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K-Patents PR-43-AC Instruction Manual

Sanitary process refractometer
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Sanitary Process Refractometer PR-43-AC/AP
Instruction Manual
IM-EN-PR43ACAP: Rev. 1.08
Effective: September 20, 2016

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Summary of Contents for K-Patents PR-43-AC

  • Page 1 Sanitary Process Refractometer PR-43-AC/AP Instruction Manual IM-EN-PR43ACAP: Rev. 1.08 Effective: September 20, 2016...
  • Page 2 General safety considerations The process medium may be hot or otherwise hazardous. Use shields and protective clothing adequate for the process medium - do not rely on avoid- • ance of contact with the process medium. • Precautions when removing a refractometer from the process line : Check first that the process line is depressurized and drained.
  • Page 3 Full warranty information is available in the Support section of http://www.kpatents.com. Please note that prior to shipping any products or items to K-Patents, a Request for Return Materials Authorization (RMA) must be filled in and submitted to K-Patents Order Handling department.
  • Page 4 Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 5: Table Of Contents

    3.3.1 PR-43-AC model code ........11 3.3.2...
  • Page 6 PR-43-AC/AP instruction manual Refractometer verification ........52 PR-43 refractometer verification form .

  • Page 7: Refractometer

    1 Refractometer 1 Refractometer The sanitary refractometers PR-43-AC and PR-43-AP provide a digital interface detec- tion system for alimentary industry. The PR-43-AC/AP (figure 1.1) measures the refractive index n and the temperature of the process medium. The concentration of the process liquid is calculated from these values when the composition of the process medium is known.

  • Page 8: Mounting

    Important: If the process pipe vibrates, support the pipe. A vibrating pipe might dam- age the in-line refractometer mounted on it. A K-Patents inline refractometer can be located either indoors or outdoors in most cli- mates. However, when a refractometer is located outdoors, some basic protection against direct exposure to sunlight and rain should be provided.

  • Page 9: Check List For Mounting In A Tank, A Vessel Or A Large Pipe

    The inserted probe refractometer is mounted close to a stirrer to ensure represen- tative sample of the process liquid and to keep the prism clean. The refractometer should be conveniently accessible for service. © Copyright K-Patents 2016. All rights reserved.
  • Page 10 PR-43-AC/AP instruction manual Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 11: Electrical Connections

    Figure 2.3 for the wiring when only analogue output is used. Options for connecting the refractometer with both analogue and digital outputs are shown in Figure 2.4. Both Compact user interface CI and Multichannel user interface MI use the digital output signal. © Copyright K-Patents 2016. All rights reserved.
  • Page 12 Cables PR-43 REFRACTOMETER M-12-8 pin, A-code, M PR-8431 non-Ex Split cable M12 M12-8 pin, A-code, F PR-43-AC/AP instruction manual Ethernet (M12-4 pin, D-code,M) mA, 24V 10m (33ft) m (33ft) PR-43 REFRACTOMETER PR-8431 M-12-8 pin, A-code, M Split cable M12...
  • Page 13 2 Mounting Figure 2.4 Wiring options when both analogue and digital outputs are used © Copyright K-Patents 2016. All rights reserved.
  • Page 14 PR-43-AC/AP instruction manual When a refractometer is connected to a computer or another device with RJ45 port, an ethernet converter cable is needed as well as the split cable. Figure 2.5 Connecting the refractometer with network converter Document/Revision No. /1.08 Effective: September 20, 2016...

  • Page 15: Specifications

    3.2 Refractometer rangeability The refractive index standard range of a PR-43-AC/AP is 1.320-1.530 (corresponds to 0-100 Brix), Figure 3.1, with a Sapphire prism. A PR-43-AC can also be equipped with a Sapphire prism with a refractive index range 1.260-1.470. PR-43-AC-74 PR-43-AC-73 1.25...
  • Page 16 PR-43-AC/AP instruction manual Figure 3.2 PR-43-AC dimensions Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 17: Pr-43-Ac Model Code

    EHEDG option -EH = EHEDG Type EL class I Certified Model Polishing option -EP = Electropolished refractometer wetted parts (Ra 0.4 µm, 15 µ inch) (A) EHEDG certified version available (B) Sanitary 3-A certified © Copyright K-Patents 2016. All rights reserved.

  • Page 18: Pr-43-Ac Mounting Hardware Model Code

    PR-43-AC/AP instruction manual 3.3.2 PR-43-AC mounting hardware model code Mounting hardware (without wash nozzles) MODEL AND DESCRIPTION MODEL AFC = Elbow flow cell Refractometer connection -H = Sanitary 3A clamp, 2 1/2 inch Construction material SS = AISI 316 Process connection...
  • Page 19 -PG = Plug for nozzle connection (A) with -SI option only Example: Refractometer:PR-43-AC-73-H25-P15 Flow cell: AFC-HSS-H20-SI Note: Prism wash control and diagnostics require the use of a Multichannel user in- terface MI (or customer’s own control system). © Copyright K-Patents 2016. All rights reserved.
  • Page 20 PR-43-AC/AP instruction manual Mounting hardware, mini flow cell MODEL AND DESCRIPTION MODEL MFC = Mini flow cell Refractometer connection -H = Sanitary 3A clamp, 2 1/2 inch Construction material SS = AISI 316 Process connection -H = Sanitary 3A clamp Pipe section diameter 05 = 15 mm (½...

  • Page 21: Pr-43-Ac Specifications

    (A) Includes one 2½ inch blind flange with 2½ inch EPDM gasket and 2½ inch sanitary clamp is included 3.3.3 PR-43-AC specifications Standard Optional REFRACTOMETER PR-43-A PR-43-AC Compact model for small pipelines Models Refractive Index range Full range, n = 1.3200...1.5300 1.2600...1.4700.
  • Page 22 PR-43-AC/AP instruction manual Standard Optional Patented CORE-Optics No mechanical adjustments and digital measurement with 3648 pixel CCD element, sodium D-line light emitting diode (LED) built-in Pt-1000 temperature sensor (linearization according to IEC 751). Temperature compensation Automatic, digital compensation. Instrument verification With NIST traceable Cargille standard R.I.

  • Page 23: Pr-43-Ac Parts List

    13.1 P4 connector & cable set (general purpose, Ex nA) PR-14101 13.2 P4 connector & cable set (Ex ia) PR-14101-EX PR-43 sensor cover PR-14000 O-ring 68x3 FPM PR-10048 O-ring 14x1,78 FPM PR-14102-FPM Disk spring Figure 3.3 Refractometer cover assembly © Copyright K-Patents 2016. All rights reserved.
  • Page 24 3.1 H73 Optics module PR-14020 3.2 H74 Optics module PR-14022 Sensor head 4.1 PR-43-AC-H25-SS head PR-10001 4.2 PR-43-AC-E25-SS head PR-10028 4.3 PR-43-AC-H25-HC head PR-10001-HC 4.4 PR-43-AC-E25-HC head PR-10028-HC 4.5 PR-43-Z25-SS head Figure 3.4 PR-43-AC assembly Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 25: Pr-43-Ac Mounting Specifics

    (a ferrule, length 21.5 mm, is delivered with standard refractometer delivery from K- Patents). For smaller pipe diameters, flow cells are available from K-Patents, Figures 3.6, 3.7, 3.8 and 3.9. The flow cells are exchangeable with standard 90° bend pieces.
  • Page 26 PR-43-AC/AP instruction manual Figure 3.5 Mounting with sanitary ferrule Pipe diameter 3" (80 mm) or more Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...
  • Page 27 Sanitary clamp 1"/1.5" AISI304 Customer PR-03-A/PR-23-AC sensor K-Patents AFC-HSS-H10/H15-SI/RI Flow cell AISI316L K-Patents Material General tolerances Scale Join File AISI316L MTG428.drw Drawing description AFC-HSS-H10/H15-SI/RI Drawn 1.9.2004 HS Drawing number MTG428/B Appr. 1.9.2004 HS © Copyright K-Patents 2016. All rights reserved.
  • Page 28 PR-43-AC/AP instruction manual Rev. Date Rev. by Appr. Mark SECTION A-A SCALE 1 : 2 AFC-H10/H15-SI-NC AFC-H10/H15-RI-NC Flow ce ll type Flow ce ll type AFC-H10-RI-NC AFC-H10-RI-NC 16 [0.630] 16 [0.630] 22.6 [0.890] 25.6 [1.008] 22.6 [0.890] 25.6 [1.008] 50.8 [2] 50.8 [2]...
  • Page 29 AFC-HSS-H20-SI 48.6 48.6 51.6 89.0 AFC-HSS-H20-RI 35.6 AFC-HSS-H25-SI 60.3 60.3 64.1 108.0 Figure 3.8 Flow cell AFC-HSS- H20 for pipe diameter 2" (50 mm) and H25 for pipe diameter 2 1/2" (65 mm) © Copyright K-Patents 2016. All rights reserved.
  • Page 30 PR-43-AC/AP instruction manual SECTION A-A SCALE 1 : 2 Flow cell type 45° 48.6 51.6 89.0 AFC-HSS-H20-SI-NC 48.6 AFC-HSS-H20-RI-NC 35.6 48.6 51.6 89.0 60.3 64.1 108.0 AFC-HSS-H25-SI-NC 60.3 SECTION B-B SCALE 1 : 5 Figure 3.9 Flow cell AFC-HSS- with wash nozzle connection (-NC) H20 for pipe diameter 2"...
  • Page 31 SFC-HHSS-H10-180 90° SFC-HHSS-H15-090 1,5" PR-9212 PR-9211 Sanitary 180° SFC-HHSS-H15-180 refracto- PR-9202 PR-9201 PR-9200 meter 90° SFC-HHSS-H20-090 2" PR-9222 PR-9221 180° SFC-HHSS-H20-090 90° SFC-HHSS-H25-090 2,5" PR-9202 PR-9201 180° SFC-HHSS-H25-090 Figure 3.10 Side flow cells © Copyright K-Patents 2016. All rights reserved.
  • Page 32 PR-43-AC/AP instruction manual K-Patents Sanitary Refractometer PR-43-AC-Z is mounted using 3-A Sanitary certified 2.5 inch Cherry Burrell I-Line fittings that are made of interlocking flat face ferrules, a flat gasket and a clamp. This interlocking, metal-to-metal design eliminates over com- pression by the clamp not allowing the gasket to be extruded into the product contact side.

  • Page 33: Mounting Specifics For Ehedg Certified Pr-43-Ac Configuration

    3 Specifications 3.3.6 Mounting specifics for EHEDG certified PR-43-AC configuration K-Patents offers certain PR-43-AC configurations which have been certified to fulfill the sanitary requirements published by EHEDG (European Hygienic Engineering & Design Group) organization. During this certification the hygienic characteristics of both the refractometer and the process connection were evaluated against the applicable re- quirements.
  • Page 34 PR-43-AC/AP instruction manual TYPE EL CLASS I November 2015 No Item Material 1 Sensor PR-43-AC 2 Sanitary ferrule 2 1/2" ISO 2852 AISI 316L ISO2852 type 3 Sanitary gasket 2 1/2" EHEDG certified Figure 3.12 Mounting with sanitary ferrule Pipe diameter 3" (80 mm) or more EHEDG certified configuration...

  • Page 35: Sanitary Process Refractometer Pr-43-Ap

    3 Specifications 3.4 Sanitary process refractometer PR-43-AP The K-Patents sanitary probe refractometer PR-43-AP provides an accurate in-line Brix measurement in cookers, tanks and large pipelines. The PR-43-APT refractometer ver- sion can be installed through an APV Tank bottom flange. It is flush mounted in the side wall and it allows the use of scrapers and mixers.
  • Page 36 PR-43-AC/AP instruction manual Figure 3.14 Flush mounted refractometer PR-43-AP-T10-L00 Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 37: Pr-43-Ap Model Code

    -L63 = insertion length 63 mm (A) (C) -L63 -L170 = insertion length 170 mm (A) (C) -L170 Insertion length, models T10-P15 -L00 = flush mount insertion length (C) -L100 -L170 = insertion length 170 mm (B) -L170 © Copyright K-Patents 2016. All rights reserved.
  • Page 38 PR-43-AC/AP instruction manual Insertion length, models E25-P15 -L170 = insertion length 170 mm (A) (C) -L170 Insertion length, models V25-P15 -L170 = insertion length 170 mm (B) -L170 Insertion length, models I-clamp Z25-P15 -L178 = insertion length 178 mm (C)
  • Page 39 -WP = integral high pressure water cleaning nozzle -WN = integral warm water cleaning nozzle -YC = no integral nozzle connection Note: Prism wash control and diagnostics require use of Multichannel user interface MI (or customer’s own control system). © Copyright K-Patents 2016. All rights reserved.

  • Page 40: Pr-43-Ap Mounting Hardware Model Code

    PR-43-AC/AP instruction manual 3.4.2 PR-43-AP mounting hardware model code Mounting hardware for PR-43-AP refractometer Part number and description Part No. VFMA-T10 = MT4 DN25/1T APV tank bottom flange for PR-43-AP T10 VFMA-T10 VFBP-T10 = blind flange for MT4 DN25/1T APV tank bottom flange...
  • Page 41 UDP/IP Protocol connection for data acquisition. Power supply +24 VDC ±10%, max. 2 VA INTERCONNECTING CABLES Standard length 10 m. Single cable maximum length 90 meters, with cable extender PR-8660 maximum length 90+90 meters. © Copyright K-Patents 2016. All rights reserved.

  • Page 42: Pr-43-Ap Parts Lists

    PR-43-AC/AP instruction manual 3.4.4 PR-43-AP parts lists Item Description Part no. Screw M4x10 DIN7380 Torx tamper proof PR-14003 PR-43 end plate PR-14001 Dryer pack PR-9108 PR-43 sensor interface card PR-43 interface card (Ex ia) PR-50011 mA-output card (general purpose, Ex nA)
  • Page 43 PR-23-AP-SSS head PR-10024 PR-43-AP-H40-L63 PR-23-AP-ISS head PR-10025 PR-43-AP-H25-L42 PR-23-AP-BSS head PR-10026 PR-43-AP-T10-L170 4.10 PR-23-AP-HSS head PR-10027 PR-43-AP-H25-L14 4.11 PR-23-AP-CSS head (DN65 Varivent head) PR-10029 PR-43-AP-E25-L170 4.12 PR-23-AP-ZP head PR-10046 PR-43-AP-Z25-L178 Figure 3.16 PR-43-AP assembly © Copyright K-Patents 2016. All rights reserved.

  • Page 44: Pr-43-Ap Mounting Specifics

    To ensure that the measurement is representative and that the prism stays clean, the probe should be installed close to a stirrer. K-Patents probe refractometer type PR-43-AP-H25 is connected to the process by a 2½inch 3-A sanitary clamp. Note: For higher process (or ambient) temperature, use instead a flush mounted re- fractometer, where the electronics in the refractometer head are farther away from the process heat.
  • Page 45 3 Specifications Figure 3.18 Flush mounting Probe refractometer PR-43-AP-T10-L100 K-Patents Sanitary Refractometer PR-43-AP-Z is mounted using 3-A Sanitary certified 2.5 inch Cherry Burrell I-Line fittings that are made of interlocking flat face ferrules, a flat gasket and a clamp. This interlocking, metal-to-metal design eliminates over com- pression by the clamp not allowing the gasket to be extruded into the product contact side.
  • Page 46 PR-43-AC/AP instruction manual Figure 3.19 I-Line fitting for PR-43-AP SECTION A-A Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...

  • Page 47: Mounting Specifics For Ehedg Certified Pr-43-Ap Configuration

    3 Specifications 3.4.6 Mounting specifics for EHEDG certified PR-43-AP configuration K-Patents offers certain PR-43-AP configurations which have been certified to fulfill the sanitary requirements published by EHEDG (European Hygienic Engineering & Design Group) organization. During this certification the hygienic characteristics of both the refractometer and the process connection were evaluated against the applicable re- quirements.
  • Page 48 K-Patents offers a 3-A Sanitary Standard accepted repair and maintenance package in which all wetted parts, prism, gaskets and dryer are replaced. Note that this repair service can be completed by 3-A authorized service center only (K-Patents factory or regional headquarters).

  • Page 49: Prism Wash

    4 Prism wash Prism wash requires a system for wash control and diagnostics. This can be achieved with K-Patents Multichannel user interface (MI) with a relay module. 4.1 Prism coating Deposit build-up on the prism surface disturbs the measurement. An abnormally high concentration reading, an upward concentration (CONC) drift, decreased QF value or increased LED value may indicate coating.

  • Page 50: Recommended Wash Pressures And Times

    Note: In water wash, water temperature should be above the process temperature. Note: The K-Patents check valve pressure drop is 0.7 bar (10 psi). 4.2.2 Prism wash systems The prism wash system for steam is described in Figure 4.1. The prism wash system for high pressure water is described by Figure 4.3.
  • Page 51 Warning! In high pressure wash systems, pressure increase can occur in a closed pipe section when the high pressure pump is operated. K-Patents recommends to mount a pressure relief valve in the pipe section. Relief pressure should be according to pipe pressure rating.
  • Page 52 PR-43-AC/AP instruction manual Figure 4.1 A prism wash system for steam Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...
  • Page 53 4 Prism wash Figure 4.2 Wiring for a prism wash system for steam © Copyright K-Patents 2016. All rights reserved.
  • Page 54 Safe water for sanitary use. No. Description Supplied by Qty 1 PR-43 refractometer K-Patents 2 Multichannel user interface K-Patents 3 Power relay unit PR_3603-300-U/M-230/110 K-Patents 4 Platform 4 cable PR-8430 K-Patents 5 Relay cable 3x1 (AWG 17) Customer 6 Power supply for MI Customer 6.1 Power supply 100-240 VAC/50-60 Hz...
  • Page 55 4 Prism wash Figure 4.4 Wiring for a prism wash system for high pressure water © Copyright K-Patents 2016. All rights reserved.

  • Page 56: Prism Wash Nozzles

    PR-43-AC/AP instruction manual 4.2.3 Prism wash nozzles When selecting a wash nozzle for PR-43-AP, take into account both the wash medium and the flowcell model: flowcells with larger pipe diameters need longer wash nozzles. Figure 4.5 below shows a wash nozzle for a flowcell and gives the measurements and part numbers for each nozzle type.
  • Page 57 Figure 4.6 Process connection of a wash nozzle in a flowcell For PR-43-AP, select the wash nozzle according to wash medium, see Table 4.1 below. PR-43-AP Steam nozzle PR-9321 Water nozzle PR-9320 Pressurized water nozzle PR-9322 Table 4.1 Prism wash nozzle selection © Copyright K-Patents 2016. All rights reserved.
  • Page 58 PR-43-AC/AP instruction manual 5 Refractometer verification Each K-Patents refractometer is provided with a calibration certificate comparing a set of standard liquids to the actual refractometer output. Therefore, the calibration and accuracy can be easily verified on-site with the certified refractive index liquids and K-Patents documented and menu guided verification procedure.
  • Page 59 The refractometer’s serial number is shown in the upper right corner of each display. The list of CCD and TEMP values are found on the Verification results display. Send the form to K-Patents or your nearest K-Patents representative or email the collected data to info@kpatents.com and wait for further instructions.
  • Page 60 PR-43-AC/AP instruction manual Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...
  • Page 61 Fill in this form and email (or fax) it to your local service representative. For contact information, please see http://www.kpatents.com/. Refractometer serial no: Customer: Address: Fax: Email: Date: Verification made by: VERIFICATION RESULTS DISPLAY Sample no Nominal n Measured n Temp 1.330 1.370 1.420 1.470 1.520 © Copyright K-Patents 2016. All rights reserved.
  • Page 62 PR-43-AC/AP instruction manual Document/Revision No. /1.08 Effective: September 20, 2016 IM-EN-PR43ACAP...
  • Page 64 K-Patents Oy K-Patents, Inc. K-Patents (Shanghai) Co., Ltd P.O. Box 77 1804 Centre Point Circle, Room 1509, FI-01511 Vantaa, Finland Suite 106 Tomson Commercial Building, No.710 tel. +358 207 291 570 Naperville, IL 60653, USA Dongfang RD fax +358 207 291 577 tel.

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