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KxS DCM-20 User Manual

Inline optical brix monitor
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USER'S MANUAL
DCM-20 INLINE OPTICAL BRIX MONITOR
KXS TECHNOLOGIES
v.1.09/2022

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Summary of Contents for KxS DCM-20

  • Page 1 USER’S MANUAL DCM-20 INLINE OPTICAL BRIX MONITOR KXS TECHNOLOGIES v.1.09/2022...

  • Page 2: Table Of Contents

    Introduction ............................1 Connection ..........................2 Sensor connectors ........................2 Sensor integration concept ......................3 Cable connection with electrical modules ................. 4 System drawing of DCM-20 and Modular Connection Unit ............6 User interface ..........................7 1.5.1 PC/Computer setup ......................7 1.5.2 External display setup ......................
  • Page 3 Display options for User Interface access................33 6.2.1 Computer or mobile device with display and RJ45 Ethernet cable ........ 33 6.2.2 WLAN for remote access with Computer or mobile device ..........34 6.2.3 Industrial touch panel display specifications ..............40 6.2.4 Industrial Panel PC display with IP65 protection .............
  • Page 4 Only licensed or authorized personnel may install or connect electrical components. Follow local and state legislation and regulations. DCM-20 overvoltage is category I and pollution degree 2. High pressure Always ensure that the process piping and steam/hot water wash lines are un-pressurized and empty of liquid before mounting/removing the inline optical sensor in/from process piping.

  • Page 6: Introduction

    The sensor calibration is performed with NIST traceable standard refractive index liquids and a defined process at KxS Technologies’ technology center. The inline optical Brix monitor DCM-20 includes an integrated pT-1000 temperature element for process temperature measurement and simultaneous automatic temperature compensation of the Brix concentration measurement.

  • Page 7: Connection

    1. Connection The inline optical Brix monitor DCM-20 operates with 24VDC input power supply. The communication signal is transferred through either an analog 4-20mA port, or a digital Modbus TCP port. Respective shielded connector port carries a 24VDC input power supply pinout. When the analog output port is chosen, the other digital port is used as a service channel for sensor parameter and diagnostics update in the user interface on a computer web browser, external display, or mobile device.

  • Page 8: Sensor Integration Concept

    1.2 Sensor integration concept Inline optical Brix monitor DCM-20 is 3-A and EHEDG certified. The stand-alone optical sensor is connected directly to 1.5” or larger process pipes. Single piece flow cells SPC are available for 1” or larger pipes. The SFC is with an optional optical window wash nozzle mount. Sensor mounting instructions found in section 2.

  • Page 9: Cable Connection With Electrical Modules

    RJ-45 connector SP-9310 (Fig.5) in Pin no. 1-4 according to the wiring schedule in Fig. 4. The corresponding color coding is found on the RJ-45 connector SP-9310 with A coding. An assembled M12 cable with RJ-45 connector is available from KxS Technologies upon request.
  • Page 10 4+1 ports (Part No: SP-9320), and Universally configurable limit value switch with 1x relay output (Part No: SP-9700). The inline optical Brix monitor DCM-20 can be configured with high and low measurement alarms as described in section 4.4.3, as well as optical window wash system as described in section 3.3 and its user interface configuration in section 4.4.4.

  • Page 11: System Drawing Of Dcm-20 And Modular Connection Unit

    Each MCU can be mounted in a stainless-steel enclosure with IP66, NEMA 4x classification. Figure 4 System drawing of inline optical Brix monitor DCM-20 and Modular Connection Unit MCU. DWG No. 10176.

  • Page 12: User Interface

    192.168.0.100. is entered in the address field of a computer web browser, external display, or mobile device. The homepage offers access to measurement values and diagnostics, configuration of parameter and verification of sensor calibrations. KxS Technologies recommends using Google Chrome or Microsoft Edge web browsers.

  • Page 13: External Display Setup

    In the PC Start menu by typing Ethernet, the IP setting window is accessed. By going to Change adapter settings Ethernet Ethernet Properties , a window will open where is chosen. A new window for Internet Protocol Version 4 (TCP/IPv4) opens, where is double-clicked.
  • Page 14 To set up the display panel’s IP address go to section Network and dial in settings as in Fig 10. Select Static IP. IP address with 192.168.x.y where x.y is any other ending than the corresponding for the sensor .10.20. Subnet Mask 255.255.255.0. Confirm by pressing √. Figure 8 Display IP settings in section Network and connecting display to sensor IP in section Web application.

  • Page 15: Mobile Device Setup

    1.5.3 Mobile device setup A mobile device with a USB-C port can be connected for accessing the user interface. An Ethernet cable from the industrial switch is connected through a standard RJ-45 to USB-C adapter. The USB-C connector is connected to the mobile device. The mobile device is set to Airplane mode. Following the Settings mobile device path from left to right in Fig.

  • Page 16: Inline Brix Monitor Dcm-20 Mounting

    2. Inline Brix monitor DCM-20 mounting The inline optical Brix monitor DCM-20 can be mounted straight into process pipe sizes of 1.5” or larger. For 1” or smaller pipe sizes and optical window wash nozzle connections, the sensor is mounted with flow cells designed by KxS Technologies.

  • Page 17: Flow Cell Mounting

    Single piece flow cells SFC are designed for 1”, 1.5”, 2”, 2.5” and 3” pipe sizes. The SFC is mounted with corresponding sanitary tri-clamp connections to the process pipe. DCM-20 inline optical Brix monitor is mounted with a 1.5” sanitary half-flange to the SFC. When a single piece flow cell SFC is chosen, the recommended mounting orientation is in a vertical pipe.
  • Page 18 In installations without sanitary requirements, a flange connected flow cell GFC with wash nozzle connection is available where the sensor is connected to the flow cell with 42.4 PN40 Sandvik L coupling. Figure 13. Flange Flow cell. DWG No. 10134.

  • Page 19: Optical Window Wash Nozzle Mounting

    2.3 Optical window wash nozzle mounting The wash medium needs to be specified with either steam or high-pressure water to determine the wash nozzle model. The wash nozzle is connected to the single-piece flow cell SFC through a sanitary mini clamp connection on the opposite side of the sensor. Note: During Steam in Place SIP or Clean in Place CIP it is essential that optical window wash is activated multiple times during SIP/CIP-cycle to ensure a clean nozzle before next process sequence.

  • Page 20: Wiring Drawing Of Modular Connection Unit System

    2.4 Wiring drawing of Modular Connection Unit system The wiring drawing consists of all standard modules for power supply, wiring, control, and converter modules. Components listed from bottom to up: 60W power supply unit 110-240V in 24V out SP-9400, limit value switches with analog mA input and relay output SP-9700, wire connection unit for 100-240V input, analog signal wiring output unit, patch panel for digital communication 4 wire free-end connection SP-9330, wire connection unit for 24VDC input and output, industrial ethernet switch SP-9320, digital communication protocol converter SP-9800.

  • Page 21: Prism Wash Systems

    3.1 Sensor optical window wash The inline optical Brix monitor DCM-20 can be equipped with a wash nozzle integrated in the Single- piece Flow Cell SFC for applications that requires an automatic wash of the optical window. The SFC design accommodates connections to process pipe sizes of 1”, 1.5”, 2”, 2.5”...

  • Page 22: Steam Wash System

    3.1.2 Steam wash system Figure 17 DCM-20 steam wash system. DWG No. 10168.

  • Page 23: Recommended Wash Settings

    3.2 Recommended wash settings: In limited demanding applications either high pressure water or steam wash medium is available for cleaning of the optical window. The recommended wash settings and times given in Fig. 20. Wash system parameters setting in DCM-20 Maximum Maximum...

  • Page 24: Modular Connection Unit For Wash Systems

    3.3 Modular Connection Unit for Wash Systems The optical window wash is functional through one of the sensor analog 4-20mA outputs. The sensor mA wiring is connected to a Modular Connection Unit MCU for Wash Systems. The unit consists of two modules: One or two analog limit value switches SP-9700 and 24VDC power supply SP-9400 in a rail mounted stainless steel enclosure assembly SP-8000 with IP66, NEMA 4X category.

  • Page 25: Calibration And Configuration

    4. Calibration and configuration The inline optical Brix monitor DCM-20 is factory calibrated for refractive index units RIU according to NIST traceable procedures. The DCM-20 is pre-calibrated for Brix according to ICUMSA references. The refractive index unit RIU and Temperature are used to convert the measurement to Brix. The factory Brix calibration is automatically temperature compensated.

  • Page 26: Diagnostics

    4.2 Diagnostics The optical image, measurements, and sensor internal diagnostics are useful in analyzing the sensor performance and application functionality. During process troubleshooting the optical image is a key indicator of measurement quality. The ‘Field sample’ button activates sampling of 10 measurement data points and calculates an average for display.

  • Page 27: Trend Plots

    4.3 Trend plots Realtime trends of user selected two measurement values (e.g., concentration and temperature) are Trends. available in page DCM-10 internal memory logs and stores 6000 measurement data points that can be saved in a txt file format. The storage interval is user selectable 1, 10 or 60 seconds. When the memory is full the log continues active, and old measurement points are over written.
  • Page 28 Figure 25 Trend data saved in txt file...

  • Page 29: Parameters Configuration

    4.4.1 User interface password Operating and changing DCM settings and parameters is password protected. The password Login is found in the user interface section Parameters/Special. Please consult KxS Technologies or its authorized local partner for the default password. Figure 26 DCM Login with password After the Login is activated, settings and parameters in the user interface can be changed.

  • Page 30: Calibration Parameters

    4.4.2 Calibration parameters Parameters Output In the user interface the mA configuration is found on page . The mA-output is user configurable for Brix, Temp, diagnostics, and Wash (of optical window). The range of chosen measurement value is user configurable to correspond the analog 4-20mA range. The sensor calibration is configured in three layers.

  • Page 31: Output Configuration And Analog Signal Settings

    4.4.3 Output configuration and analog signal settings Parameters/Output The mA output function is found in the user interface section . Two independent mA ports are available for user configuration. In the drop-down menu the selectable output functions are Concentration, Temperature, Quality of optical image, refractive index unit nD, diagnostics, automatic Wash functions of the optical window, and measurement low/high limit alarms.

  • Page 32: Configuration Of Low And High Alarms

    4.4.4 Configuration of low and high alarms Low and high alarm limit values are user selectable for measurements or diagnostics. The alarm limit settings are configured in Parameters/Output/Extras. Figure 30 User selectable alarm limit function. Simultaneously corresponding physical DIP switches are activated ‘ON’. When both low and high alarms are used, 2x limit value switches SP-9700 are connected in serial per wiring drawing in section 2.4, Fig.

  • Page 33: Configuration Of Optical Window Wash

    4.4.5 Configuration of optical window wash The optical window wash is functional through one of the sensor analog 4-20mA outputs. Wash times can be set in the user interface and controlled by external relay units. Parameters Outputs The configuration of wash parameters is found in the user interface on page Function Wash For the chosen mA output (1 or 2),...

  • Page 34: Display

    4.4.6 Display User selectable engineering units in a drop-down menu are available for display of concentration and temperature. The number of displayed decimals of the final output CONC is user selectable 1-6. Note! The displayed CONC engineering unit is not connected to the Chemical calibration parameters as described in 3.4.2.

  • Page 35: Software Update

    During the update progress the user interface should not be operated nor power to the DCM-20 interrupted. Once the update is successful, there is an indication of allowing for 10 seconds prior to rebooting the sensor through a power cycle. The sensor software version is visible in page Diagnostics.

  • Page 36: Digital Modbus Tcp Configuration

    5. Digital Modbus TCP configuration The DCM-20 digital output signal is designed with Ethernet communication in a Modbus TCP protocol. The protocol uses by default Port 502 as local port in the server. When configuring programmable logic controllers PLC, the DCM-20 measurement quantities are found in defined registers and addresses.

  • Page 37: Technical Specifications Of Modules

    6. Technical specifications of modules 6.1 Modular Connection Unit MCU Enclosure The power and communication modules in the Modular Connection Unit MCU are with DIN rail mounting and can optionally be mounted in a stainless-steel enclosure SP-8000 with protection category IP66, NEMA 4X certified by the enclosure manufacturer.

  • Page 38: Display Options For User Interface Access

    6.2 Display options for User Interface access KxS Technologies offers options for user interface displays. The user interface features and functions are identical regardless which option is chosen. Product certificates of modules and displays are available per the third-party manufacturer.

  • Page 39: Wlan For Remote Access With Computer Or Mobile Device

    6.2.2 WLAN for remote access with Computer or mobile device The Modular Connection Unit MCU stainless steel enclosure can be equipped with a WLAN wireless module SP-9600 Fig. 17 for wireless connection to a computer or mobile device with corresponding WLAN features.
  • Page 40 Note Degree of protection when installed Wireless interface Designation Wireless LAN Antenna connection method (Internal) Wireless standard IEEE 802.11 Frequency band 2.4 GHz 5 GHz Transmission power max. 20 dBm (EIRP) Number of wireless interfaces 1 IEEE 802. 11 a/b/g/n Wireless modules that can be connected 10 (In Access Point mode max.
  • Page 41 Assembly instructions Permanently installed Antenna Assembly instructions Internal antenna Number Connection method permanently installed Note on the connection method MIMO Gain 5 dBi Ethernet interface Interface Ethernet (RJ45) Number of interfaces Connection method RJ45 Note on the connection method Auto negotiation and autocrossing Transmission speed 10/100 Mbps Transmission physics...
  • Page 42 Current consumption max. 250 mA (at 18 V DC) max. 400 mA (at 9 V DC) Connection data Designation 1966101 FMC 1,5/ 3-STF-3,5 Connection method Push-in spring connection Conductor cross section solid min. 0.2 mm² Conductor cross section solid max. 1.5 mm²...
  • Page 43 Greece Great Britain Ireland Italy Latvia Liechtenstein Lithuania Luxembourg Malta Netherlands Norway Austria Poland Portugal Romania Sweden Switzerland Slovakia Slovenia Spain Czech Republic Hungary Cyprus (rep.) China Japan South Korea Thailand...
  • Page 44 Brazil Note Degree of protection when installed Standards and Regulations Mechanical tests Shock in acc. with EN 60068-2-27/IEC 60068-2-27 30g, 11 ms half-sine shock pulse Vibration resistance in acc. with EN 60068-2-6/IEC 60068-2-6 5g, 10 ... 150 Hz Continuous shock according to EN 60068-2-27/IEC 60068-2-27 10g, 16 ms, 6000 shocks Broadband noise according to EN 60068-2-64 Category 1, Class A Standards/regulations EN 61000-4-2...

  • Page 45: Industrial Touch Panel Display Specifications

    6.2.3 Industrial touch panel display specifications An external industrial display SP-9500 is available with a panel mount design and 7” touch display for user interface and measurement reading purposes with IP20 protection category. The display is powered with 24VDC. The display with a RJ-45 port is used for the sensor Ethernet cable connection. The touch panel unit can display four sensors by selecting respective sensor url line ‘active’...
  • Page 46 Reading angle right 85 ° Reading angle top 85 ° Reading angle bottom 85 ° Computer data Processor ® Cortex ® -A53, 4x 1.2 GHz Operating system Yocto/Linux User software Chromium Browser 1 GB LPDDR3 Mass storage Flash eMMC, 8 GB Network 1 x Ethernet (10/100 Mbps), RJ45 Interfaces...
  • Page 47 Shock DIN EN 60068-2-27 Device supply Supply voltage 24 V DC Supply voltage range 18 V ... 30 V Typical current consumption 0.4 A Power supply unit 24 V DC ±20 % Standards and Regulations Shock DIN EN 60068-2-27 Vibration (operation) DIN EN 60068-2-6 Environmental Product Compliance REACh SVHC...

  • Page 48: Industrial Panel Pc Display With Ip65 Protection

    6.2.4 Industrial Panel PC display with IP65 protection When an enclosure for the display is required, an external industrial 15” display SP-9540 is available with a panel PC of IP65 protection category. The panel PC holds an RJ-45 port for Ethernet cable connection from the Industrial Ethernet Switch SP-9320.
  • Page 49 Mass storage Configurable Network 2x Ethernet (10/100/1000 Mbps), RJ45 Interfaces 1x COM (RS-232/422/485) 2x USB 2.0 2x USB 3.0 Realtime clock Yes (battery-backed) Service life of battery 5 years (typical) General Note Assembly instruction: Arm/pole mount [A24] option is required to use the stack light, pushbuttons, and pole mounting.

  • Page 50: Limit Value Switch Specifications

    6.3 Limit value switch specifications Figure 42 Limit value switch. Universally configurable limit value switch with PDT relay output and plug-in connection technology for switching analog limit values. Configurable via DIP switch or software. Push-in connection technology, standard configuration. Dimensions Width 6.2 mm Height...
  • Page 51 0 mA ... 24 mA (can be set via software) max. input voltage 12 V Max. input current 24 mA Input resistance of voltage input > 120 kΩ Input resistance current input approx. 50 Ω (+ 0.7 V for test diode) Switching output Output name Relay output...
  • Page 52 Power consumption ≤ 0.5 W Connection data Connection method Push-in connection Stripping length 10 mm Conductor cross section solid 0.2 mm² ... 2.5 mm² (with ferrule) 0.14 mm² ... 2.5 mm² (without ferrule) Conductor cross section flexible 0.14 mm² ... 2.5 mm² Conductor cross section AWG 24 ...
  • Page 53 Fire protection for rail vehicles (DIN EN HL 1 - HL 2 45545-2) R22 Fire protection for rail vehicles (DIN EN HL 1 - HL 2 45545-2) R23 Fire protection for rail vehicles (DIN EN HL 1 - HL 2 45545-2) R24 Standards and Regulations Electromagnetic compatibility...
  • Page 54 Class I, Zone 2, Group IIC T4A Designation Shipbuilding approval Certificate DNV GL TAA000021E Temperature Humidity Vibration Enclosure Required protection according to the Rules shall be provided upon installation on board Environmental Product Compliance REACh SVHC Lead 7439-92-1 China RoHS Environmentally Friendly Use Period = 50 years For details about hazardous substances go to tab “Downloads”, Category “Manufacturer's declaration”...

  • Page 55: Sensor M12 Cable Specification

    6.4 Sensor M12 cable specification Dimensions Length of cable 10 m Ambient conditions Degree of protection IP65 IP67 Ambient temperature (operation) -25 °C ... 90 °C (M12 connector) General data Note Further products with variable cable type and variable cable length can be found in the accessories section Rated current at 40°C 0.5 A...
  • Page 56 Material (component) CuZn (Contact) Ni/Au (Contact surface) PA (Contact carriers) TPU, hardly inflammable, self-extinguishing (Grip) Zinc die-cast, nickel-plated (Screw connection) Insulation resistance ≥ 100 MΩ Insertion/withdrawal cycles ≥ 100 Torque 0.4 Nm Ambient temperature (operation) -25 °C ... 90 °C Shielded Outer sheath, material External sheath, color...
  • Page 57 Cable structure 4x2xAWG26/7; S/FTP Conductor cross section 4x 2x 0.14 mm² AWG signal line Conductor structure signal line 7x 0.16 mm Core diameter including insulation 1.04 mm Wire colors white/blue-blue, white/orange-orange, white/green-green, white/brown-brown Twisted pairs 2 cores to the pair Type of pair shielding Aluminum-lined foil Overall twist...
  • Page 58 66.3 dB (at 4 МHz) 61.8 dB (at 8 МHz) 60.3 dB (at 10 MHz) 57.2 dB (at 16 MHz) 55.8 dB (at 20 МHz) 54.3 dB (at 25 MHz) 52.8 dB (at 31.25 МHz) 48.4 dB (at 62.5 МHz) 45.3 dB (at 100 MHz) 40.8 dB (at 200 MHz) 39.3 dB (at 250 MHz)
  • Page 59 35.1 dB (at 300 MHz) 33.3 dB (at 400 MHz) 31.8 dB (at 500 MHz) Attenuation 3.1 dB (with 1 MHz) 5.7 dB (at 4 МHz) 8 dB (at 8 МHz) 8.9 dB (at 10 MHz) 11.2 dB (at 16 MHz) 12.6 dB (at 20 МHz) 14.1 dB (at 25 MHz) 15.8 dB (at 31.25 МHz)
  • Page 60 19 dB (at 100 MHz) 16.4 dB (at 200 MHz) 15.6 dB (at 250 MHz) 15.6 dB (at 300 MHz) 15.6 dB (at 400 MHz) 15.6 dB (at 500 MHz) Signal runtime 5.13 ns/m Shield attenuation ≥ 80 dB (at 30 ... 100 MHz) Nominal voltage, cable ≤...
  • Page 61 KxS Technologies Oy KxS Technologies LLC Zirkonipolku 2 A 1400 Roaring Fork FI-00170 Vantaa FINLAND 78641 Leander TX USA TEL. +358 50 343 7456 TEL: +1 480 390 2504 info@kxstechnologies.com info@kxstechnologies.com www.kxstechnologies.com...

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