Vaisala PR-43-AC User manual

M212438EN-C

User Guide

Sanitary Process Refractometer

PR-43-AC/AP

PUBLISHED BY

Vaisala Oyj

Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland

P.O. Box 26, FI-00421 Helsinki, Finland

+358 9 8949 1

Visit our Internet pages at www.vaisala.com.

No part of this document may be

reproduced, published or publicly

displayed in any form or by any means,

electronic or mechanical (including

photocopying), nor may its contents be

modiﬁed, translated, adapted, sold or

disclosed to a third party without prior

written permission of the copyright holder.

Translated documents and translated

portions of multilingual documents are

based on the original English versions. In

ambiguous cases, the English versions are

applicable, not the translations.

The contents of this document are subject

to change without prior notice.

Local rules and regulations may vary and

they shall take precedence over the

information contained in this document.

Vaisala makes no representations on this

document’s compliance with the local

rules and regulations applicable at any

given time, and hereby disclaims any and

all responsibilities related thereto.

This document does not create any legally

binding obligations for Vaisala towards

customers or end users. All legally binding

obligations and agreements are included

exclusively in the applicable supply

contract or the General Conditions of Sale

and General Conditions of Service of

Vaisala.

This product contains software developed

by Vaisala or third parties. Use of the

software is governed by license terms and

conditions included in the applicable

supply contract or, in the absence of

separate license terms and conditions, by

the General License Conditions of Vaisala

Group.

Table of contents

1. About this document.....................................................................................5

1.1 Version information.......................................................................................... 5

1.2 Related manuals................................................................................................5

1.3 Documentation conventions........................................................................... 5

1.4 Trademarks........................................................................................................ 6

2. Product overview............................................................................................ 7

2.1 Vaisala Sanitary Process Refractometers PR‑43‑AC and PR‑43‑AP...........7

2.2 Safety..................................................................................................................7

3. Installation..........................................................................................................9

3.1 Choosing mounting location........................................................................... 9

3.2 Checklist for pipe mounting............................................................................ 9

3.3 Checklist for mounting in tank, vessel or large pipe...................................10

3.4 Mounting guide.................................................................................................11

3.5 Electrical connections.....................................................................................12

4. Prism wash........................................................................................................16

4.1 Prism coating................................................................................................... 16

4.2 Prism wash....................................................................................................... 16

4.2.1 Recommended wash pressures and times............................................17

4.2.2 Prism wash systems................................................................................. 18

4.2.3 Prism wash nozzles................................................................................. 22

5. Technical data................................................................................................ 25

5.1 Compatibility...................................................................................................25

5.2 Refractometer rangeability........................................................................... 25

5.3 Sanitary process refractometer PR-43-AC..................................................25

5.3.1 PR-43-AC model code............................................................................26

5.3.2 PR-43-AC mounting hardware model code.........................................28

5.3.3 PR-43-AC speciﬁcations.........................................................................32

5.3.4 PR-43-AC parts list................................................................................. 34

5.3.5 PR-43-AC mounting speciﬁcs................................................................37

5.3.6 Mounting speciﬁcs for EHEDG certiﬁed PR-43-AC conﬁguration....44

5.3.7 3-A Sanitary Standard compliance.......................................................44

5.4 Sanitary process refractometer PR-43-AP................................................. 46

5.4.1 PR-43-AP model code............................................................................47

5.4.2 PR-43-AP mounting hardware model code........................................ 49

5.4.3 PR-43-AP speciﬁcations........................................................................ 50

5.4.4 PR-43-AP parts lists................................................................................52

5.4.5 PR-43-AP mounting speciﬁcs................................................................55

5.4.6 Mounting speciﬁcs for EHEDG certiﬁed PR-43-AP conﬁguration.... 58

5.4.7 3-A Sanitary Standard compliance....................................................... 59

Appendix A:

Refractometer veriﬁcation.................................................. 60

Table of contents

1

Appendix B: PR-43 refractometer veriﬁcation form..............................62

Appendix C: EU declaration of conformity.............................................. 63

Warranty............................................................................................................65

Technical support............................................................................................ 65

Recycling........................................................................................................... 65

PR-43-AC/AP User Guide M212438EN-C

2

List of ﬁgures

Figure 1 Refractometer models..................................................................................... 7

Figure 2 PR-43-AC and PR-43-AP mounting guide.................................................11

Figure 3 The M12 connector........................................................................................... 12

Figure 4 Connecting refractometer cable to refractometer................................. 13

Figure 5 Wiring with analogue output only.............................................................. 13

Figure 6 Wiring options with both analogue and digital outputs...................... 14

Figure 7 Wiring options with both analogue and digital outputs

and RJ45 ethernet connector.......................................................................14

Figure 8 Connections in M12 and RJ-45 connectors...............................................15

Figure 9 Prism wash system for steam.......................................................................19

Figure 10 Wiring for prism wash system for steam................................................. 20

Figure 11 Prism wash system for high pressure water............................................. 21

Figure 12 Wiring for prism wash system for high pressure water........................22

Figure 13 Wash nozzles for ﬂowcell AFC-HSS-XXX-XX-NC................................... 22

Figure 14 Process connection of wash nozzle in ﬂowcell....................................... 24

Figure 15 PR-43-AC rangeability...................................................................................25

Figure 16 PR-43-AC dimensions....................................................................................26

Figure 17 Refractometer cover assembly................................................................... 34

Figure 18 PR-43-AC assembly....................................................................................... 36

Figure 19 Mounting with sanitary ferrule, pipe diameter 80 mm

(3 in) or more....................................................................................................37

Figure 20 Flow cell AFC-HSS-H10 for pipe diameter 25 mm (1 in)

and H15 for pipe diameter 40 mm (1.5 in)................................................38

Figure 21 Flow cell AFC-HSS- with wash nozzle connection (-NC)

H10 for pipe diameter 25 mm (1 in) and H15 for pipe

diameter 40 mm (1.5 in)................................................................................39

Figure 22 Flow cell AFC-HSS-H20 for pipe diameter 50 mm (2 in)

and H25 for pipe diameter 65 mm (2.5 in)..............................................40

Figure 23 Flow cell AFC-HSS- with wash nozzle connection (-NC)

H20 for pipe diameter 50 mm (2 in) and H25 for pipe

diameter 65 mm (2.5 in)................................................................................ 41

Figure 24 Side ﬂow cells.................................................................................................. 42

Figure 25 I-Line ﬁtting for PR-43-AC........................................................................... 43

Figure 26 Mounting with sanitary ferrule, pipe diameter 80 mm

(3 in) or more EHEDG certiﬁed conﬁguration........................................ 45

Figure 27 Dimensions of an inserted refractometer PR-43-AP-H25-L170........ 46

Figure 28 Flush mounted refractometer PR-43-AP-T10-L00................................47

Figure 29 Refractometer cover assembly....................................................................52

Figure 30 PR-43-AP assembly....................................................................................... 54

Figure 31 Insertion of probe refractometer PR-43-AP-H25.................................. 56

Figure 32 Flush mounting probe refractometer PR-43-AP-T10-L100................. 57

Figure 33 I-Line ﬁtting for PR-43-AP............................................................................58

Figure 34 EHEDG certiﬁed PR-43-AP...........................................................................59

Figure 35 Universal sample holder PR-1012............................................................... 60

List of ﬁgures

3

List of tables

Table 1 Document versions (English)...........................................................................5

Table 2 Related manuals.................................................................................................. 5

Table 3 Wash medium parameters for integral wash nozzles in PR-43-AP......17

Table 4 Wash medium parameters for ﬂowcell wash nozzle AFC.......................17

Table 5 Flowcell -H10 or -H15........................................................................................23

Table 6 Flowcell -H20 or -H25......................................................................................23

Table 7 Flowcell -H30......................................................................................................23

Table 8 Flowcell -H40..................................................................................................... 23

Table 9 Prism wash nozzle selection.......................................................................... 24

Table 10 Sanitary compact refractometer for pipelines.......................................... 27

Table 11 Mounting hardware without wash nozzles................................................ 28

Table 12 EHEDG certiﬁed mounting hardware.......................................................... 28

Table 13 Mounting hardware with wash nozzles.......................................................29

Table 14 Mounting hardware, mini ﬂow cell............................................................... 30

Table 15 Mounting hardware, Varivent DN65 connection......................................30

Table 16 Mounting hardware........................................................................................... 31

Table 17 PR-43-AC speciﬁcations..................................................................................32

Table 18 Refractometer cover assembly parts list....................................................34

Table 19 PR-43-AC assembly parts list........................................................................ 36

Table 20 I-Line ﬁtting for PR-43-AC............................................................................. 43

Table 21 Mounting materials...........................................................................................45

Table 22 SANITARY PROBE REFRACTOMETER for large pipelines

and vessels..........................................................................................................47

Table 23 SANITARY PROBE REFRACTOMETER with prism wash

for large pipelines and vessels...................................................................... 49

Table 24 Mounting hardware for PR-43-AP refractometer.................................... 50

Table 25 PR-43-AP speciﬁcations.................................................................................50

Table 26 Refractometer cover assembly parts list.................................................... 52

Table 27 PR-43-AP assembly parts list........................................................................54

Table 28 Veriﬁcation results display..............................................................................62

PR-43-AC/AP User Guide M212438EN-C

4

1. About this document

1.1 Version information

This document provides instructions for installing and using the Vaisala K‑PATENTS® Sanitary

Process Refractometers PR‑43‑AC and PR‑43‑AP.

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

Information in this manual is subject to change without notice. When the manual is changed, a

revised copy is published at www.kpatents.com.

Table 1 Document versions (English)

Document Code Date Description

M212438EN-C April 2020 Manual updated to new format, template, and document

code. Minor changes to content.

IM‑EN‑PR43ACAP

2.00

September

2019

Changed K-Patents to Vaisala.

IM‑EN‑PR43ACAP

1.12

June 2018 IP rating updated.

1.2 Related manuals

Table 2 Related manuals

Document Code Name

M212455EN Sanitary Process Refractometer PR-43 Series User Guide

IM-EN-MI Multichannel User Interface MI Instruction Manual

IM-EN-CI Compact User Interface CI Instruction Manual

IM-EN-PR43IAAX Process Refractometer PR-43-…-IA/AX/CU Instruction Manual

1.3 Documentation conventions

Warning alerts you to a serious hazard. If you do not read and

follow instructions carefully at this point, there is a risk of injury or even death.

WARNING!

Chapter 1 – About this document

5

Caution warns you of a potential hazard. If you do not read and

follow instructions carefully at this point, the product could be damaged or

important data could be lost.

CAUTION!

Note highlights important information on using the product.

Tip gives information for using the product more eciently.

Lists tools needed to perform the task.

Indicates that you need to take some notes during the task.

1.4 Trademarks

Vaisalaâ and K-PATENTS® are registered trademarks of Vaisala Oyj.

Linuxâ is a registered trademark of Linus Torvalds.

Windowsâ is either a registered trademark or trademark of Microsoft Corporation in the

United States and other countries.

Varivent® is a registered trademark of GEA Tuchenhagen GMBH.

All other product or company names that may be mentioned in this publication are trade

names, trademarks, or registered trademarks of their respective owners.

PR-43-AC/AP User Guide M212438EN-C

6

2. Product overview

2.1 Vaisala Sanitary Process Refractometers

PR‑43‑AC and PR‑43‑AP

The sanitary refractometers PR‑43‑AC and PR‑43‑AP provide a digital interface detection

system for alimentary industry.

The PR‑43‑AC/AP measures the refractive index n

D

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.

The output values of the refractometer are transmitted through mA output and digitally

through an Ethernet connection by using a UDP/IP protocol (for speciﬁcation see PR-43

general manual). mA output is available with mA output cable (mA only) or with a split cable

(mA and Ethernet).

Figure 1 Refractometer models

2.2

Safety

This product has been tested for safety. Note the following precautions:

Only licensed experts may install electrical components. They

must adhere to local and state legislation and regulations.

WARNING!

Chapter 2 – Product overview

7

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

adequate for the process medium. Do not rely on avoidance of contact with the process

medium.

Wear protective eyewear.

Wear protective gloves.

Precautions when removing a sensor from the process line :

• Check that the process line is depressurized and drained

• Loosen the ﬂowcell screws cautiously; be prepared to tighten again

• Ensure you are clear of any possible spillage and you have a clear emergency escape path

PR-43-AC/AP User Guide M212438EN-C

8

3. Installation

3.1 Choosing mounting location

The refractometer mounting location should be chosen with care to ensure reliable readings

from the process.

The mounting location needs to be such that sediments or gas bubbles cannot accumulate by

the refractometer. Good ﬂow velocity is essential in keeping the prism clean.

If the process pipe vibrates, support the pipe. A vibrating pipe

might damage the inline refractometer mounted on it.

CAUTION!

A Vaisala K‑PATENTSâ inline refractometer can be located either indoors or outdoors in most

climates. However, when a refractometer is located outdoors, some basic protection against

direct exposure to sunlight and rain should be provided. Special care should be taken if the

pipe wall is translucent (e.g. of ﬁberglass), as light from outside reaching the prism through the

pipe wall may disturb the measurement.

The refractometer cover should not be exposed to high temperature radiation. In most cases,

draft and natural convection provide sucient air cooling if the air gets to ﬂow freely around

the refractometer head.

Additional cooling is necessary when the ambient temperature is higher than 45 °C (113 °F) or

when the process temperature is above 110 °C (230 °F) and the ambient temperature is above

35 °C (95 °F). The air cooling is improved by blowing pressurized air against the refractometer

cover. The pressurized air can be supplied by the ventilation system. It is also possible to

mount a PR‑14038 cooling cover for cooling with water.

Always mount the refractometer so that the interconnecting cable

points downwards from the refractometer head.

CAUTION!

3.2 Checklist for pipe mounting

The PR‑43‑AC and PR‑43‑AP are mounted in a pipe. Vaisala recommends a ﬂow velocity

between 1 and 3 m/s (3–10 ft/s). If the ﬂow velocity exceeds 6 m/s (20 ft/s), there is a risk of

cavitation. Cavitation may damage the refractometer and the piping. Too slow a ﬂow velocity

may cause erraneous measurement readings due to coating of stratiﬁcation (layering) of the

sample on the prism.

The diameter and form of the pipe and the process temperature all aect the measurement

and need to be taken into account.

• If the process pipe diameter varies, select the position with the smallest diameter(and

accordingly highest velocity). Then the prism stays clean better.

Chapter 3 – Installation

9

• If the refractometer is used in a feed-back control loop, make the time lag short. E.g. when

a dilution valve is controlled, mount the refractometer close to the dilution point.

However, make sure complete mixing has occurred at mounting location.

• If the temperature varies along the process pipe, select the position with the highest

process temperature. That minimizes the risk of coating, because higher temperature

means higher solubility and also lower viscosity.

• Often the position with the highest process pressure (= after pump + before valve) has

favorable ﬂow conditions without sedimentation or air trapping risks.

• The refractometer should be conveniently accessible for service.

3.3 Checklist for mounting in tank, vessel or large

pipe

A probe refractometer PR‑43‑AP can be inserted with a ﬂange or clamp into tanks and vessels

which either don’t have a scraper or where the mixer doesn’t touch the vessel wall. A probe

refractometer can also be ﬂush mounted in a cooker where the scraper touches the wall.

• The inserted probe refractometer is mounted close to a stirrer to ensure representative

sample of the process liquid and to keep the prism clean.

• The refractometer should be conveniently accessible for service.

PR-43-AC/AP User Guide M212438EN-C

10

3.4 Mounting guide

Prevent outside light

Easy access

High pressure

High temperature

High pressure

Small diameter

High temperature

High velocity >1.5m/s

(>5ft/s)

Upper pipe bend

Ambient air

cooling

Figure 2 PR-43-AC and PR-43-AP mounting guide

Chapter 3 – Installation

11

3.5 Electrical connections

The refractometer has an M12 connector in the refractometer for power supply, mA output and

Ethernet connections.

Figure 3 The M12 connector

PR-43 refractometers are powered with 24 VDC. For connecting the refractometer to

Multichannel user interface MI, see the Instruction manual for Multichannel User Interface MI.

For connecting the refractometer to Compact user interface CI, see the Instruction manual for

Compact User Interface CI. See the following ﬁgure for instruction how to connect the M12

refractometer cable.

PR-43-AC/AP User Guide M212438EN-C

12

Turn to tighten

Align groove and

guide

P4-031

Connector screw thread

Figure 4 Connecting refractometer cable to refractometer

The PR-43 refractometer provides both analog (mA) and digital output signals. See the

following ﬁgure for the wiring when only analog output is used.

PR-43 REFRACTOMETER

M-12-8 pin, A-code, M

non-Ex

max. 200m (656ft)

PR-8680

M12-8 pin, A-code, F

Field plug

PR-8432

Power supply and

mA output cable

F

Figure 5 Wiring with analogue output only

The following ﬁgure shows the options for connecting the refractometer with both analog and

digital outputs. Both Compact user interface CI and Multichannel user interface MI use the

digital output signal.

Chapter 3 – Installation

13

10m (33ft)

90m (295ft)

180m (590ft)

PR-43 REFRACTOMETER

M-12-8 pin, A-code, M

non-Ex

PR-43 REFRACTOMETER

M-12-8 pin, A-code, M

non-Ex

PR-43 REFRACTOMETER

M-12-8 pin, A-code, M

non-Ex

max. 90m (295ft) max. 90m (295ft)

max. 90m (295ft)

10m (33ft)

PR-8430

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8430

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8430

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8660

Platform 4 cable extender

M12-8 pin, A-code, F+M

PR-8431

Split cable M12

M12-8 pin, A-code, F

Ethernet (M12-4 pin, D-code,M)

mA, 24V

PR-8431

Split cable M12

M12-8 pin, A-code, F

Ethernet (M12-4 pin, D-code,M)

mA, 24V

1m (3ft)

PR-8431

Split cable M12

M12-8 pin, A-code, F

Ethernet (M12-4 pin, D-code,M)

mA, 24V

1m (3ft)

M

M M

M MM

F

F F

Figure 6 Wiring options with both analogue and digital outputs

The following ﬁgure shows the wiring options when both analogue and digital outputs are

used, with RJ45 ethernet connector.

10m (33ft)

90m (295ft)

180m (590ft)

PR-43

REFRACTOMETER

M-12-8 pin, A code, M

Unclassied area

max. 90m (295ft) max. 90m (295ft)

max. 90m (295ft)

PR-8430-___

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8430-___

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8430-___

Platform 4 cable

M12-8 pin, A-code, F+M

Ethernet, mA, 24V

PR-8660

Platform 4 cable extender

M12-8 pin, A-code, F+M

PR-8444-001/010

Split cable M12

M12-8 pin, A-code, F

Ethernet (RJ 45)

mA, 24V

1m (3ft) or 10m (33ft)

M

MM

F

PR-43

REFRACTOMETER

M-12-8 pin, A code, M

Unclassied area

PR-43

REFRACTOMETER

M-12-8 pin, A code, M

Unclassied area

Figure 7 Wiring options with both analogue and digital outputs and RJ45 ethernet connector

PR-43-AC/AP User Guide M212438EN-C

14

Figure 8 Connections in M12 and RJ-45 connectors

In split cables the power cable and the mA output cable are marked near the end of the cable.

Power cable:

• White: +24DC

• Brown: GND

mA output cable:

• White: mA+

• Brown: mA-

Chapter 3 – Installation

15

4. Prism wash

Prism wash requires a system for wash control and diagnostics. This can be achieved with

Multichannel user interface (MI) with a relay module.

4.1 Prism coating

Deposit build-up on the prism surface disturbs the measurement. Anabnormally high

concentration reading, an upward concentration (CONC) drift, decreased QF value or increased

LED value may indicate coating.

In most applications the prism will keep clean due to the self-cleaning eect. If coating occurs,

check the following:

• Sucient ﬂow velocity

• A temperature dierence between the process ﬂuid and refractometer probe may cause

coating. This may happen with small ﬂows if the thermal insulation is inadequate. In some

cases it helps to also insulate the clamp connector.

In case of a coating problem, the preferred solution is to try to increase the ﬂow velocity, for

example, by installing a pipe portion with smaller diameter.

Installing a wash nozzle can be considered, if increasing the velocity does not provide a

solution. For more information, see Prism wash (page 16).

4.2

Prism wash

Three alternative wash media can be used for prism wash:

• Steam

• Water

• High pressure water

Relay modules in a Multichannel user interface MI can be conﬁgured to control the prism wash

cycle, see MI manual, Chapter 6, "Module cards" and Chapter 7, "Prism wash".

Important: In food industry applications, wash medium must be

culinary steam or safe water. Shut-o valve and check valve must meet 3-A

sanitary standards.

CAUTION!

Culinary steam: Means steam produced using a system meeting criteria in the 3-A Accepted

Practices for a Method of Producing Steam of a Culinary Quality, Number 609.

Safe Water: Means water from a supply properly located, protected, and operated, and shall be

of safe, sanitary quality. The water shall meet the standards prescribed in the National Primary

Drinking Water Regulation of the Environmental Protection Agency (EPA) as referenced in The

Code of Federal Regulations (CFR), Title 40, Parts 141, 142, and 143.

PR-43-AC/AP User Guide M212438EN-C

16

4.2.1 Recommended wash pressures and times

The following tables provide the recommended wash pressures and times.

Table 3 Wash medium parameters for integral wash nozzles in PR-43-AP

Minimum above

process pressure

Maximum above

process pressure

Wash

time

Recover

y

Interval

Steam (SN) 2 bar (30 psi) 4 bar (60 psi) 3 s 20 ‑ 30 s 20 ‑ 30

min

Water (WN) 2 bar (30 psi) 4 bar (60 psi) 10 s 20 ‑ 30 s 10 ‑ 20 m

in

High pressure water

(WP)

15 bar (220 psi) 40 bar (600 psi) 10 s 20 ‑ 30 s 10 ‑ 20 m

in

Table 4 Wash medium parameters for ﬂowcell wash nozzle AFC

Minimum above

process pressure

Maximum above

process pressure

Wash

time

Recover

y

Interval

Steam (SN) 3 bar (45 psi) 6 bar (90 psi) 3 ‑ 5 s 20 ‑ 30 s 20 ‑ 30

min

Water (WN) 3 bar (45 psi) 6 bar (90 psi) 10 ‑ 15 s 20 ‑ 30 s 10 ‑ 20 m

in

High pressure water

(WP)

25 bar (350 psi) 35 bar (500 psi) 10 ‑ 15 s 20 ‑ 30 s 10 ‑ 20 m

in

In steam wash, do not exceed the recommended wash times,

because some process media may burn to the prism surface if steamed for

longer time. In case of coating, shorten the wash interval.

CAUTION!

In water wash, water temperature should be above the process temperature.

The check valve pressure drop is 0.7 bar (10 psi).

Chapter 4 – Prism wash

17

4.2.2 Prism wash systems

In high pressure wash systems, pressure increase can occur in a

closed pipe section when the high pressure pump is operated. It is

recommended to mount a pressure relief valve in the pipe section. Relief

pressure should be according to pipe pressure rating.

WARNING!

The following ﬁgures describe the prism wash system for steam.

PR-43-AC/AP User Guide M212438EN-C

18

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