software has been designed Sensor type is selected from the display shown in Fig. in such a way that the compulsory configuration must 6.2. - Page 20 6.A.3. Device info (Enter date, time...) The display shown in Fig. 6.3 contains settings for date, Enter date, time ... time, temperature unit, tag number, installation point, Date: 17-10-00 Time: 10:20 and password. Use the UP/DOWN arrow keys to move from field to field, and press [ENTER] to accept the Installation info: “MCAI DESCRIPTOR”...
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Page 21: Current Output Scaling
6.B. Current Output Scaling The MCAi Field Connection Board contains current outputs for consistency, temperature, and the relative chemical content measurement. Current output 2 is isolated, current output 3 non-isolated. A current output for consistency is also provided among the connections on the Display Unit. - Page 22 6.B.3. Scaling the current output for chemical con- tent => C => N => N Press [F1&F2] E to edit the output. URRENT UTPUT (Current output 3, Fig. 6.8). 1. Enter the signal level corresponding to the low limit This output indicates variations in the chemicals (4mA).
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Page 23: Editing Device Information
6.C. Editing Device Information 6.D. Reset-Abort => S (Fig. 6.10). => S (Fig. 6.10). ELFDIAGNOSTICS ETTINGS ELFDIAGNOSTICS ETTINGS Device information can be edited in the “Settings” Press [F7&F8] R to reset the settings. ESET BORT display. Press [F1&F2] E to start editing. Type the The software will ask for confirmation before proceed- required values with the keypad;... -
Page 24: Calibration
7. Calibration 7.A. First Calibration The MCAi is calibrated using single-point calibration; 7.A.2. Entering laboratory result only one sample at some process consistency level is Go from M => E => L NTER LAB ATEST SAMPLE needed. In addition, the laboratory consistency value of When calibrating for the first time, the laboratory the process sample is needed. -
Page 25: Modifying The Calibration
7.B. Modifying the Calibration 7.C. Calibration and Sample History If calibration remains inaccurate for some reason, a All samplings and changes to calibration are stored as constant level difference will be observed between the history data in the memory. The data can be scrolled measured consistency and the laboratory analysis re- using the following displays. - Page 26 7.C.2. Sample history Go from M => E => S NTER LAB AMPLE HISTORY (Fig. 7.5). The taken samples are stored in the history table, arranged according to the date of sampling. The display shows the following data: • Sample: date and time of sampling. •...
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Page 27: Data Collection
8. Data Collection 8.A. Trend Table => S => T (Fig. The following measured values will be shown for ELFDIAGNOSTICS REND TABLE 8.1). the time indicated by the cursor: The MCAi stores measurement results in a trend • MCA: measured process consistency (%). table which can be scrolled using this display. -
Page 28: Special Functions
9. Special Functions 9.A. Special Functions 9.B. Chemicals compensation Go from M => S => S 9.B.1. Principle ELFDIAGNOSTICS PECIAL (Fig. 9.1). Large variations in the chemicals content of the pulp FUNCTIONS The “Special functions” menu contains functions affect the measurement of microwave propagation time. for chemical content and temperature compensation, As a result, the MCAi will show a too high reading filler content, sampling, recipes, and sensitivity coeffi-... - Page 29 9.B.2. Setting chemicals compensation 9.B.3. Performing chemical compensation In the example shown in Fig. 9.2, the calibration points Go from M => S => S ELFDIAGNOSTICS PECIAL are selected from the laboratory follow-up data as => C (Fig. 9.4). FUNCTIONS HEMICAL COMPENSATION follows: The graph shows the total error (MCA –...
- Page 30 Sample taking Press “Start sample 1/2” NOTE: Enter data on two sample points selected from Sample 1: not taken laboratory follow-up data (see section 7.A.2), or take new Sample 2: not taken calibration samples as described below. Cs % Temp Sig.lev u Compens.
- Page 31 9.C. Correction Curve for Temperature Com- If required, chemicals compensation can be deacti- pensation vated in the “Chemical compensation” menu (Fig. 9.4) by pressing [F7&F8] T . The “Chemical com- URN OFF Water temperature affects the propagation velocity of pensation” display then reads “Not in use”, and the microwaves.
- Page 32 Example 1. NOTE: Make sure that you use the same “MCAi – Lab” The normal process temperature is 40...50°C value for the last two points! Otherwise the correction (104...122°F) but drops temporarily to 20°C (68°F) curve will continue using the slope between the last two when the process is started up.
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Page 33: Recipes
9.D. Recipes The recipe function can be used when the process Selection mode: binary inputs conditions vary so much that one calibration cannot When this selection mode is used, the MCAi will use cover the entire range. Such process changes may be the recipe number set to binary inputs bin1...bin3 caused by a conductivity or temperature change that (where input bin1 is the least significant). - Page 34 9.D.4. Naming a recipe 9.D.5. Connecting binary inputs Name the recipes as follows: The binary inputs are isolated. The recipe number can 1. In the “Recipe” menu press [F7&F8] E be entered either from the mill system or manually with DIT RECIPE a switch.
- Page 35 9.D.6. MCAi recipe selector 9.D.7. Automation system Fig. 9.12 shows an example of connecting the MCAi- Connect the binary outputs from the automation system recipe selector to the binary inputs. directly to the binary inputs of MCAi Field Connection Connect the operating power and the positive poles Board.
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Page 36: Filler Correction Through Analog Input
9.E. Filler Correction through Analog Input The MCAi is less sensitive to fillers than to fibers. In Scale the voltage into a filler content value as follows: practice the sensor measured slightly over a half of a 1. Go from M =>... -
Page 37: Sampling Signal To Binary Input
9.F. Sampling Signal to Binary Input If samples for laboratory follow-up are taken from the MCAi measurement point, information of sampling STARTING SAMPLING THROUGH BINARY INPUT should also be taken to the MCAi. This ensures that at the time of sampling the MCAi will store its measure- Binary inputs line: BIN4 ment results (consistency, temperature, signal level,... -
Page 38: Sensitivity Correction
9.G. Sensitivity Correction Connecting the binary input In the connection shown in Fig. 9.15, the sampler As the main applications of the MCAi are in the pulp controls a switch which receives +24V voltage from the and paper industry, its consistency sensitivity is tuned MCAi Field Connection Board. -
Page 39: Self Diagnostics
10. Self Diagnostics 10.A. Self-Diagnostics Functions 10.B. Error Table Go from M => S (Fig. 10.1). Go from M => S (Fig. 10.1). ELFDIAGNOSTICS ELFDIAGNOSTICS This display contains functions necessary for the This display shows the error messages, if errors have monitoring and testing of the MCAisensor. -
Page 40: Simulation Cable Test
10.C. Simulation Cable Test 10.D. Error Limits Go from M => S => S Go from M => S => S ELFDIAGNOSTICS ETTINGS ELFDIAGNOSTICS ETTINGS => S (Fig. 10.2). => D (Fig. 10.3). IMUL CABLE IAGN LIMITS The simulation cable test can be used to check for Limits and functions for each error can be config- possibly faulty sensor electronics;... -
Page 41: Troubleshooting & Service
The signal level can be The kajaaniMCAi does not require any regular main- increased by performing a new start-up (section 6.A) at tenance. This chapter contains instructions for possible the new, higher signal level. -
Page 42: Error Messages Of Selfdiagnostics
11.B. Error Messages of Selfdiagnostics 11.A.5. Antenna contamination Contamination problems will appear as an upwards When the sensor’s self-diagnostics detects a fault, the drift of the measurement. If the antenna gets cleaned current signal is set to the selected fault status (0, 4, 20 from time to time, for example when the wood species mA, or freeze) and gives an alarm through the alarm changes, the drift may disappear. - Page 43 Two red wires and two white wires are connected to Temperature measurement error Process temperature measured by the sensor is below the connector. The wires must be connected alternately: 0°C (32°F). Possible causes: red – white – red – white. It does not matter which color •...
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Page 44: Replacing Components
11.C. Replacing Components The following sections contain instructions for the replacement of sensor electronics, antenna cables, and antennas of the flow-through sensor. The antennas of the fork-type sensor are not included in spare parts, and they must always be replaced by the manufacturer. The following instructions apply for all MCAi sensor types. - Page 45 • Installing: 11.C.1. Replacing the Electronics Unit (Fig. 11.2) • Removing: NOTE: When tightening the connectors, only use the 1. Switch power off from the sensor. special torque spanner provided for this purpose! 2. Remove the sensor sensor cover assembly. 1.
- Page 46 NOTE: The outlet pipe blows hot air! Make sure that there are no cables or other objects touching the tube or close to its outlet end. Fig. 11.3. Installing a Vortex cooler to an MCAi-FT sensor. - 11.6 - kajaaniMCAi – Installation, Operating & Service W4610201 V2.5 EN...
- Page 47 6. Carefully detach the Pt-100 wire from the groove 11.C.5. Replacing a Pt-100 temperature sensor in on the bottom plate. MCAi-FT 7. Detach the bottom plate assembly from the sensor NOTE: The process pipeline must be empty when the body (4 outermost hex socket screws). temperature sensor is replaced! 8.
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Page 48: Hart® Communication
The HART communicator is connected parallel to the current signal line, for example to the HART connectors on the kajaaniMCAi Display Unit. From version V1.4 upwards, the kajaaniMCAi software is Fig. 12.1. HART® communicator. provided with device-specific HART programming. In... -
Page 49: Starting Up
If all functions of a menu cannot be displayed at the Temp. units same time, a downward arrow symbol will appear in the Select the required temperature unit, °C or °F. bottom left corner of the display. Press the DOWN arrow key to scroll all functions on the display. -
Page 50: Operating
12.B. Operating 12.B.1. Reading the measured values 12.B.2. Calibration The MCAi reports the measured values in the M Consistency calibration of the MCAi is made using the EASURE menu (Fig. 12.4). Menu items: menu shown in Fig. 12.5. MENTS ALIBRATION •... - Page 51 Entering laboratory values Correcting the calibration When the laboratory analyses are ready, select C If the first calibration is inaccurate for some reason, ALIBRA => L and the display shown in Fig. 12.6 laboratory follow-up will show a continuous level TION AB RESULTS will appear.
- Page 52 12.B.3. Scaling and configuring the current out- Current output for consistency Select C and enter the following data: puts ONS RANGE VALUES The current outputs for consistency, temperature and • LowRnge: measurement result corresponding to ® 6 HART user interface chemicals content are scaled in the C the low limit (4 mA) of the current signal.
- Page 53 12.B.4. Diagnostics Device values The D menu is shown in Fig. 12.8. From this menu you can read the following measured IAGNOSTICS The first two functions (temperature & chemicals values: compensation) are described in section 12.C of this • Mlev = measurement signal level (u), manual.
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Page 54: Special Functions
12.C. Special Functions The following functions can be used to eliminate the chemicals content) is on the X-axis. The graph should disturbing effect of various process variables. then be a rising straight line; the error (MCAi – Lab.) Chemicals compensation may be needed if the grows when conductivity increases. - Page 55 • Compensation with HART • Entering laboratory values When using the HART communicator, proceed as Select D => C . => L IAGNOSTICS COMP AB RESULTS follows: In the D menu select C the display shown in Fig. 12.12 will appear. IAGNOSTICS COMPEN with the cursor and then press the RIGHT arrow...
- Page 56 • Changing the compensation Chemicals compensation can be changed by either changing the values of existing calibration points, or by MCAi: MCAI-000 determining new calibration samples as instructed above. Select: When taking new calibration samples, remember that Show Values the MCAi treats the calibration samples as a sample pair Edit Values –...
- Page 57 12.C.2. Correction curve for temperature compen- • Example 1. The normal process temperature is 40...50°C sation Water temperature affects the propagation velocity of (104...122°F) but drops temporarily to 20°C (68°F) microwaves. The sensor therefore measures process when the process is started up. The graph (MCAi – Lab temperature with a Pt-100 temperature sensor, and Cs vs.
- Page 58 • Example 2. • Adjusting the temperature compensation curve The process temperature is in the range 20...25°C To change the temperature compensation, edit the (68...77°F), and thus errors in the temperature compen- existing curve. In this mode you can edit the existing sation can be expected.
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Page 59: App. 1 - Technical Specifications
App. 1 - Technical specifications - A1 - kajaaniMCA i – Installation, Operating & Service W4610201 V2.5 EN... -
Page 60: Mcai-Ft 150&6
Page 1 (1) kajaaniMCAi Technical Specifications Measuring range ......0 – 75 % (if >15 % consult Alarm output ......open/closed contact, with Metso Automation) 48VDC/0.5A Repeatability........±0.01% Cs Binary inputs......4 inputs, isolated, 12–48 VDC Sensitivity........0.001 % Cs Analog Inputs......2 inputs, one isolated, one not isolated Ambient temperature....-20...+50°C (-4...+122°F) -
Page 61: App. 2 - Contents Of Delivery
App. 2 - Contents of delivery - A2 - kajaaniMCA i – Installation, Operating & Service W4610201 V2.5 EN... - Page 62 –FS AISI 316L or M800530 kajaaniMCAi –FS Hastelloy C276 or M800560 kajaaniMCAi –FS Titanium GR3 M800219 kajaaniMCAi –F /FS installation set AISI 316L or M800220 kajaaniMCAi –F /FS installation set Hastelloy C276 or M800221 kajaaniMCAi –F /FS installation set Titanium GR 2 M800502 MCAi Display Unit + 10 m sensor cable Operating power cabling 90...260 VAC...
- Page 63 HA RT Select Code Item symb. Metso Cust. M800512 kajaaniMCAi –FT 150/6" or M800513 kajaaniMCAi –FT 200/8" M800502 MCAi Display Unit + 10 m sensor cable Operating power cabling 90...260 VAC Current output cabling Alarm output cabling Binary input cabling...
- Page 64 –FT100/4" PN16 or M800514 kajaaniMCAi –FT 250/10" PN16 or M800515 kajaaniMCAi –FT 300/12" PN16 or M800526 kajaaniMCAi –FT 100/4" ANSI class 150 or M800524 kajaaniMCAi –FT 250/10" ANSI class 150 or M800525 kajaaniMCAi –FT 300/12" ANSI class 150 or M800550 kajaaniMCAi –FT 100/4"...
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Page 65: App. 3 - Mcai-Ft Construction Drawing
App. 3 - MCA i -FT construction drawing No ... Code ....Item ..........Standard ......pcs 1 ..5060011 ..Spring washer ....... DIN 127-B4 A4 ......8 2 ..5060014 ..Lockwasher ........DIN127-B8 A4 ......16 3 ..5160015 ..Slothead screw ......DIN 84-M4x8 A4 ..... 8 4 .. -
Page 66: App. 4 - Spare Parts
App. 4 - Spare parts - A4 - kajaaniMCA i – Installation, Operating & Service W4610201 V2.5 EN... - Page 67 A4611041 Microwave Cable Set for MCAi FT 300 V2.0 Other Spare Parts Code Description M800505 MCAi Communicator P4610004V1.0 M800502 Display Unit A4610933 Display Unit Front Panel © Metso Automation Manufacturer reserves the right to changes without prior notice. A4 Spareparts...
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Page 68: App. 5 - Installation Instruction
App. 5 - Installation instruction - A5 - kajaaniMCA i – Installation, Operating & Service W4610201 V2.5 EN... - Page 69 Installing an MCAi-F / MCAi-FS consistency sensor Check List for MCAi installation Installation dimensions of the sensor MCAi-F &FS process coupling NOTE: Before any installation work, make sure that the process pipeline is not pressurized Installing (welding) the process coupling to a horizontal pipeline: 2 7 0 m m 2 7 2 m m and that the installation will be safe!
- Page 70 Installing an MCAi-FT consistency sensor Check List for MCAi installation Installation dimensions of the sensor • When choosing the installation point, pay attention to the space required for the sensor. NOTE: Before any installation work, make sure that the process pipeline is not pressurized and that the installation will be safe! •...
- Page 71 MCAi-FT 100/4", 250/10" & 300/12" – installation dimensions MCAi-FT 150/6" & 200/8" – installation dimensions Model L/mm L/inch 150/6” 6 57/64 Model L/mm L/inch 200/8” 8 55/64 100/4” 11 13/16 250/10” 275 10 13/16 300/12” 350 13 25/32 D1/mm D2/mm D3/mm 150/6"...
- Page 72 Installation and connections of MCAi sensor Electric connections Connection between MCAi Field Connection Board and Display Unit Installing the Display Unit and its shield NOTE: Before connecting the mains 1. Choose an easily accessible location, and mount the shield on the wall with three screws. power wires, make sure that the wires 2.
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Page 73: App. 6 - Specifications, Communicator-I
App. 6 - Specifications, Communicator-i - A6 - kajaaniMCA i – Installation, Operating & Service W4610201 V2.5 EN... - Page 74 Keypad..........Membrane keypad Dimensions (h x w x d) ...... 180 x 198 x 40 mm (6 5/16” x 7 51/64” x 1 37/64”) Weight............1.4 kg (3.1 lbs) © Metso Automation Manufacturer reserves the right to changes without prior notice. Communicator _specs.doc...
- Page 75 Manufacturer reserves the right to alter the contents of this document without prior notice. Modbus is the trademark of Modicon Inc. Copyright © January 2002. Metso Automation Inc., Field Systems Division. Documentation: Creabyte Ay. Translation: Marjo Nygård.
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