Vaisala PR-33-S User manual

IM-EN-PR33S v. 2.00

Instruction Manual

Semicon Process Refractometer

PR-33-S

PR-33-S instrucon manual

Document/Revision No. Rev. IM-EN-PR33S/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-PR33S/2.00 Eecve: September 2, 2019

Table of contents

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

1.1 Principle of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Ethernet specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Connecon sengs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2.1 IP sengs for sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2.2 IP sengs for stand-alone computer . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2.3 Conguring a network of sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3 Tesng the Ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3.1 Troubleshoong the connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4 Instrument homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4.1 Main page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.4.3 Diagnoscs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Inline refractometer sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Mounng the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.1 Choosing sensor mounng locaon . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1.2 PR-33-S sensor installaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.1.3 Check list for pipe mounng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.4 Mounng cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 Connecng the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Connecng with Fieldbus converter . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 Startup and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1.1 Inial check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1.2 Calibraon check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2 Viewing sensor status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Conguraon and calibraon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.1 Conguring the refractometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.1.1 Signal damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Calibrang the concentraon measurement . . . . . . . . . . . . . . . . . . 26

5.2.1 The chemical curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2.2 Direct BIAS adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.1 Prevenve replacement of o-ring in EKC265 applicaon . . . . . . . . 29

7 Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.1.1 Message HIGH SENSOR HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.1.2 Message HIGH SENSOR TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2.1 Message OUTSIDE LIGHT ERROR or OUTSIDE LIGHT TO PRISM . . . . . . . . . . 30

7.2.2 Message NO OPTICAL IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2.3 Message PRISM COATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2.4 Message LOW IMAGE QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2.5 Message NO SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2.6 Message TEMP MEASUREMENT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2.7 Concentraon dri during NORMAL OPERATION . . . . . . . . . . . . . . . . 32

7.3 Diagnosc messages table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8 Ethernet protocol specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1 Communicaon protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1.1 Request format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.1.2 Response format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.1.3 Request and response errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.2 Request-response pair specicaon . . . . . . . . . . . . . . . . . . . . . . . . 35

8.2.1 NULL message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.2.2 Protocol version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8.2.3 Refractometer informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.2.4 Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.3 Error message specicaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

EC declaraon of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

PR-33-S refractometer eld calibraon form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1 Introducon 1

1 Introducon

The inline refractometer sensor PR-33-S (gure 1.1) measures the refracve index n

D

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

calculated from these values when the composion of the process medium is known.

The output values of the sensor are transmied through its Ethernet connecon by

using a UDP/IP protocol (see chapter 2). An oponal mA output unit is also available.

Figure 1.1 PR-33-S sensor

1.1 Principle of measurement

The Vaisala K-PATENTS® inline refractometer determines the refracve index n

D

of the

process soluon. It measures the crical angle of refracon using a yellow LED light

source with the same wavelength (589 nm) as the sodium D line (hence n

D

). Light from

the light source (L) in Figure 1.2 is directed to the interface between the prism (P) and

the process medium (S). Two of the prism surfaces (M) act as mirrors bending the light

rays so that they meet the interface at dierent angles.

The reected rays of light form an image (ACB), where (C) is the posion of the crical

angle ray. The rays at (A) are totally internally reected at the process interface, the rays

at (B) are parally reected and parally refracted into the process soluon. In this way

the opcal image is divided into a light area (A) and a dark area (B). The posion of the

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L

P

MM

S

A C B

Figure 1.2 Refractometer principle

shadow edge (C) indicates the value of the crical angle. The refracve index n

D

can

then be determined from this posion.

The refracve index n

D

changes with the process soluon concentraon and temper-

ature. For most soluons the refracve index increases when the concentraon in-

creases. At higher temperatures the refracve index is smaller than at lower tempera-

tures. From this follows that the opcal image changes with the process soluon con-

centraon as shown in Figure 1.3. The color of the soluon, gas bubbles or undissolved

parcles do not aect the posion of the shadow edge (C).

BB

C

AA

Low concentration High concentration

Figure 1.3 Opcal images

The posion of the shadow edge is measured digitally using a CCD element (Figure 1.4)

and is converted to a refracve index value n

D

by a processor inside the instrument.

This value is used together with the measured process temperature to calculate the

concentraon.

1 Introducon 3

a. Optical image

b. CCD element

c. CCD output

V

Figure 1.4 Opcal image detecon

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2 Ethernet connecon

The Ethernet connecon enables data download from a PR-33 sensor to a computer.

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

necon can be congured to view and download data from the sensor. Sensor congu-

raon and monitoring can be carried out without special soware by using a standard

web browser. Secon 8.1 gives all the specicaons necessary to write a data acquisi-

on program.

2.1 Ethernet specicaon

The sensor is designed to be connected to a network with PoE (Power over Ethernet,

IEEE-802.3af) mode A support, as it receives its operang power through the Ethernet.

The sensor is equipped with an integrated Ethernet cable, 10 meter long. The cable

can be connected to any standard RJ45 Ethernet equipment. Addional length can be

gained by using a UTP joint adapter/coupler with a standard Ethernet cable, length up

to 90 meters. The maximum communicaon speed of the sensor is 100 Mbit/s (Ether-

net 100BASE-T).

In the simplest form the network consists of a sensor, a computer, and a PoE switch.

This conguraon is shown in gure 2.1.

PR-33

PoE

switch

Laptop

Figure 2.1 Simple network conguraon.

Several sensors can be connected to the same Ethernet network. Also, the sensors have

an automac funcon to detect 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 sensors to an exisng LAN with

no PoE funconality. A single PoE switch will suce in this case.

2 Ethernet connecon 5

PR-33

LAN

PoE

switch

Figure 2.2 Three sensors in the same network.

PR-33

PoE

switch

WLAN

Access

point

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

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

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).

Fiber

Media

converter

Media

converter

PR-33

PoE

switch

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

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2.2 Connecon sengs

2.2.1 IP sengs for sensor

All sensors 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 (gure 2.1), usually without

changing the network sengs of the computer. This address will remain in the sensor

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 PR-33 in the same network, this address cannot be

used (secon 2.2.3).

The IP address of the sensor can be changed through the instrument homepage (sec-

on 2.4).

2.2.2 IP sengs for stand-alone computer

When you start up a computer with automacal IP sengs (DHCP enabled) in a net-

work with only the PR-33 sensor, the computer should automacally obtain an IP ad-

dress 169.254.x.x. In this case you can connect to the factory default address of the

sensor without any further changes in sengs. If this does not work, please make sure

that your WLAN (Wireless network connecon) is not acve when you connect to the

sensor. 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 you sll have dicules in connecng to the sensor, you may check the IP address of

the computer by opening the command window (command prompt) and by typing the

command ipconfig at the command prompt (press Enter to give the command), see

gure 2.5 (in Mac OS X and Linux the same command is called ifconfig). The result

will give you your computer’s IP address. If the address does not start by 169.254,

you will have to manually congure the IP address of the computer to 169.254.23.34,

netmask 255.255.0.0.

For further troubleshoong, see secon 2.3.1.

2 Ethernet connecon 7

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

connected to a sensor; laptop wireless (WLAN) is turned o

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

same IP address.

When you have congured the network sengs of the sensor (and/or the computer)

according to the instrucons above, you can proceed to test the connecon as in-

structed below in Secon 2.3.

2.2.3 Conguring a network of sensors

In case you have more than one sensor in a network, the sensor IP addresses have to

be congured, as the factory default will not work.

If you are connecng the sensor to a factory network, please consult the network ad-

ministrator for the correct sengs.

If the network is a stand-alone network with only PR-33’s 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).

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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

P

o

E

s

w

i

t

c

h

Figure 2.6 A network of PR-33 sensors.

Note: There are no sengs for subnet mask, default gateway or name servers in PR-33,

as these sengs are not required.

2.3 Tesng the Ethernet connecon

When you connect the sensor to a powered PoE switch, the indicator lights should light

up. The actual posion and funcon of the lights depend on the switch, but gure 2.7

shows the indicators on a typical PoE switch. There’s one indicator showing that the

instrument is drawing power, another indicator (next to the Ethernet connector) shows

the connecon status. In this case a 100 Mbit/s connecon is formed between two

instruments at the switch ports 1 and 3 (a sensor per port), and there is a PoE device

connected in these ports, 1 and 3.

1 2

3 4

PoE

FAULT

PWR2

1000M

100M

PWR1

4

2

3

1

5

7

6

8

Figure 2.7 An example of PoE switch indicator lights

2 Ethernet connecon 9

Note: It is typical that, e.g., 8-port PoE switches only have 4 ports supplying power.

If you keep the sensor in a dimly lit space, you should see the ashing of the processor

indicator lights on the instrument cover (see gure 2.8). If the lights are ashing, the

instrument receives power from the PoE connecon.

Figure 2.8 Process indicator lights in the sensor

Once the sensor is powered up, it should be reachable from any correctly congured

computer connected to the same Ethernet network by typing the IP address of the

instrument to a web browser (see secon 2.4).

Note: The factory-default IP address of the sensor is 169.254.23.33. This address

should always respond (see secon 2.2.1).

2.3.1 Troubleshoong the connecon

In case you are unable to reach the instrument through the network, please check the

following things:

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• the instrument receives power; there is a faint ashing light on the cover of the

instrument (gure 2.8) or the PoE switch indicates ’power OK’.(see gure 2.7).

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

(secon 2.2.2)

• if you try to reach the instrument at IP address 169.254.23.33, check that there is

only one PR-33 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 sensor, PoE switch, and a computer (gure 2.1)

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

on is turned o (secon 2.2.2)

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

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 address

given to ping is correct, the sensor will answer to ping and return any data packets sent

to it, see gure 2.9.

2.4 Instrument homepage

Every PR-33 sensor has a built-in web server with the instrument homepage. The home-

page oers facilies to congure, monitor, diagnose and verify the instrument.

Once there is a funconal Ethernet connecon between the instrument and the com-

puter, the homepage can be opened by typing the instrument’s IP address to the ad-

dress bar of a web browser. The recommendaon is to use Firefox 2.0 or newer, but

most funconality is available with any modern web browser.

Opening the instrument homepage:

2 Ethernet connecon 11

Figure 2.9 Pinging address 169.254.23.33, ping returned fully and connecon ok.

1. Establish a working Ethernet connecon (see above) to the sensor.

2. Start your preferred web browser (for example Mozilla Firefox, Internet Explorer,

Safari, Chrome or Opera).

3. The address (URL) of the instrument homepage is the sensor’s IP address, for a

factory set sensor it is hp://192.168.23.33/. Give the address to the browser just

like you’d enter any other address (for example hp://www.vaisala.com/)

4. Wait unl the homepage is loaded, this may take a few seconds.

The page looks approximately like in Figure 2.10; the exact look of the page depends

on your browser and screen sengs so slight variaon can be expected.

5. Use the links in the link bar on the le side of the page to nd more extensive

informaon on the instrument.

Important: In order for the web pages to funcon as designed, the JavaScript support

has to be enabled in the browser.

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2.4.1 Main page

Once the instrument homepage is loaded, the most important informaon is visible on

the main page (gure 2.10). This page shows the measurement values, serial number

and the tag of the instrument.

Figure 2.10 Main page (sensor not in process)

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Vaisala PR-33-S User manual

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