Vaisala PR-33-AC User manual

Brand: Vaisala

Model: PR-33-AC

Type: User manual

IM-EN-PR33AC v. 2.00

Instruction Manual

Sanitary OEM Refractometer

PR-33-AC

PR-33-AC instrucon manual

Document/Revision No. Rev. IM-EN-PR33AC/2.00 Eecve: September 2, 2019

General safety consideraons

The process medium may be hot or otherwise hazardous. Use shields and

protecve clothing adequate for the process medium - do not rely on avoid-

ance of contact with the process medium.

Precauons when removing a sensor from the process line :

• Check rst that the process line is depressurized and drained.

• Loosen the owcell screws cauously, be prepared to ghten again.

• Ensure you are clear of any possible spillage and you have a clear emer-

gency escape path.

Warranty

For standard warranty terms and condions, see www.vaisala.com/warranty.

Please observe that any such warranty may not be valid in case of damage due to nor-

mal wear and tear, exceponal operang condions, negligent handling or installaon,

or unauthorized modicaons. Please see the applicable supply contract or Condions

of Sale for details of the warranty for each product.

Important: The warranty is void if the sensor has been taken apart or in any way

tampered with.

Disposal

When wishing to dispose of an obsolete instrument or any parts of an in-

strument, please observe local and naonal regulaons and requirements

for the disposal of electrical and electronic equipment.

This product manual is delivered to the end user with a Vaisala K-PATENTS® product.

Informaon in this manual is subject to change without noce. When the manual is

changed, a revised copy is published at hp://www.kpatents.com/.

Document/Revision No. Rev. IM-EN-PR33AC/2.00 Eecve: September 2, 2019

Table of contents

1 Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Instrument connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 mA output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.3 Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.3.1 Ethernet specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3.2 IP sengs for the Sanitary OEM Refractometer . . . . . . . . . . . . . . . . 4

2.3.3 IP sengs for a stand-alone computer . . . . . . . . . . . . . . . . . . . . . . . 5

2.3.4 Conguring a network of refractometers . . . . . . . . . . . . . . . . . . . . . 6

2.3.5 Tesng the Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3.6 Troubleshoong the connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Refractometer mounng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Choosing the refractometer mounng locaon . . . . . . . . . . . . . . . . . 9

3.2 Check list for pipe mounng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Refractometer wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Startup and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1.1 Inial check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1.2 Calibraon check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Viewing refractometer status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Instrument homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1 Main page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.3 Diagnoscs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3.1 Measuring eld samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.3.2 Opcal image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.4 Vericaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6 Conguraon and calibraon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1 Conguring the refractometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1.1 Signal damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1.2 Skip count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.2 Calibrang the concentraon measurement . . . . . . . . . . . . . . . . . . 24

6.2.1 The chemical curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.2.2 Field calibraon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.2.3 Direct bias adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.3 Default mA output value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7 Instrument vericaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.1 Refractometer vericaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

7.1.1 Handling the R.I. liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2 Vericaon procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.3 Vericaon report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7.4 Correcve acon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9 Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1.1 Message HIGH SENSOR HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1.2 Message HIGH SENSOR TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2.1 Message OUTSIDE LIGHT ERROR or OUTSIDE LIGHT TO PRISM . . . . . . . . . . 35

9.2.2 Message NO OPTICAL IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2.3 Message PRISM COATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.2.4 Message LOW IMAGE QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.2.5 Message NO SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.2.6 Message TEMP MEASUREMENT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.2.7 Concentraon dri during NORMAL OPERATION . . . . . . . . . . . . . . . . 37

9.3 Diagnosc messages table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10 Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10.1 PR-33-AC model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10.2 Mounng specics for EHEDG cered PR-33-AC conguraon . . 42

11 Ethernet protocol specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11.1 Communicaon protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11.1.1 Request format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11.1.2 Response format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

11.1.3 Request and response errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2 Request-response pair specicaon . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2.1 NULL message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2.2 Protocol version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2.3 Refractometer informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.2.4 Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11.3 Error message specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

12 Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

EC declaraon of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Sanitary OEM refractometer eld calibraon form . . . . . . . . . . . . . . . . . . . . . . . . 53

1 Introducon 1

1 Introducon

The inline Sanitary OEM Refractometer PR–33–AC (gure 1.1) measures the refrac-

ve index n

and the temperature of the process medium. The concentraon of

the process liquid is calculated from these values when the main components of the

process medium are known.

The output values of the sensor are transmied through a 4–20 mA output and an Eth-

ernet connecon by using a UDP/IP protocol (see chapter 11). An oponal mA output

unit is also available, if more than one current output is required.

Figure 1.1 Sanitary OEM Refractometer PR–33–AC.

2 PR-33-AC instrucon manual

Document/Revision No. Rev. IM-EN-PR33AC/2.00 Eecve: September 2, 2019

2 Instrument connecons

The instrument has three dierent connecons: power supply (+24 Vdc), 4 – 20 mA cur-

rent output, and an Ethernet connecon for digital data acquision and conguraon.

These connecons are grouped into two connectors so that one of the connectors car-

ries both the power supply and the current output. The other connector is an Ethernet

connecon.

Both connecons use the industrial M12 connector. The Ethernet connector has the

industry standard M12-Ethernet pin-out. The power supply and current output use an

A-coded M12 male on the instrument side. The Ethernet connecon uses a D-coded

female connector on the instrument side.

For the wiring details, please see gure 3.3.

2.1 Power supply

The Sanitary OEM Refractometer requires a 24 V DC power supply (allowable tolerance

is ±10 %). The current consumpon of the refractometer is less than 100 mA. The power

supply should be shielded from external voltage surges.

2.2 mA output

The mA output of the refractometer supplies voltage and it is galvanically isolated. The

compliance (maximum resisve load) for the output is 1000 Ω.

2.3 Ethernet connecon

The Ethernet connecon enables data download from a Sanitary OEM Refractometer

to a computer. Any type of computer (PC, Mac, PDA, mainframe...) with a compable

network connecon can be congured to view and download data from the refrac-

tometer. The Sanitary OEM Refractometer can be congured and monitored without

any special soware by using a standard web browser. Chapter 11 gives all the speci-

caons necessary to write a data acquision program.

2 Instrument connecons 3

2.3.1 Ethernet specicaon

The Sanitary OEM Refractometer is designed to be connected to a network with a stan-

dard Ethernet cable. The cable supplied with the instrument has an industrial M12

connector in the instrument and a RJ-45 connector in the other end. The maximum

communicaon speed of the refractometer is 100 Mbit/s (Ethernet 100BASE-T).

In the simplest form the network consists of one refractometer and one computer. This

conguraon is shown in gure 2.1.

Ethernet

cable

Figure 2.1 Simple network conguraon.

Several refractometers can be connected to the same Ethernet network. Also, the San-

itary OEM Refractometer has an automac funcon (known as Auto MDI/MDIX) to de-

tect the polarity of the network so that the network may ulize either cross-over or

straight interconnecng cables.

Figure 2.2 shows an example of how to connect three refractometers to an exisng LAN

with a switch.

Hub/Switch

LAN

Ethernet

cable

Ethernet

cable

Figure 2.2 Three refractometers in the same network.

4 PR-33-AC instrucon manual

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It is possible to use a WLAN access point to decrease the number of cables (gure 2.3).

WLAN

Access

point

Ethernet

cable

Figure 2.3 Connecng refractometer(s) via wireless.

The maximum distance of a single Ethernet connecon is 100 m (incl. one joint

adapter/coupler), but if longer distances are required, a ber link may be used to

extend the range (see gure 2.4). The range may be up to several kilometers with a

suitable ber connecon.

Fiber

Media

converter

Media

converter

Ethernet

cable

Figure 2.4 Using ber link to connect refractometer(s).

2.3.2 IP sengs for the Sanitary OEM Refractometer

All Sanitary OEM Refractometers are shipped with the factory default IP address of

169.254.23.33. This address belongs to the Zeroconf addresses (as dened in IETF

standard RFC 3927) so that it can easily be reached from a stand-alone computer (g-

ure 2.1), usually without changing the network sengs of the computer. This address

will remain in the instrument even aer a dierent IP address has been set. The sensor

answers in the address that is rst called up aer startup.

Note: If there are more than one Sanitary OEM Refractometers in the same network,

this address cannot be used (secon 2.3.4).

The IP address of the instrument can be changed through the instrument homepage

(see chapter 5).

2 Instrument connecons 5

2.3.3 IP sengs for a stand-alone computer

When a computer with automacal IP sengs (DHCP enabled) is turned on in a network

with only the Sanitary OEM Refractometer, the computer should automacally obtain

an IP address 169.254.x.x. In this case the factory default address of the refractometer

can be used for connecng without any further changes in sengs. If this does not

work, make sure that the WLAN (Wireless network connecon) is not acve on the

computer that is connected to the refractometer. If the WLAN is acve, the computer’s

Ethernet connecon may not funcon as expected. Also, obtaining the 169.254.x.x.

address may take up to a minute.

If the connecon to the instrument sll cannot be achieved, the computer’s IP ad-

dress can be checked by opening the command window (command prompt) and by

typing the command ipconfig at the command prompt (press Enter to give the com-

mand), see gure 2.5 (in Mac OS X and Linux the same command is called ifconfig).

The informaon given will include the computer’s IP address. If the address does not

start by 169.254, the IP address of the computer needs to be congured manually to

169.254.23.34, netmask 255.255.0.0.

For further troubleshoong, see secon 2.3.6.

Figure 2.5 Typical IP conguraon for a stand-alone laptop when connected to a

Sanitary OEM Refractometer; laptop wireless (WLAN) is turned o

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Note: The connecon will not work if the computer and the refractometer have exactly

the same IP address.

When the network sengs of the instrument (and/or the computer) have been con-

gured according to the instrucons above, the next step is to test the connecon as

instructed below in Secon 2.3.5.

2.3.4 Conguring a network of refractometers

In case there are more than one Sanitary OEM Refractometer in a network, their IP

addresses have to be congured manually as the factory default will not work.

If the Sanitary OEM Refractometer is to be connected to a factory network, consult the

network administrator for the correct sengs.

If the network is a stand-alone network with only one Sanitary OEM Refractometer and

one or more computers with no connecon to any other network, then the IP addresses

can be chosen rather freely. One possibility is to number the instruments so that they

all have 192.168.33.x addresses so that every computer and instrument has a dierent

number x between 1...254. The subnet mask (or netmask) is in this case 255.255.255.0

(see gure 2.6).

Hub/Switch

IP = 192.168.33.1

IP = 192.168.33.2

IP = 192.168.33.3

IP = 192.168.33.100

netmask = 255.255.255.0

Figure 2.6 A network of Sanitary OEM Refractometers.

Note: There are no sengs for subnet mask, default gateway or name servers in the

Sanitary OEM Refractometer, as these sengs are not required.

2.3.5 Tesng the Ethernet connecon

When the Sanitary OEM Refractometer is connected to a switch, the corresponding link

light should light up in the switch.

2 Instrument connecons 7

Once the refractometer is powered up, it should be reachable from any correctly con-

gured computer. Typing the IP address of the instrument to the address bar of a web

browser should bring up the instrument homepage (see chapter 5).

Note: The factory-default IP address of the Sanitary OEM Refractometer is 169.254.23.33.

This address should always respond (see secon 2.3.2).

2.3.6 Troubleshoong the connecon

In case the instrument cannot be reached through the network, check the following

things:

• the instrument receives power; the ethernet switch link light is lit.

• the network sengs of the computer are compable with those of the instrument

(secon 2.3.3)

• if the instrument should be at IP address 169.254.23.33, but cannot be reached,

check that there is only one Sanitary OEM Refractometer in the same network, as

otherwise there is an address conict

• check that the soware rewall of the computer does not block the connecons

A useful test to determine whether the problem is in network sengs is to set up a

small network. Perform the following steps:

• set up a network of only one Sanitary OEM Refractometer and one computer (g-

ure 2.1)

• check that the computer has suitable network sengs and that its WLAN connec-

on is turned o (secon 2.3.3)

• use the ping ulity of the computer to try and reach the refractometer

The ping ulity menoned above is in Windows systems available by using the Com-

mand Prompt (usually found in the Accessories; or open Run, type cmd in the empty

line and press enter to open Command Prompt). The usage of ping is very simple: go to

the command interface, type the name of the command and the IP address you want

to check and press Enter. If the Ethernet connecon is physically working and the ad-

dress given to ping is correct, the Sanitary OEM Refractometer will answer to ping and

return any data packets sent to it, see gure 2.7.

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Figure 2.7 Pinging address 169.254.23.33,

ping returned fully and connecon ok.

3 Refractometer mounng 9

3 Refractometer mounng

The Sanitary OEM Refractometer mounng locaon should be chosen with care to en-

sure reliable readings from the process.

3.1 Choosing the refractometer mounng locaon

The mounng locaon needs to be such that sediments or gas bubbles cannot accumu-

late by the refractometer. Good ow velocity is essenal in keeping the prism clean.

Important: If the process pipe vibrates, support the pipe. A vibrang pipe might dam-

age the in-line refractometer mounted on it.

The refractometer cover should not be exposed to high temperature radiaon. In most

cases, dra and natural convecon provide sucient air cooling if the air gets to ow

freely around the refractometer head.

Important: Always mount the refractometer so that the interconnecng cable points

downwards from the refractometer head.

3.2 Check list for pipe mounng

Most Sanitary OEM Refractometers are mounted in a pipe. The recommended ow

velocity is between 1 and 3 m/s (3–10 /s). If the ow velocity exceeds 6 m/s (20 /s),

there is a risk of cavitaon. Cavitaon may damage the sensor and the piping. Too

slow a ow velocity may cause erraneous measurement readings due to coang of

stracaon (layering) of the sample on the prism.

10 PR-33-AC instrucon manual

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IP:169.254.23.33

Figure 3.1 Pipe mounng of Sanitary OEM Refractometer

3 Refractometer mounng 11

The diameter and form of the pipe and the process temperature all aect the measure-

ment and need to be taken into account. (See gure 3.1)

1. If the process pipe diameter varies, select the posion with the smallest diameter

(and accordingly highest velocity). Then the prism stays clean beer.

2. If the refractometer is used in a feed-back control loop, make the me lag short. E.g.

when a diluon valve is controlled, mount the refractometer close to the diluon

point. However, make sure complete mixing has occurred at mounng locaon.

3. If the temperature varies along the process pipe, select the posion with the highest

process temperature. That minimizes the risk of coang, because higher tempera-

ture means higher solubility and also lower viscosity.

4. Oen the posion with the highest process pressure (= aer pump + before valve)

has favorable ow condions without sedimentaon or air trapping risks.

5. The refractometer should be conveniently accessible for service.

3.3 Refractometer wiring

There are two M12 connectors in the Sanitary OEM Refractometer sensor. The A-coded

male sensor is for power supply and milliamp output signals. The D-coded female con-

nector is for the Ethernet connecon.

Figure 3.2 Connectors on the Sanitary OEM Refractometer

Please see the wiring drawing (gure 3.3) for wiring instrucons.

12 PR-33-AC instrucon manual

Document/Revision No. Rev. IM-EN-PR33AC/2.00 Eecve: September 2, 2019

Figure 3.3 Wiring drawing

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Vaisala PR-33-AC User manual

Vaisala PR-33-AC User manual

Vaisala PR-33-AC User manual

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