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Metso MCA - Installation, Operating & Service manual

1. Fig 1 Metso MCA F 1 Pt 100 Thermoelement 2 Microwave Antennas 3 Sensor Electronics 4 Sensor Cable Connector Metso Mircowave Consistency Transmitter 2 2 MCA FT The body of the Flow Through sensor is a pipe which when installed replaces an identical length of process pipe Flush mounted antennas are installed on opposite sides of the sensor body so measurement takes place through the pipe The sensor electronics casings is in stalled on the sensor body by means of a connecting pipe The Pt 100 sensor which measures process tem perature is installed inside the connecting pipe The antenna cables which are protected within casing run to the base plate of the electronics casing on the outside of the connecting pipe Figure 4 shows the sensor s construction drawing The material of the wetted sensor and antenna bodies is AISI 316 316L The antenna material is polished ceramic A H Fig 2 Metso MCA FT 1 Sensor Electronics 2 Sensor Cable Connector 3 Antenna Cable 4 Pt 100 Ther moelement 5 Microwave Antennas Installation operating amp service manual OUL00298 V2 2 EN SS o Oo Fig 3 Metso MCA F co
2. 0 100 32 212 F Process pressure Minimum recommended over 1 5 bar no free air Maximum F model PN25 Maximum FT model DIN PN16 ANSI Class 150 JIS 10k max 20 m s 10 2000 Hz Environment Temperature 20 70 4 158 F protect from direct heat sources Housing class 65 NEMA 4 Connections Operating power communication cable from TCU Materials F amp FS models AISI 3161 OPTION Titanium GR2 or Hastelloy C276 Titanium Ceramic Process coupling L coupling AISI 316L OPTION Titanium GR2 or Hastelloy C276 Metso Automation Manufacturer reserves the right to changes without prior notice Materials FT model Sensor AISI 316L Titanium Ceramic Process coupling FT100 4 fixed flange machined according to DIN ANSI or JIS standard FT150 6 FT200 8 no flange FT250 10 FT300 amp 12 fixed flange machined according to DIN ANSI or JIS standard Conductivity limits and sensor weights Conductivity max mS cm 30 C 50 C 70 C Weight 86 F 122 F 158 kg lbs MCAi F 17 14 12 12 0 26 5 MCAi FS 20 17 15 12 0 26 5 a 18 16 13 23 0 50
3. 45 11 2 Antenna cables Fork Sensor 46 11 3 Antenna Cables FT 48 11 4 Antennas Fork 49 11 5 Antennas FT 49 11 6 TOU ecd niet etin dre na 50 11 7 Installing Vortex 50 12 HARTO User Interface 51 12 1 About the 51 12 2 222 22 52 12 9 Dn 52 12 4 53 12 5 57 13 Upgrade Kit for MCAi 59 13 1 Structure ier re Rite 59 13 2 Electrical 59 13 3 Installation Guide Upgrade Kit for MCAi 60 13 5 Startup incite etre rrt tener eei hene 63 13 6 Configuration and Calibration 63 13 7 User 42 4 63 13 8 Troubleshooting and Maintenance 63 14 Recycling and disposing of a device re moved from service 65 Technical Specifications Service kits amp Spare parts Installation operating amp service manual 00298 V2 2 EN Metso Mircowave Consistency Transmitter 4 Installation operating amp service manual OUL00298 V2 2 EN Caution Warning During installation maint
4. Metso Automation Manufacturer reserves the right to changes without prior notice 4 4 Metso MCA Service kits amp spare parts Spare parts MCA F Part Order Code Description Pcs 1 OULO00278 Sensor Cover 1 2 00100051 Sensor Electronics 1 3 OULO00276 Assembly Set F 1 OULO00046 Microwave Antenna AISI 316L 1 4 OULO00259 Microwave Antenna Titanium Gr 2 1 OULO00260 Microwave Antenna Hastelloy 1 OULO00010 Sensor Head AISI 316L 1 5 OULO00263 Sensor Head Titanium Gr 2 1 00100264 Sensor Head Hastelloy 1 00016 Thermoelement Assembly AISI 316L 1 6 OULO00267 Thermoelement Assembly Titanium 1 00268 Thermoelement Assembly Hastelloy 1 7 OUL00339 Microwave Cable Set F 1 8 00198 O Ring 23 4x3 5 Viton 1 9 OULO00003 Screw DIN912 M8x20 A4 70 2 10 5060014 Washer DIN127 B8 A4 2 11 5160011 Screw DIN84 M4x16 2 12 5060011 Washer DIN127 B4 A4 2 13 5460041 Screw DIN912 M6x20 A4 70 6 14 5060013 Washer DIN127 B6 A4 6 Metso Automation Manufacturer reserves the right to changes without prior notice This document discloses subject matter in which the manufacturer has proprietary rights Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document any part thereof any physical article or device except by written permission from the manufacturer Manufacturer reserves
5. 156 119 FLOW min 500 mm 20 Fig 11 Metso MCA F Mounting dimensions Metso Mircowave Consistency Transmitter 19 Metso MCA FT When installed the flow through sensor replaces the corresponding length of process pipe Fig 12 The sticker on the electronics casing indicates the installa tion direction in relation to the direction of flow The sensors do not include flanges but rather they are tightened with stud bolts between flanges mounted on the process pipe MIN 500 mm 20 Fig 12 Metso MCA FT Mounting dimensions Installation operating amp service manual OUL00298 V2 2 EN 3 5 Transmitter Central Unit TCU and shield The TCU is delivered attached to the shield The shield is attached to the wall with three mounting screws in a place that is easily accessed When selecting a place for the TCU remember that the sensor cable is 10 m long Figure 13 shows shield mounting dimensions 3 6 Electrical Connections NOTE When connecting the power supply cables check that the cables are de energized Perform and check all connections before you connect the power supply to the cables NOTE If the TCU has been swi
6. 25 5 2 Operations 26 6 Configuration 27 6 1 Configuration 27 6 2 Choosing and scaling the output signal 27 6 3 User Settings err ee 27 6 4 Device information 28 6 5 Setting the date and 28 6 6 Addr65S58 ie retten taie denne ende Rna 28 7 Calibration 29 7 1 Sample Taking eene 29 7 2 Entering Laboratory Results 30 7 3 Offset 2222 22 2 30 CA FillerS iai d eds 30 7 5 Calibration and sample history 31 Metso Mircowave Consistency Transmitter 8 Diagnostics 33 98 1 Error 33 8 2 Diagnostics 33 8 3 Diagnostics 33 9 Special Functions 35 9 1 Chemical 35 9 2 Sensitivity 38 9 3 Recipes 39 10 Troubleshooting 41 10 1 0 000 41 10 2 Process 41 10 3 Self diagnostics error messages 43 11 Replacing Components 45 11 1 Sensor
7. Master Reset Resets the TCU Similar to powering the TCU off calibration is not discarded Status Status nxt alarm on off State of diagnostics variables Installation operating amp service manual OUL00298 V2 2 Notes Metso Mircowave Consistency Transmitter 58 Installation operating amp service manual OUL00298 V2 2 EN 13 Upgrade Kit for MCAi 13 1 Structure Upgrade Kit for MCAi allows you to upgrade MCAi to contain Metso MCA s performance and diagnostics characteristics It consists of new Metso MCA sensor electronics and the user interface which is called Transmitter Central Unit TCU The part that is connected to the sensor consists of sensor electronics and an adapter plate with which the electronics is installed into the Metso MCA base plate In addition the sensor unit includes a separate cable assembly with which you can install the sensor cable s connector on the base plate The sensor cable is connec ted to the TCU connector casing The delivery also in cludes shield plugs with which to replace the removed cables in the base plate inlet bushings Fig 1 Upgrade Kit for structure Metso Mircowave Consistency Transmitter 13 2 Electrical connections NOTE The Upgrade Kit s current output is passive and needs an external power source In MCAi the current output is active so in the upgrade you must also make changes to the ne
8. REFERENCE CHANNEL FAILURE P Pieces of string Sensor Check self diagnostic s Check process Antenna Contamination etc around the electronics failure error messages conditions leakage of antennas Fork Sensor body pz Pa ae Vd o pa 7 i Ed Pd ie rl Pd Metso MCA ED D a b Sensor Broken fork probe Sensor electronics failure Fig 1 Troubleshooting chart Metso Mircowave Consistency Transmitter 41 Installation operating amp service manual 00298 V2 2 EN Chemicals Chemicals in the pulp weaken the measurement signal Therefore a maximum conductivity limit has been defined for each sensor type If conductivity exceeds this limit the measurement signal becomes too small and the measurement result contains noise and errors A large overshoot in conductivity can cause the meas urement signal to disappear altogether Fluctuatations in the chemical concentration may also cause small errors within the conductivity specification limits You can eliminate these errors by using MCA chemical compensation See Chapter 9 Special Func tions Temperature Temperature affects consistency measurement which MCA compensates for with its own temperature measurement If the measurement is nonetheless noted to be temperature dependent it can be eliminted with the help of temperature compensation See Chapter 9 Special Functions Antenna Leakage Antenna Leakage causes a measurement error
9. 0 05 01 0 15 0 2 41 42 43 44 45 46 47 48 49 50 Temp C Fig 2 Results of new consistency calibration Metso Mircowave Consistency Transmitter 37 Installation operating amp service manual OUL00298 V2 2 EN 9 2 Sensitivity Correction The sensitivity of Metso MCA consistency measure ment is set according to the wood fiber If the device measures something else the sensitivity may have to be changed If the sensitivity of the measured material is previ ously unknown the sensitivity must be determined based on laboratory analysis The lab results must be from a sufficiently broad consistency area in order for the sensitivity to be accurately determined The results of the analysis are plotted on the graph MCA vs Laboratory consistency in which MCA is on the ver tical axis and laboratory consistency is on the horizontal axis The slope of the points on the graph is calculated and it represents the MCA consistency measurement sensitivity Inthe sample MCA vs Lab graph in Figure 3 a linear regression curve is plotted for the points The slope of the curve equation indicates the measurement sensitiv ity which is 0 89 To go to the Sensitivity Correction menu select Special Functions Sensitivity Corr The following dis play appears Input new correction Press the Edit button and enter the sensitivity value you determined for sensitivity correction Press the Sa
10. od uU i _ b D OOOO9 5 H o 3 9 6 ji 23000900 ms Y BA 9 Ul 31 1225 SP SE 70 2 76 Y Installation operating amp service manual OUL00298 V2 2 EN Power Supply NOTE The current signal cable s protective shield must Insert the power supply cable 90 260 VAC into the not be connected from TCU to the device in TCU Rev TCU connector casing through the inlet on the leftedge connection is made only from the system The and connect it to the terminal block as shown in Figure Cable s protective shield has been guided to be connec ted alsoto the connector SHIELD in TCU Rev 0 and TCU 15 Rev A Current Signal Cables Figure 14 shows resistance as a function of supply Another current output has been added to TCU Rev B voltage Resistance here means the sum of measurement VConsistency is hardwired the current output 1 CS resistance cable resistance and power source resistance CSIN Process temperature or process conduct in the current loop ivity mS cm can be chosen to the current output 2 52 CSIN2 Insert the current signal cable into the TCU connect orcasing through the inlet and connect to the terminal block as shown in Figure 15 1000 Connect the voltage supply line to connector or CS2 Connect the current output line to connector CSIN or CSIN2 500 N
11. 00298 V2 2 EN 10 Troubleshooting NOTE Before disconnecting the sensor or the flow through antenna check that the process pipe is empty and unpressurized and that disconnection is safe Metso MCA does not require scheduled maintenance The instructions in this chapter refer to fault conditions 10 1 Troubleshooting Metso MCA s self diagnostics monitors certain internal measurements and generates error messages if the measurements exceed alarm limits Self diagnostics also detects definite faults which are often caused by sensor electronics An erroneous measurement result may also be due to antenna leakage contamination a fault in the antenna cable or a process variable that is skewing the meas urement Self diagnostics may not detect such a fault The fault may also be in the current output sent by the TCU In this case the measurement is correct but the current output sent to the automation system is in correct The following figure 1 contains a troubleshooting chart for faults that appear in different ways 10 2 Process Conditions Air Air in the pulp is seen in measurements as an excess in consistency Air exists as bubbles of different sizes Small bubbles dissolve in water at pressure of approx imately 1 5 bar but large bubbles may disturb processes even at pressures higher than that At most the error caused by air may be in the range of several percentage points percentage of consistency Air cause
12. 1 Remove the sensor electronics as described in Chapter 11 1 2 Remove the antenna cable as described in 11 2 3 Remove the antenna s six mounting screws with a 5mm Allen wrench In the FT 100 model there are four mounting screws and the washers are self sealing Pull the antenna out of the inlet hole and remove the O ring 5 Remove the antenna from the flange by unscrew ing two 4 screws Installation 1 Attach the antenna to the flange with two M4x12 screws with washers Clean the sealing surfaces of the antenna installa tion hole using e g isopropanol 3 Place a new O ring into the installation hole against the collar Put locking medium Loctite 270 onto the flange s six mounting threads 5 Check that the antenna flange O ring is in place and then insert the antenna into place in the an tenna coupling 2 6 Tighten the antenna s six M6x16 mounting screws and washers with a 5mm Allen wrench to 8 Nm torque In the FT 100 model there are four screws and the washers are self sealing 7 Connect the sensor cable and the sensor electron back in reverse order Installation operating amp service manual OUL00298 V2 2 EN 11 6 NOTE Before removing the antennas check that the process pipe is empty and unpressurized and that remov al is safe Removal 1 Disconnect the network voltage form the TCU and remove the network voltage lines from the TCU terminal block 2 Remove t
13. 483 5 00198 O Ring 23 4x3 5 Viton 5 00100182 O Ring 33 2 62 Viton 5 00100184 O Ring 56 2 3 0 Viton 5 OULO00294 Seal Ring 16x10x1 Polyamide 10 OULO00183 Seal Washer U6 7x11 0x1 5 506001 1 Lock Washer DIN127 B4 A4 5 5060013 Lock Washer DIN127 B6 A4 5 01100364 Rec Countersunk Screw DIN965 M3x12 5 5160025 Slot head Screw DIN84 M4x8 A4 5 5160015 Slot head Screw DIN84 M4x12 A4 5 OUL00185 Socket Head Screw DIN912 M6x16 A4 5 Metso Automation Manufacturer reserves the right to changes without prior notice 2 4 Metso MCA Service kits amp spare parts Service Kit Options MCA F AISI 316L Order Code Description OUL00339 Microwave Cable Set F OUL00046 Microwave Antenna AISI 316L OUL00010 Sensor Head AISI 316L 00100016 Thermoelement Assembly AISI 3161 Service Kit Options MCA F Titanium Gr 2 Order Code Description OUL00339 Microwave Cable Set F OUL00259 Microwave Antenna Titanium OUL00263 Sensor Head Titanium 00100267 Thermoelement Assembly Titanium Service Kit Options MCA F Hastelloy C 276 Order Code Description OUL00339 Microwave Cable Set F 0000260 Microwave Antenna Hastelloy 00100264 Sensor Head Hastelloy 0000268 Thermoelement Assembly Hastelloy Service Kit Options MCA FT Order Code Description 00420 Microwave Cable FT 50 2 OULO001 14 Microwave Cable FT 100 4 00118 Microwa
14. 5 mS cm After entering these values go to Special Functions conductivity and select Chemical Compensation to begin using chemical compensation The following display appears MCA MCA 1234 Chemicals Comp Chem comp OFF Comp value 0 00 Chemical NaOH Lab cond 2 45 mS cm ABORT OK To begin using chemical compensation set the Chem Comp value from OFF to ON Comp Value shows the chemical compensation value which chem ical compensation subtracts from the consistency res ults The lower two rows show the chemical and labora tory conductivity values entered in Enter lab menu Installation operating amp service manual OUL00298 V2 2 EN Temperature Compensation Correction Curve You can define temperature compensation correction curve for Metso MCA if you notice temperature depend ency in the measurement results Define the correction curve by entering 2 6 pairs of temperature consistency points Based on the curve drawn from these points Metso MCA subtracts the curve consistency from the measurement results Determine the correction curve pairs of points as described in section 9 1 Then enter the pairs of points in the menu Temp Comp which appears as follows MCA MCA 1234 Temp Comp 1 1 m 0 00 2 1 0 00 3 2 0 00 4 2 0 00 9 b iG 0 00 5 0 00 6 0 00 6 0 00 Enter temperature and consistency values for the desired points 1 6 Then press SEND F2
15. Consistency Transmitter 24 Installation operating amp service manual OUL00298 V2 2 EN 5 User Interface and Operation 5 1 Transmitter Central Unit The operation unit of Metso MCA is the Transmitter Central Unit TCU Number buttons Use number keys to enter numerical data and choose menus On certain displays you can also enter letters To enter letters press a number button several times in rapid succession and the letters on the button appear on the display one after another Sample Use the Sample button to start and stop a calibration sample in the Calibration menu s Take calib sample function You can also use the Sample button in the main display to start and stop a monitoring sample Edit Save Use the Edit Save button to go into Edit mode When you are in Edit mode use this button to save data ESC Use the ESC button to exit Edit mode without saving data You can also use the button to move between the main display and the function menu Enter Use the Enter button to move between the main display and the Info display In Edit mode use the Enter key to jump to the next edit field Back arrow Use the back arrow in an edit field to re turn to the previous character Metso Mircowave Consistency Transmitter Forward arrow Use the forward arrow in Edit mode to move to the next character Down arrow Use the down arrow to scroll down if there are more than four lines A downwards pointing arrow in the lo
16. Diagnostics 8 1 Error Table In the Diagnostics menu select Error table 1 If self diagnostics has not detected any errors the display shows NO ERRORS If self diagnostics has detected errors the first line of the display shos the timestamp when the error state began The second row shows the timestamp when the error state ended The third row shows the error type If the error state is still in effect the ending timestamp is shown as The message Shutdown in the place of the error state end time notifies that the error state was on when the power was shut down If the error state is still on when the power is switced on next time the error is reported as a new error The Error table shows the 10 most recent errors 10 12 10 15 32 45 RLEV ALARM ENTER for next 8 2 Diagnostics Values In the Diagnostics menu select Diag Values 2 The following display appears Cab temp 40 6 C Proc temp 42 0 C lev 121 mV Rlev 214 4 mV stab 9 8 Rstab 2 1 El drift 2 4 VCO drift 3 2 Metso Mircowave Consistency Transmitter The display shows values for the following diag nostics measurements Cab temp Sensor electronics temperature Proc temp Process temperature Mlev Measurement signal level Rlev Reference channel signal level Mstab Measurement channel signal stability Rstab Reference channel signal stability El drift Reference channel drift VCO drift Sig
17. MCA s user interface and calculator Perform operations using the number buttons and other buttons and the four line display The TCU is delivered attached to the shield as shown in figure 5 Connectors Forthe sensor unit sensor electronics supply voltage and RS485 serial port connectors For the current outputs passive From TCU Rev B 2 current outputs For HART communicator HART only in the cur rent output 1 For RS232 connection to a PC for maintenance purposes For network voltage Fig 5 Transmitter Central unit Fig 6 Sensor Electronics 1 Power Cable Connector 2 Fixing Screw 3 Pt 100 Connector 4 Guide hole 5 Antenna Cable Connectors Metso Mircowave Consistency Transmitter Installation operating amp service manual 00298 V2 2 EN 3 Installation 3 1 General principles The sensor model is selected according to the size of the pipe Flow through models are FT50 2 FT100 4 FT150 6 FT200 8 FT250 10 and FT300 12 Flowthrough models can be installed on the following pipe flanges DIN PNIO DIN PNI6 ANSI Class 150 JIS 10K In laboratory analysis of measurement results it is important to use a proper sampler e g NOVE Install it according to MCA installation instructions NOTE Before installing the process coupling or sensor check that the process pipe is empty and unpressurized and that installation is sa
18. This menu shows the history of samples that have been taken Move the cursor onto Sample History and press the right arrow The following display appears MCA MCA 1234 12 10 10 107232209 MCA 3 04 Cs Att 49 3 dB T 53 2 C ABORT OK On the display you can read the date and time when the sample was taken as well as the sample s measure ment values Press OK F4 to browse backward through the samples Press ABORT F3 to exit the menu Metso Mircowave Consistency Transmitter Special functions Special functions include chemical compensation temperature compensation correction curve sensitivity compensation and recipes Chemical Compensation Large fluctuations in chemical content may cause errors in Metso MCA consistency measurements These errors can be compensated for with chemical compensation based on microwave damping measurement You must perform operations in two menus in order to use chemical compensation In Enter lab menu first select the chemical and then enter the laboratory con ductivity for the sample you take Note that the labo ratory conductivity is given in unites mS cm If the conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 umho in 10 mS cm If the conductivity meter shows results in units mS m divide the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 uS cm 5
19. a 10 mm socket key to open the lock bushing that is attached to a connector on the electronics side of the base plate NOTE Don t allow the connector body to rotate while you turn the lock bushing 8 10 11 12 13 14 Remove the long steering screw and the base plate from the sensor body At the same time guide the Pt 100 cable through the base plate Remove the cable of the flush mounted antenna with an SMA wrench Remove the cable support bushing by pulling it through the feed through hole with drawing pliers Open the Pt 100 coupling on the outer edge of the sensor shaft with plug spanner OUL00323 Check that the cable also rotates during removal Pull the Pt 100 sensor about 100mm outwards and let it hang by its cables Remove the MCX connector from the probe an tenna by prying with pointed pliers Push the Pt 100 cable to the side so that the connector is able to be removed Pull the microwave cable carefully out through the feed through hole on the shaft toward the flushmounted antenna Metso Mircowave Consistency Transmitter 46 Connecting 1 Install the probe antenna s microwave cable into the MCX connector Push the cable end with the straight angle connector through the shaft such that the connector is just oppisite the probe an tenna connector Connect the connector to the end hole by prying with a 4mm screwdriver Handle the cable with care so that it stays in shape and eases future
20. a new consistency calibration is performed on Metso MCA by taking a new sample after temperature consist ency correction is determined the measurement pro gram performs a level adjustment on the compensation curve In the level adjustment the program sets the value of the compensation curve to zero in the calibration temperature i e the effect of the compensation curve is zero at the calibration temperature If for example you performed a new consistency calibration with a sample that has a temperature of 45 the program would perform a level adjustement of 0 05 on the compensation curve and the compensation curve would Changing the correction If after the correction there is still some amount of temperature dependency evident you can most easily perform the correction by editing the existing points In this case the size of the desired correction iss added to existing correction values If for example after the temperature compensation performed above and the new consistency calibration the results appeared as shown in Figure 2 The correc tion value for 42 C would be increased by 0 0346 and the correction value for 48 1 C would be decreased by 0 02 96 after which the correction would appear as follows appear as follows Temp MCA Lab 1 42 0 90 02 2 48 1 C 00 03 Temp MCA Lab 1 42 0 0 05 2 48 1 0 05 MCA Lab vs Temp 0 2 0 15 0 1 E 5 0 05 0
21. and compare these to the error results if such error data is available e g in laboratory monitoring This requires a deeper knowledge of the sensor and is typically per formed by Metso maintenance personnel Reference Channel Failure Refer to Sensor Electronics Failure Installation operating amp service manual 00298 V2 2 EN 10 3 Self diagnostics error messages Self diagnostics monitors the signal of the measurement channel measuring the process and the signal of device s internal reference channel Self diagnostics is capable of detecting clear fault states in which case it generates an alarm by freezing the current signal or setting it to 3 75 or 22 5 mA according to user specifications If however the fault is not a clear device fault but rather measurement drifting then self diagnostics may not necessarily be able to detect it In such cases comparing self diagnostics measurements with device drifting and seeking correlations between these may help in locating the source of the error Cab temp Shows sensor electronics temperature A continuously high temperature reduces the average fault interval If the electronics temperature is continu ously over 75 degrees C then it is recommended to install the Vortex cooler in the sensor base plate Refer to chapter 11 7 for more information Mlev Shows the measurement signal level in milli volts A decrease in measurement signal level below the alarm level may be
22. and Pt 100 sensor con nectors to the electronics Place the sensor cover into position Connect the sensor cable to its connector at the edge of the base plate If after the electricity is switched on MCA asks you to choose calibration choose as follows TCU if you did not replace the TCU Default calibration if you have replaced the TCU as well Fig 1 Removal diagram for sensor electronics Metso Mircowave Consistency Transmitter Installation operating amp service manual OUL00298 V2 2 EN 11 2 Antenna cables Fork Sensor NOTE Before removing the sensor check that the pro cess pipe is unpressurized and empty and that it is safe to remove the sensor Removal Fig 2 and 3 1 Place the body of the sensor into a table vice such that the sensor head is on top Use aluminum buffers in the between the vice jaws and the sensor Remove the sensor electronics according to chapter 11 1 Lift the Pt 100 cable from the tape on the base plate Remove the uppermost mounting screw on the probe antenna side Screw in a longer screw in its place e g M6x50 is a suitable size This screw will serve to hold the sensor in place when the base plate is removed Remove the five other base plate mounting screws Pull the base plate 10mm away from the sensor body Disconnect the antenna cable from the base plate by holding the connector in place with an 8mm wrench e g SMA wrench while you use
23. calibration and sample history data MCA MCA 1234 Calibrate 1 Sample taking Enter Lab Level corr Filler Lab cal History Sample history Special functions O1 Sample taking This function allows you to take a sample for single point calibration Move the cursor on to Sample taking and press the right arrow The following display appears Press OK to start sample taking ABORT OK Press F4 OK Metso MCA begins to average the measurement result for the sample and the following display appears Press OK to stop sample taking ABORT OK Take the sample and then press OK F4 again Metso MCA shows the results of its measurement MCA MCA 1234 Sampling ready Average Cs 3 02 Min 3 01 Max 3 03 T 42 3 C ABORT OK Select OK F4 to return to Calibrate display Installation operating amp service manual OUL00298 V2 2 EN Enter Lab This function allows you to enter the laboratory value for the sample taken Move the cursor onto Enter Lab and press the right arrow The following display appears CA MCA 1234 Enter lab Lab Cs Filler Kaolin 1 TiO2 Chemical Lab Cond Enter the necessary laboratory information Lab Cs Laboratory consistency Filler The relative proportion of filler in the total consistency shown as a percentage Kaolin The relative proportion of Kaolin in the filler sh
24. holes are in line with each other 3 Screw in the washers and screws and tighten them with a 5mm Allen wrench Insert the air hose with internal diameter of 6 mm 1 4 into the hose nipple using a hose clamp 2 During installation note the following The cooler is installed between elements If lack of available space so dictates you can move the cooler to one end of the element by removing the plug and pla cing the cooler into that thread Then put the plug in the central thread The cooler s outlet pipe can point upwards recommended or to the side but not down wards Cooling The maximum volume flow in cooling is 230 nl min If you do not use a flow meter start the air flow care fully and then increase it slowly until the necessary cooling efficiency is reached NOTE The outlet pipe releases hot air Check that there are no cables that touch the outlet pipe or in its near vi cinity Installation operating amp service manual 00298 V2 2 EN 12 HART User Interface 12 1 About the interface HART is a registered trademark of HART Commu nication Foundation HART communication is method of transferring information digitally between field devices and host devices e g HART Communic ator In order to function properly HART requires TCU program version C or higher and a HART Communic ator that contains the Metso MCA command base You can perform the same operations on Metso MCA HART
25. on the calibration as explained in chapter 7 3 MCA Lab graph points that are in a position other than the horizontal indicate that there is temperature dependency in the measurement figure 1 Temperature dependency is eliminated by entering into MCA the temperature compensation correction curve To go to the Temperature Compensation menu Select Special Functions Temperature Comp The following display appears Temp MCA Lab 1 42 0 0 00 2 48 1 0 10 3 00 0 0 00 4 00 0 0 00 5 00 0 0 00 6 00 0 0 00 Press the Edit button Then enter the correction curve as pairs of points Metso MCA then performs the cor rection based on lines drawn through these points You can enter up to six pairs of points In the example in Figure 1 two pairs of points are sufficient The pairs of points can be selected based on the results as in the following example Compensation is also successful outside the defined interval such that the compensation curve is continued beyond the outermost points using the same slope 0 2 MCA Lab vs Temp 0 15 0 1 0 05 MCA Lab 0 05 0 1 0 15 43 44 45 Temp C 46 47 48 49 Fig 1 Determination of temperature dependence Metso Mircowave Consistency Transmitter 36 Installation operating amp service manual OUL00298 V2 2 EN The effect of a new consistency calibration If
26. per formed on the device in connection with final testing using clean water We recommend that you calibrate the device again when setting it up This allows the device settings to be optimized for the conditions in which it will be used Perform calibration by taking a consistency sample and entering its laboratory value into Metso MCA When you have performed this according to the instructions in the next chapters the status line on the display will change from Factory Calibration to OK Calibration menu contains the following functions Sample taking Enter lab Offset correction Filler Calib history Sample history 1 2 3 a 4 5 6 7 1 Sample Taking In the main display press the ESC button to move to the Operations menu Select Calibration Sample taking Whenever a factory calibrated device takes a sample it adjusts the measurement signal to the optimal level before taking the sample This may cause a small steplike change in the device s consistency measure ment For this reason the device may not be kept on consistency control in this phase In addition whenever a device that has been calib rated takes a sample it checks whether the measure ment signal level is within an acceptable area If the signal level is outside the acceptable area the device suggests that the signal level be adjusted The signal level adjustment may cause a small step like change in the consistency measurement T
27. removing the sensor check that the pro cess pipe is unpressurized and empty and that it is safe to remove the sensor Removal 1 Remove sensor electronics according to the instruc tions in section 11 1 2 Open the inlet bushing of the antenna cable con nected to the base plate Slide it down until the connector body at the end of the cable becomes visible 3 Hold the connector body in place with an 8 mm wrench e g SMA wrench while you use a 10 mm box wrench to open the lock bushing that is attached to the connector on the other side of the base plate NOTE Don t allow the connector body to rotate while you turn the lock bushing 4 Loosen the four mounting screws of the sensor cover and lift the cover off Loosen the antenna cable s SMA connector from the antenna end with an SMA wrench or SMA wrench adapter In sensor model FT 100 you must also loosen two cable feed through mounting screws Lift the antenna cable out of its mounting groove by for example prying the casing tube with a screwdriver such that the cable begins to come out of the groove starting with the antenna end When the cable s casing is separated from the sensor body pull the cable connector on the base plate carefully out of its hole NOTE Lift the cable by its casing tube not by the cable itself NOTE Be careful not to dent the antenna cable connector on the base plate Metso Mircowave Consistency Transmitter 48 Installatio
28. result so electronic drift does not cause an error in the meas urement result An El drift alarm is caused by sensor electronic failure VCO drift VCO drift shows the drift in sensor elec tronics signal generator A VCO drift alarm is caused by sensor electronic failure Installation operating amp service manual OUL00298 V2 2 EN Notes Metso Mircowave Consistency Transmitter 44 Installation operating amp service manual OUL00298 V2 2 EN 11 Replacing Components 11 1 Sensor Electronics Removal Fig 1 1 Disconnect the electricity by separating the sensor cable from the connector at the edge of the base plate Remove the electronics protective cover Disconnect the sensor cable and Pt 100 sensor connectors from the electronics and bend them to the side Loosen the three mounting screws and lift the sensor electronics evenly out of its position by pulling on the mounting screws NOTE Sensor electronics is aligned into place by three guide pins which keep it in place even when the mounting screws are loosened Installation l Align the groove in the edge of the electronics with the connector on the edge of the base plate Move the electronics and press gently until the guide pins on the base plate are aligned with the holes on the base of the electronics Then press the electronic evenly onto the base plate Screw in the three sensor electronics mounting Screws Connect the sensor cable
29. the right to alter the contents of this document without prior notice Modbus is the trademark of Modicon Inc Copyright March 2011 Metso Automation Inc Documentation JT Tieto Oy D metso Metso Automation Inc Kehr m ntie 3 P O Box 177 87101 Kajaani Finland Tel 358 20 483 120 fax 358 20 483 121 www metso com automation
30. to send the values to Metso MCA Sensitivity Correction Metso MCA consistency sensitivity is set according to the wood fiber The measurement sensitivity can be changed if necessary e g if you are measuring some material other than wood fiber If you do not know the sensitivity correction of the material beforehand you can determine it according to the instructions in section 9 2 and enter it in the Sens Corr menu MCA MCA 1234 Sens Corr 12200 1 00 DEL ESC ENTE Metso Mircowave Consistency Transmitter 56 Recipes The Recipe function may be necessary in special functions in which measurement conditions change so much that one calibration cannot cover it Such a change may be e g A change in consistency greater than the device measurement range 9 15 depending on the type of sensor A change in the measured material since different materials have different consistency sensitivity A large chemical fluctuation e g change of chem ical type that cannot be compensated for with chemical compensation In these cases each process condition has its own calibration and configuration performed This calibration and configuration is saved as its own recipe In addition to consistency calibration for each recipe you can set chemical compensation temperature consistency correction sensitivity correction and cur rent output scaling You can save a maximum of four recipes T
31. 00298 V2 2 EN 12 2 Measurement Measurement menu shows the Metso MCA measure ment results MCA MCA 1234 Measurement 1 Sensor Type FT200 2 Cs 0 00 Cs 3 Prc Temp ig 4 Status OK 5 Conductivity 2 43 mS cm 6 of range 36 72 7 mA 9 88 mA 8 meas Att 32 4 dB Recipe OFF Sensor Type Cs Measured consistency Prc Temp Process temperature Status Device status OK Alarm etc Cab Temp Sensor electronics temperature of range Consistency current output value as a percentage of the current output range value of in milliampers meas Att The measured microwave damping in the process Recipe The number of the recipe in use refer to Chapter 9 3 Metso Mircowave Consistency Transmitter 52 12 3 Configure In Configure menu you can configure Metso MCA s current output and certain other parameters Configure menu also shows device information MCA MCA 1234 Configure 1 Range Values User settings Device info SENSOR ELECTRONICS TCU Set Clock Wd Range values LowRnge Consistency that correlates to current output lower limit 4 mA UppRnge Consistency that correlates to current output upper limit 20 mA Damping Damping time of the current output Alarm cur How the output signal reacts to error situations detected by self diagnostics Options 3 7 22 5 mA freeze User settings Trend Int The sam
32. 7 ae 13 12 10 23 0 50 7 pid 13 11 9 28 0 61 7 sow oe fes xonz 9 9 9 26 After the upgrade there is no more a conductivity low limit for the MCAi FT 100 4 sensor MCA Specification EN docx 31 01 2011 Page 1 4 D metso Expect results Metso MCA Service kits amp spare parts Metso MCA Service Kit OUL00335 Order Code Description Qty OUL00347 Accessory Case 1 OUL00298 Manual 1 OUL00051 Sensor Electronics 1 OUL00241 Operating Unit TCU 1 OUL00334 Simulation Cable 1 OUL00325 Tool for Sensor Head 1 OUL00323 Tool for Fork Pt 100 Cap 1 A4611042 Sma Torque Wrench Modified 1 OUL00407 Sma Torque Wrench Adapter 1 OUL00349 Torque Driver 1 4 1 OUL00409 Box Key 10 mm 1 83200021 Thread Locking Compound Loctite 270 10 ml 8360019 Instant Glue Loctite 480 20g OUL00350 Thermoelement Simulator 1 OUL00351 Spare Part Set MCA F 1 00100007 O Ring 13 1 1 6 Simrit 483 5 00100198 O Ring 23 4x3 5 Viton 5 80500860 Gasket Ptfe 5 00100277 90 3 5 5060011 Lock Washer DIN127 B4 4 5 5060013 Lock Washer DIN127 B6 A4 5 5060014 Lock Washer DIN127 B8 A4 5 5160011 Slot head Screw DIN84 M4x16 A4 5 5460041 Socket Head Screw DIN912 M6x20 A4 5 OULO00003 Socket Head Screw DIN912 M8x20 4 5 OUL00352 Spare Part Set MCA FT 1 8060036 O Ring 14 3x2 4 Simrit
33. Chem NaOH Lab cond 3 4 mS cm Press the Edit button to make the cursor appear in the Chemical Compensation field The OFF text indic ates that chemical compensation is not in use Use the up and down arrows to change the text from OFF to ON Press Save after which MCA begins using chem ical compensation The second line Comp Value shows the chemical compensation value or the value that chemical com pensation subtracts from the measurement result The third and fourth lines show the chemical and laboratory conductivity values entered by the user Installation operating amp service manual OUL00298 V2 2 EN Temperature compensation correction curve Metso MCA compensates for the effect of temperature on the measurement based on Pt 100 sensor measure ment results If however temperature dependency still exists in the measurement result it can be eliminated by using the temperature compensation correction function The temperature dependency must first be determined via laboratory monitoring To ensure that the temperature dependency is accurately defined the temperature area must be sufficiently broad The results of the laboratory monitoring are shown on an MCA Laboratory vs Temperature graph MCA Lab graph points that are horizontal indicate that there is no temperature dependency in the measurement res ults If the graph points are in a horizontal position at a level other than zero you must perform offset correc tion
34. MCAi Upgrade Kit Connections Cable to sensor length 10 m 33 ft Option 30 m 98 ft Operating voltage 90 260 VAC 0 1 VA Connections to mill systems analog outputs 2 current outputs 4 20 mA Cs process temperature conductivity 12 36 VDC binary inputs 2 x 12 28 VDC 10 mA isolated Connection to PC Device HART Profibus PA Operating environment Temperature 5 50 41 122 Housing class IP65 NEMA 4 Dimensions amp weight WwXxhxd 232 x 282 x 133 mm 9 13 x 11 10 x 5 24 Weight ssss 2 kg 4 4 Ibs MCA Specification EN docx 2 2 Metso MCA Technical specification MCAi Upgrade Kit Measurement Measuring range 0 16 Cs if greater than 16 Cs or if used in an application other than for paper or pulp please consult Metso Automation Repeatability 50 01 Cs 0 001 Cs Filtering 1 99 s Microwave power 15 mW Cv values 200 4200 7 2 FT 250 10 7800 2 4 FT 300 12 9700 7 2 Process conditions pH 2 5 11 5 Temperature
35. N Clearing the Recipe If you wish to empty the recipe go to Recipe menu and press 2 Clear Recipe The following display appears Clear recipe 1 Press the Edit button and use the up and down arrow buttons to select the desired recipe Press the Save button after which the program asks you to confirm your selection This action will clear recipe 1 ENTER Clear ESC Cancel Press Enter to clear the recipe Note You cannot empty the recipe that is currently in use Metso Mircowave Consistency Transmitter 40 Selecting the Recipe with Binary Inputs The recipe can be selected using two digital control lines connected to the TCU connector casing In this case you can use up to four recipes If only one binary input is in use you can use two recipes Select Binary as the recipe selection method accord ing to the instructions in section Using Recipes Select BIN 1 01 150405 ON 2 02 220405 Qu cem EU 000000 SSS gsn 000000 Connect e g the automation system s digital control lines to the connector casing binary inputs BINO and BIN1 Connect the grounded line to BINGND Select the recipe with the digital control lines according to the following table The text next to the recipe number indicates which recipe is selected BINO Recipe 0 0 1 1 0 2 0 1 3 1 1 4 Installation operating amp service manual
36. OTE Metso current supply is passive and needs 250 an external source of current The minimum supply voltage is dependent on resistance Operating region 0 6 12 17 28 35 V Fig 14 TCU s Current output load capacity Automation system Power supply L Input 1 a i Channel 90 260 VAC 47 63 Hz 4 20 mA HART Consistency 4 20 mA Process temperature conductivity Sensor cable 2x 2 1 x0 5 shield Fig 15 Electrical connections to the TCU Metso Mircowave Consistency Transmitter 21 Installation operating amp service manual 00298 V2 2 EN 3 7 Metso Sensor Deflector Plate Installation Guide If the flow contains pieces of string lumps etc the Metso MCA must be protected with a special deflector plate Install the deflector plate at a distance of 170 mm before the sensor on a process unit welded in line with the sensor After you install the process unit position the deflector plate such that its lag side is toward the sensor Select the process unit according to the sensor mater ial and the diameter of the pipe see Technical specific ations Select the deflector plate according to the ma terial of the sensor material see Technical specifica tions Installing the process coupling Makea71 mm hole in the flow pipe in line with the sensor The distance from the center of one hole to the center of the othe
37. and press the right arrow The following display appears 9 Enter Filler 0 0000 0 0000 DEL ABORT ENTER In this field enter the relative filler percentage For example if the total consistency is 3 Cs and the filler percentage of that is 0 3 Cs absolute consistency then the relative total filler percentage is 0 3 Cs 3 Cs x 100 10 96 9 Enter Kaolin 0 0000 0 0000 DEL ABORT ENTER Enter the relative percentage of kaolin and press ENTER F4 Repeat these steps for CaCO talc and TiO The sum of the filler components must be 100 After you have entered the values then the display shows the filler sensitivity compared to wood fiber as calculated by the device MCA MCA 1234 Sensitivity 0 97 ABORT OK Select OK F4 to return to Calibrate display Installation operating amp service manual OUL00298 V2 2 EN Lab cal History This menu shows a history of calibrations performed on the device Move the cursor onto Lab cal History and press the right arrow The following display appears MCA MCA 1234 23 04 05 10 32 09 Lab 3 00 MCA 3 10 Cum offset 0 00 Cs 53 2 C Att 49 3 dB ABORT OK The display shows the date and time of the calibra tion as well as the sample s measured value and labor atory values Press OK F4 to browse through the calibrations Press ABORT F3 to exit the menu Sample History
38. as described in Chapter 11 2 2 Flush mounted antenna 3 Unscrew two 8 Allen screws to remove the an tenna from its mounting clamp Pull the antenna out of the inlet hole and remove the O ring 5 Unscrew two M4 screws to remove the clamp from the antenna Probe antenna 6 Use socket key OUL00325 and a 13mm ring spanner to remove the probe antenna Installation Flush mounted antenna 1 Attach the mounting clamp to the antenna with two M4x16 screws with washers Clean the sealing surfaces of the antenna installa tion hole using e g isopropanol 3 Place a new O ring into the installation hole against the collar Place the antenna into position Attach it with M8x20 Allen screws and washers using a 6mm Allen wrench Use locking medium Loctite 270 on the threads 5 Tighten the antenna s mounting screws to 19 Nm torque Probe antenna 1 Clean the sealing surface with e g isopropanal Place a new O ring into the sealing groove Put locking medium Loctite 270 on the threads Screw the probe antenna into the sensor body us ing socket key OUL00325 to 10 Nm torque 5 Install the antenna cable s as described in Chapter 11 2 Attach the sensor electronics as described in Chapter 11 1 2 3 4 Metso Mircowave Consistency Transmitter 49 11 5 Antennas FT Sensor NOTE Before removing the antennas check that the process pipe is empty and unpressurized and that remov al is safe Removal
39. ble Press EDIT SAVE to save the selection Metso Mircowave Consistency Transmitter 27 6 3 User Settings In the main display push the ESC button to move to Operations menu In the Operations menu select Con figuration User settings The following menu appears Trend Int 10 MIN Position 5 1234 Language ENGLISH Temp unit GEG C asswor Act sigLev ON The display fits four rows at a time Use the up arrow and down arrow buttons to scroll through all the lines Press the EDIT button to perform the following Trend Int The trend table sampling interval Use the up arrow and down arrow buttons to change it Position Sensor s mounting position In this field you can use letters of the alphabet To enter letters press a number button several times in rapid succession and the letters on the button appear on the display one after another Language Language selection Use the up arrow and down arrow buttons to select the language Temp unit Temperature unit Use the up arrow and down arrow buttons to select the temperature unit Password Password Yes No Use the up arrow and down arrow buttons to make your selection If you se lect Yes the program asks for a password when you move into Edit mode or if you intend to take a calibra tion sample The password is 3121 As a default pass word is not in use Act sigLev Active signal level adjustment ON OFF Use the up arrow and
40. caused by an electronics failure antenna leakage or high conductivity of the measured pulp If it is an electronics failure then the reference channel signal level Rlev is usually decreased to below alarm limits Rlev Shows the device s internal reference channel s signal level in millivolts A decrease in the signal level to below alarm limits is always caused by a sensor electronics failure Metso Mircowave Consistency Transmitter 43 Mstab Mstab shows the stability of the measurement channel signal Stability reflects the effect of both electronics and the measured pulp Assuming that the electronics are in order see Rstab you can determine based on the Mstab value whether or not the process contains large air bubbles that are causing measurement errors Large air bubbles cause both a rise in the Mstab value as well as a temporary error in consistency measurement The level of the Mstab value is also af fected by consistency and sensor model Fork Sensor typically has a slightly higher Mstab value than FT Sensor Also Mstab value is higher at a higher consist ency than at a lower consistency Rstab Rstab shows the stability of the device s refer ence channel signal The smaller the value the more stable the signal An Rstab alarm is caused by sensor electronic failure El drift El drift value shows the drift in electronic delay measured by the reference channel This value is compensated out of the measurement channel
41. ction 4 In Upgrade Kit for MCAi startup however please note the following 1 2 3 Upgrade Kit for MCAi is not factory calibrated Calibration must be performed at the installation site You must know the sensor type for which MCAi is to be installed This information is found next to Item on the sensor plate 13 6 Configuration and Calibration l 2 Connect the electricity to the power supply feed The device asks you to select the sensor type from SET DEFAULT menu Press EDIT SAVE button Select the sensor type using the up and down ar rows You can recognize the Upgrade Kit sensors from the UPG prefix The options are JPG F JPG FS JPG FT 100 JPG FT 150 JPG FT 200 JPG FT 250 JPG FT 300 Save your selection with EDIT SAVE button Select the language and temperature unit C F according to the instructions in chapter 6 3 Set the device date and time according to the in structions in chapter 6 5 Scale the current output according to the instruc tions in 6 2 Calibrate the consistency according to the instruc tions in 7 2 and 7 3 Cc Ce After you perform these steps MCAi upgraded with the Upgrade Kit is ready to measure Metso Mircowave Consistency Transmitter 63 13 7 User Interface Refer to section 5 13 8 Troubleshooting and Maintenance For electronics issues refer to section 10 For sensor body antenna and antenna cable issues refer to sect
42. d the offset correction per formed on it Offs The third row shows the cumulative change caused by offset correction This value shows whether the calibration has continuously moved in one direction or if the change has been back and forth The former case clearly indicates device drifting while the latter case may be a question of a device error or of erroneous laboratory interpretation of the calibration sample and calibration performed based on that Metso Mircowave Consistency Transmitter 31 Sample History The sample history table saves the 20 most recent cal ibration and monitoring samples You can take a mon itoring sample without performing calibration To do 5 press the Sample button when you are in the main display To perform calibration you must access Take calib sample menu You can also use the table as an aid if you wish to read Metso MCA values for a certain sample To access the sample history table select Calibration Sample history in the Operations menu 10 12 10 12 10 48 MCA 3 00 40 2 T 47 4C ENTER for next att The first row shows the sample s date and time The second and third rows show consistency measured by Metso MCA the attenuation of the measurement signal and process temperature Installation operating amp service manual OUL00298 V2 2 EN Notes Metso Mircowave Consistency Transmitter 32 Installation operating amp service manual OUL00298 V2 2 EN 8
43. down arrow buttons to make your selection If you Select ON program make measure ment signal level adjustment automatically when it goes too low Installation operating amp service manual 00298 V2 2 EN 6 4 Device information In the Configuration menu select Device Info 3 The following menu appears 1 Sensor Electronics 2 TCU Select Sensor Electronics 1 to view sensor electron ics information Type S N 123456 HW Ver 0001 SW Ver 0001 S N Sensor electronics serial number HW Ver Sensor electronics version number SW Ver Sensor electronics software version number Select TCU 2 to view corresponding data for the TCU Metso Mircowave Consistency Transmitter 28 6 5 Setting the date and time In the Configuration menu select Set clock The fol lowing menu appears Date 10 12 10 Time 12 14 53 Enter to accept The date and time shown in this menu are used as a time stamp in the trend table and for calibration samples The main display status line shows Set clock until you have set the time Use the EDIT and SAVE buttons to edit and save date and time settings 6 6 Address Metso MCA s address on HART bus Installation operating amp service manual OUL00298 V2 2 EN 7 Calibration The Metso MCA is delivered with factory calibration which means that it will measure consistency as soon as you switch the power on Factory calibration is
44. enance and service operations remember that the sample line may contain hot sample or water be careful Always check that the incoming voltage amp frequency are correct before making any electric connections Wrong connection may damage the equipment The applicable electrical safety regulations must be closely followed in all installation work Before any welding works in the vicinity of the devices make sure that operating voltage is not connected Metso Mircowave Consistency Transmitter 5 Installation operating amp service manual OUL00298 V2 2 EN Metso Mircowave Consistency Transmitter 6 Installation operating amp service manual OUL00298 V2 2 1 Introduction 1 1 General Metso Mircowave Consistency Transmitter Metso MCA functions based on the measurement of mi crowave propagation time Microwaves are electromagnetic radiation the flying time depends on the media s dielectric constant Flying time is calculated as follows speed of light in a vacuum e media s dielectric constant In water microwaves advance at a much slower speed that in wood fiber Therefore consistency can be calcu lated based on the time it takes the microwaves to move through the measured mass The advantages of this measurement procedure are pulp type independence insensitivity to flow speed and single point calibration There are two different models of Metso MCA sensors Metso Fork senso
45. er Filler sensitivity changes if the filler sensitivity of the measured mass changes considerably 21096 Press the down arrow to scroll down the display one row at a time Filler 20 0 Kaolin 100 0 00 0 Talc 00 0 TiO2 Filler sens 0 C C OJ 97 Enter a new value for Filler amount in the Filler field and new values for the filler components in the respect fields In the bottom row the Filler sens field the program calculates the change in sensitivity caused by filler components in proportion to the wood fiber sensitivity wood fiber sensitivity 1 Installation operating amp service manual OUL00298 V2 2 EN 7 5 Calibration and sample history Calibration history Ten last calibration changes are stored in the calibration history table To see the calibration history table press the ESC button to move from the main display to Op erations menu In the Operations menu select Calibra tion Calib history The following display appears 10 12 10 12 10 48 Lab 3 20 Cs 3 00 Cum offset 00 00 47 4 att 40 2 dB The first row shows the calibration change s date and time in the following format dd mm yy hh mm If calibration was performed on a new sample the second row shows the entered laboratory value Lab and the Metso MCA measurement result Cs If offset correction was performed the second row shows the laboratory value Lab an
46. etso Mircowave Consistency Transmitter 1 6 Installation operating amp service manual OUL00298 V2 2 3 3 Sensor dimensions Fig 7 Dimensions Metso MCA F MCA FT50 2 MCA FT100 4 100 3 97 Fig 8 Dimensions Metso 50 and FT100 Metso Mircowave Consistency Transmitter 1 7 Installation operating amp service manual 00298 V2 2 EN 150 6 200 8 Fig 9 Dimensions Metso MCA FT150 and FT200 MCA FT250 10 MCA FT300 12 s 5 AI QJIN HOH Fig 10 Dimensions Metso MCA FT250 and FT300 Metso Mircowave Consistency Transmitter 1 8 Installation operating amp service manual 00298 V2 2 EN 3 4 Mounting dimensions Metso MCA F The fork type Metso MCA F sensor is installed in a process coupling welded onto the side of the process pipe in such a way that the probe antenna is directed against the direction of the flow Fig 11 The sensor is loosely tightened into place with mounting clamps and then approximately aligned with the pipe based on the position of the electronics casing After aligning tighten the mounting clamps to their final tightness The sticker on the electronics casing indicates the in stallation direction in relation to the direction of flow NOTE The probe antenna on the end of the sensor is ceramic so avoid denting it
47. fe 3 2 Choosing the installation site The fork type Metso sensor can be installed on pipes with a diameter of 150 mm 6 or larger In choosing an installation position note the following t is not recommended to install Metso MCA F sensor in a place where the pulp may contain strings etc that may get wrapped around the sensor If ne cessary use a separate deflector plate Donotinstall the sensor on the pump s suction side or in the mixing tank After the sensor there should be a straight section of pipe length at least 2 times the pipe diameter before a change in pipe profile Adjacent to Metso MCA F sensor or one meter be fore it there must not be objects inserted into the pipe Reserve enough space for the sensor casing For the Metso MCA F reserve also space required for sensor installation TCU must be installed within 10 meters of the sensor The sensor cable is 10m long You also have the option of purchasing a 30m sensor cable Metso Mircowave Consistency Transmitter In addition you must note the following specifications Process temperature under 100 C pHrange 2 5 11 5 Conductivity according to sensor specifications Recommended process pressure is 1 5 25 bar Fork sensor 16 bar FT sensor to eliminate the effect of air bubbles Sensor pressure tolerance Fork sensor PN25 FT sensor PN16 Installation checklist Check
48. for total filler sensitivity need only be entered with a 5 percentage point accuracy The filler components can also be entered based on an estimate NOTE The sum of the proportions must equal 100 After you press Save the device calculates the filler sensitivity value in the Filler sens field in the bottom line This is the factor by which the device adjusts the default sensitivity set for the wood fiber The laboratory value for the sample can be entered only once in the Enter Lab menu If necessary you can perform offset correction for the consistency calibration or change filler content as explained in the next chapters Metso Mircowave Consistency Transmitter 30 7 3 Offset Correction If laboratory monitoring indicates that the Metso MCA measurement results are consistently overly high or low you can correct this by performing offset correc tion on the calibration To do so press the ESC to move from the main display to the Operations menu Select Calibration Offset correction after which you see the following display Offset Cum offset o o Press the Edit button to make the cursor appear in the Offset field Enter the desired offset correction value If for example Metso MCA shows a value that according to laboratory monitoring is 0 1 too high enter an offset correction value of 0 1 Press Save button to save your changes 7 4 Fillers In this menu you can ent
49. he Recipes menu is as follows MCA MCA 1234 Recipes 1 Choose OFF In Choose set the desired recipe number The op tions are as follows OFF the recipe function is not in use default 1 2 3 4 select the recipe number BIN select the recipe according to binary input Select the recipe Then perform recipe calibration and current output scaling Begin using the recipes as follows When you use the recipe selection method BIN connect the automation system digital control lines to the TCU connector casing binary inputs BINO AND BINI Connect their grounded line to BINGND Select the recipe with the digital output lines according to the following table BINO Recipe 0 0 L 1 0 2 0 1 3 1 1 4 Installation operating amp service manual 00298 V2 2 12 5 Diagnostics Menu information and functions MCA MCA 1234 Diagnostics 1 Diag History Diag Values Diag Alarms Digital Inputs Loop test Clear Logs iS Wd Diag History The 10 most recent self diagnostics alarms with beginning and ending times Diag values Measured values of diagnostics variables see Chapter 8 2 Metso Mircowave Consistency Transmitter 57 Diag Alarms Diagnostics variables alarm limits switching alarms on and off see Chapter 8 3 Digital Inputs The state of TCU binary inputs BINO and Loop test Forcing the output signal to the desired value
50. he sensor cable and the factory s system cable from the TCU terminal block 3 Remove TCU from its shield Installation 1 Attach the new TCU to the shield 2 Connect the sensor cable network voltage cable and the factory s system cable to the TCU terminal block 3 Switch on the network voltage NOTE It may take a few minutes for text to appear on the display This is due to the charging of the device s internal back up battery 4 Ifthe program asks you to select calibration select Sensorelectronics calibration if you did not replace sensor electronics Default calibration if you replaced sensor electronics as well Fig 4 Installing Vortex Cooler Metso Mircowave Consistency Transmitter 50 11 7 Installing Vortex Cooler Vortex Cooler is available as an option Its code is OUL00285 Fig 4 Vortex Xooler is used to cool the sensor electronics unit Cooling is necessary if the electronics internal temperature Cab Temp rises above 75 C 167 due to the effects of its surroundings Perform installation as for FT and Fork sensors Vortex Cooler installation kit contains the following parts Cooler with 6 hose coupling 2 Screws M6x25 2 pieces 3 Lock washers M6 2 pieces 4 Thermal conductivity grease Installation 1 Apply thermal conductivity grease to the installa tion surface of the cooler s black casing Set the cooler on the base plate such that the mounting
51. herefore you must put consistency control on manual control if you allow the device to adjust the signal level A change in chemical concentration may cause a need to adjust the signal level Metso Mircowave Consistency Transmitter The sample taking display is as follows Press sample key to start sampling Cs 3 26 Status WAITING Press the Sample button on the right side of the dis play The device begins averaging the measurement result and a message Sampling appears on the Status line Go take a calibration sample and then press the Sample button again The device finishes averaging the measurement result and displays the result Sampling ready Average Cs 3 26 3 20 3 33 T 56 3 C In addition to showing the consistency average the device also shows the sampling period s minimum and maximum values as well as the process temperature The minimum and maximum values indicate consist ency fluctuation during the sampling period This fluctuation should be small so that the consistency sample is reliable The sample you take goes to the Enter Lab menu to await the laboratory value Press the ESC button to move back in the menus NOTE If you press the Sample button when you are in a menu other than Take calib sample the device begins averaging the measurement results A sample taken this way can not be used to calibrate the device Rather it is intended to be used to read the meas
52. info Set clock Address Error log Diag values Diag alarms Chemical compensation l Temperature compensation Sensitivity correction Recipes Fig 2 Operations Menu Metso Mircowave Consistency Transmitter 26 Installation operating amp service manual OUL00298 V2 2 EN 6 Configuration 6 1 Configuration menu The configuration menu has the following functions Output signal 1 Output signal 2 User settings Device info Set clock Address HD oF 6 2 Choosing and scaling the output signal Press ESC button in the main display to move to Oper ations menu Select 1 to configure consistency current output and you see the following display Lo 4mA 0 0 Cs Hi 20mA 10 0 Cs Damping 1 S Fault sig 3 75 mA Press the Edit button and enter values for the low and high consistency values If you wish you may also change the filtering time and behavior of the electricity source if self diagnostics notes a fault state Options for this include 3 75 mA 22 5 mA and freezing Process temperature or process conductivity can be configured in the current output 2 Select 2 and you see the following display Selected variable Process temp Lo 4 mA 0 00 Hi 20 mA 100 00 Damping 1 S Fault sig 3 75 mA Press EDIT SAVE Use the up arrow and down ar row buttons to make your selection and enter low and high values for the varia
53. installation Install the flush mounted antenna s cable into the SMA connector Put the connector that is to be installed in the base plate on the side of the sensor body opposite the previous cable Tighten the SMA connector with a torque wrench to 1 Nm torque Handle the cable with care so that it stays in shape and eases future installation Install the thermoelement on the sensor body Check that the O ring is in the sealing groove Remove the old teflon tape from the thread and put two new layers of teflon tape in its place Check that the tape does not cover the O ring Take care that the cable also rotates Tighten it with plug spanner OUL00323 12 Nm torque Set the cable support bushing into place and put a drop of super glue on the side of the bushing before attaching it The antenna cable should be in the upper groove and the Pt 100 sensor cable should be in the lower groove Installation operating amp service manual OUL00298 V2 2 EN Check that O ring 90x3 is in the sensor body sealing groove 6 Place the base plate close to the installation posi tion with the current cable aligned in the same position as the probe antenna 7 Pushthethermoelement cable through the middle hole in the base plate Place the base plate about 10 mm away from the sensor body and at the same time check that the microwave cable connectors on the base plate side are lined up with their feed through holes 8 M6x50 screw tempo
54. ion 11 Installation operating amp service manual OUL00298 V2 2 EN Notes Metso Mircowave Consistency Transmitter 64 Installation operating amp service manual OUL00298 V2 2 EN 14 Recycling and disposing of a device re moved from service Most device parts are recyclable when sorted by material A materials list must accompany the device The device manufacturer can supply you with recycling and disposal instructions In addition you can return the device to the manufacturer which will recycle and dispose of the device for a fee Metso Mircowave Consistency Transmitter 65 Installation operating amp service manual OUL00298 V2 2 EN Notes Metso Mircowave Consistency Transmitter 66 Installation operating amp service manual OUL00298 V2 2 EN D metso Expect results 31 01 2011 Page 1 2 Metso MCA Technical specification Metso MCA sensor Measurement Measuring 0 16 Cs if greater than 16 Cs or if used in an application other than for paper or pulp please consult Metso Automation Repeatability 0 01 Cs Sensitivity 0 001 Cs Filtering 1 99 s Microwave power 15 mW Process conditions pH 2 5 11 5 Temperature 0 100 32 212 F Process pressure Minimum recommended over 1 5 bar no free a
55. ir Maximum F model PN25 Maximum FT model DIN PN16 ANSI Class 150 JIS 10k max 20 m s 10 2000 Hz Operating environment Temperature 20 70 4 158 F protect from direct heat sources Housing class 65 NEMA 4 Connections Operating power communication cable from TCU Materials F model Wetted AISI 316L OPTION Titanium GR2 or Hastelloy C276 Ceramic Sealing rings Viton Simrit 483 Process coupling AISI 316L OPTION Titanium GR or Hastelloy C276 Mounting clamps bolts AISI 316 Materials FT models Wetted parts 316 AISI 316L Ceramic Sealing rings Viton Simrit 483 Process coupling AISI 316 AISI 316L Metso Automation Conductivity limits and sensor weights Conductivity max mS cm 30 50 70 Weight 86 F 122 158 kg lbs MCA F 18 15 13 5 2 11 5 25 25 25 8 5 18 7 sp id 18 16 13 10 0 22 0 m 13 12 10 13 5 29 8 13 11 9 17 0 37 5 13 11 9 24 5 54 0 1 10 9 7 29 0 63 9 Operating terminal TCU Manufacturer reserves the right to changes without prior notice The same TCU is used both for Metso MCA and for the upgrade model
56. ls build up around the sensor and it can even by very rapid Checking the Fork Sensor requires it to be removed from its process coupling Broken Fork probe The Fork Sensor is inserted into the pipe and therefore itis not recommended to install in in a position in which the pulp may contain stones or other such materials which can damage the ceramic antenna shield at the end of the sensor body In order to become broken ceramic requires a powerful blow In such cases the fault appears as a rapid level change upwards or downwards in the measurement followed by drifting Checking for a broken fork probe requires that the sensor be removed from its process coupling e Sensor Electronics Failure A typical electronics failure appears as a rapid level change in the measurement and as a rapid reduction in signal level after some component breaks A reference channel failure indicates that the fault is in the sensor electronics Self diagnostics includes an alarm limit for the reference channel signal level which detects obvious cases of broken components If all the aforementioned possibilities can be elimin ated then small errors or drifting in the measurement might be caused by sensor electronics In such a case all the self diagnostics measurements might be within allowed limits due to which self diagnostics does not detect the error To locate the error it might help to analyze the device s internal trend and sample history table
57. metso Metso Microwave Consistency Transmitter A j Installation Operating amp Service manual OUL00298 V2 2 EN um mdi A A Table of contents Caution Warning 1 Introduction 7 1 General 7 2 Structure 9 21 eh dcn td 9 2 2 MOMZBeET iiic etc de i 9 2 3 Sensor Electronics 12 2 4 Transmitter Central Unit TCU 12 3 Installation 13 3 1 General 13 3 2 Choosing the installation site 13 3 3 Sensor 17 3 4 Mounting 19 3 5 Transmitter Central Unit TCU and shield 20 3 6 Electrical Connections 20 3 7 Metso MCA F Sensor Deflector Plate Installation GUIGG sires 22 4 Setting Up 23 4 1 Mechanical 23 4 2 Installation eee ntes 23 4 3 Cabling 23 4 4 Electrical 23 4 5 Configuration and Calibration 23 5 User Interface and Operation 25 5 1 Transmitter Central
58. mpensated for with chemical compensation based on microwave damping measurement You can use chemical compensation as described in the following two sections Entering Laboratory Values 1 Take sample as described in section 7 1 2 Determine the sample s consistency and its filtrate conductivity at room temperature Go to the menu Enter Lab 4 Press the Edit button and enter the laboratory consistency and filler information Press the Enter button to scroll the display down after the last line 5 Select the chemical type with the up and down arrow buttons Enter the sample s conductivity in units mS cm p Sample 12 08 04 MCA 3 00 Lab 0 00 5 Filler 0 Kaolin 0 5 0 Talc 0 TiOo2 0 Chem NaOH MCA con 2 40 mS cm Lab con 0 00 mS cm Filler sens 1 00 Metso Mircowave Consistency Transmitter If the conductivity meter shows results in units mS m divide the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 uS cm 5 5 mS cm If the conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 umho in 10 mS cm Using Chemical Compensation After you enter the laboratory values go to Special Functions menu and select 1 Chemical Compensation The following display appears Chem comp OFF Comp value 0 00 MCA con 0 00 mS cm
59. n 1 Check that the nylon sealing ring is in place in the base plate at the bottom of the antenna cable feedthrough thread Place the antenna cable connector gently into the hole in the base plate and press the antenna cable casing into its mounting groove Check that the antenna end feed through collar fits into place Take hold of the antenna cable connector on the base plate with an 8 mm set wrench From the other side of the base plate screw on the antenna cable lock bushing with a 10 mm box key attached to the Beltzer Torque driver to 1 Nm torque Do not use force in tightening the lock bushing too much force will damage the connector Slide the antenna cable s through the inlet bushing down to the base plate and screw it into place Screw the antenna cable connector on the antenna into the antenna connector with an SMA wrench or or with the SMA Torque Wrench Adapter at tached into a SMA wrench to the torque indicated by the wrench In sensor model FT 50 FT 100 you must also screw in two feed through mounting Screws Attach the antenna s cover with its four mounting Screws Installation operating amp service manual OUL00298 V2 2 EN 11 4 Antennas Fork Sensor NOTE Before removing the antennas check that the process pipe is empty and unpressurized and that remov al is safe Removal 1 Remove the sensor electronics as described Chapter 11 1 Remove the antenna cable of the antenna that is being replaced
60. nal generator drift Usage of this data for maintenance purposes is ex plained in more detail in Chapter 10 Troubleshooting and Maintenance 8 3 Diagnostics Limits In the Diagnostics menu select Diag Limits 3 The following display appears Ctmp max 90 OFF Ptmp max 1000 ON Ptmp min 0 0 ON M Lev min 10 0 ON R Lev min 100 0 0N stab max 20 0 ON Rstab max 2 0 Eldr abs 80 0 ON VCOdr abs 50 0 ON The display shows the error limit for each diagnostics measurement as well as its effect on the current signal ON OFF If necessary you can change these as fol lows press the EDIT button and then enter a new error limit or use the up arrow and down arrow buttons to change the ON OFF setting Even if the effect of the limit on the current signal is blocked by an OFF setting an error message still appears on the main display status line and error data is entered into the error table Installation operating amp service manual OUL00298 V2 2 EN Notes Metso Mircowave Consistency Transmitter 34 Installation operating amp service manual OUL00298 V2 2 EN 9 Special Functions The Special Functions menu contains the following functions Chemical comp Temperature comp Sensitivity corr Recipes 9 1 Chemical compensation Large fluctuations in chemical content may cause errors in Metso MCA consistency measurements These errors can be co
61. nstruction drawing 1 Microwave Antenna 2 Sensor Head 3 Pt 100 Thermoelement 4 Antenna Cables 5 Sensor Body 6 Antenna Sealing 7 Fixing Clamp 8 Base Plate Assembly 9 Sensor Electronics 10 Sensor Cover Metso Mircowave Consistency Transmitter 1 0 Installation operating amp service manual 00298 V2 2 EN Fig 4 Metso construction drawing 1 Sensor Cover 2 Sensor Electronics 3 Base Plate Assembly 4 Pt 100 Thermoelement 5 Sensor Body 6 Antenna Sealing 7 Microwave Antenna 8 Antenna Flange 9 Antenna Cable 10 Antenna Cover Metso Mircowave Consistency Transmitter 1 1 Installation operating amp service manual 00298 V2 2 EN 2 3 Sensor Electronics Sensor electronics is the same for both Fork and Flowthrough sensors Refer to figure 6 The sensor electronics card is installed between the round cover and base The electronics includes the microwave transmitter and receiver as well as control measurement and communication electronics On the bottom there are snap on connectors which connect with antenna cable connectors in the base plate when you press the electronics against the base plate The guide pins in the base plate help guide the connect ors into place The Pt 100 connector and the supply voltage serial communication connector are connected into the connectors located in the cover of the sensor electronics 2 4 Transmitter Central Unit TCU TCU is Metso
62. ounting screws Mounting screws Fig 7 Metso Mircowave Consistency Transmitter Fig 8 In place of the inlet bushing insert an adapter as sembly that has an adapter bushing Metso MCA sensor adapter and power cable Pay attention to get the adapter assembly on the right threads Insert shield plugs PG16 and PG21 into the open inlet bushings Figure 9 Inlet bushings Adapter assembly Installation operating amp service manual OUL00298 V2 2 EN Install the Upgrade Kit with 4 M6x20 screws 12 Connect the cables according to the instructions in Use locking medium section 3 5 of this User Guide Note that you need Connect the microwave cables 13 with an SMA an external power source to the current output be wrench cause Metso MCA s current output is passive Connect the Pt 100 cable 14 to the Upgrade Kit current output is active Figure 12 adapter Connect the power cable 15 Putthe Sensor Cover in place Figure 10 i Fig 12 Pull the Sensor Cable to the sensor and connect it Fig 10 to the adapter you installed in the sensor s base plate Perform startup according to the instructions in the User Guide Figure 13 Fig 11 Metso Mircowave Consistency Transmitter 62 Installation operating amp service manual OUL00298 V2 2 EN 13 5 Startup Refer to se
63. own as a percentage CaCO3 The relative proportion of CaCO in the filler shown as a percentage The relative proportion of talc in the filler shown as a percentage 02 The relative proportion of TiO in the filler shown as a percentage Chemical Chemical type required only for chemical compensation Lab cond Laboratory conductivity mS cm required only for chemical compensation NOTE If the conductivity meter shows results in units umho in divide the result by 2500 e g 25 000 10 mS cm If the conductivity meter shows results in units mS m divide the result by 100 e g 550 mS m 5 5 mS cm If the conductivity meter shows results in units uS cm divide the result by 1000 e g 5500 5 5 mS cm Metso Mircowave Consistency Transmitter Offset corr This function allows you to perform level correction on the measurement Move the cursor onto Level corr and press the right arrow The following display appears MCA MCA 1234 Set the offset correction 10 10 0 0 DEL ABORT ENTER Enter the desired value and press ENTER F4 The HART Communicator sends the value to Metso MCA Filler Metso MCA measures filler but at a slightly different sensitivity than fibers The Filler function allows you to inform the device about filler changes if the relative total filler percentage changes more than 5 percentage points Move the cursor onto Filler
64. pe if you wish as follows Move the cursor to the desired recipe and write the name Successive pressing on the number keys scrolls through the letters marked on the key If you do not name the recipe then the program gives it a default name 501 etc Press Save to save the recipe selection and recipe name The date ddmmyy after the recipe name indic ates the most recent calibration change The text ON after the date indicates that the recipe in question is in use Select rec 1 1 01 150405 ON Qua cie E 000000 Dias 000000 SSS SS 000000 When process conditions change such that you need a new recipe select the new recipe either manually or based on binary input according to the instructions above Select BIN 1 01 150405 ON 2 02 220405 3 000000 4 000000 The program saves the recipe calibration as for the previous recipe The date 000000 indicates that the new recipe is not calibrated with its own sample Perform calibration with a new sample according to the instruc tions in section 7 After calibration the date 000000 changes to the calibration date If necessary scale the current output according to the instructions in section 6 2 and configure the special functions according to the instructions in chapter 9 Configure recipes 3 and 4 in the same way Installation operating amp service manual 00298 V2 2 E
65. pling interval of the devices s in ternal trend table Pos Device position information Lang TCU language version Temp unit Process temperature unit F Installation operating amp service manual OUL00298 V2 2 EN Device info Poll Addr The device s HART address Manufacturer Name of device manufacturer Metso Model Device name Final asmbly num Field device identification num ber Universal rev The Universal Device Description version supported by the device Tag Text entered by the user the tag is shown at the top of the display after the device name Message Text entered by the user Descriptor Text entered by the user Sensor Electronics Sensor type Sensor model Sensor S N Sensor electronics serial number Sensor HW rev Sensor electronics revision Sensor SW rev Sensor electronics software revision TCU S N A First part of TCU serial number S N B End part of TCU serial number HW rev TCU revision SW rev TCU software revision Cal date TCU s final testing date Cal ID Tester s initials Set Clock Date The date in mm dd yy Hours Minutes Seconds Metso Mircowave Consistency Transmitter 12 4 Calibrate Metso MCA is calibrated with single point calibration Calibrate menu contains menu items for sample taking and entering the laboratory value In addition you can perform a level correction on the measurement perform various special functions and view
66. r figure 2 Metso MCA FT Flow through sensors figure 3 Metso MCA also includes a user interface known as Transmitter Central Unit TCU figure 1 Fig 1 Transmitter Central Unit TCU Metso Mircowave Consistency Transmitter Fig 2 Metso MCA F Fig 3 Metso MCA FT Installation operating amp service manual OUL00298 V2 2 Notes Metso Mircowave Consistency Transmitter 8 Installation operating amp service manual OUL00298 V2 2 EN Metso MCA comprises the sensor unit and a user inter face called Transmitter Central Unit There are two sensor models MCA F Fork Sensor and MCA FT Flow Through Sensor which come in six different sizes ranging from FT 50 to FT 300 The appropriate model is selected according to the diamater of the pro cess pipe 2 1 MCA F In the fork type MCA F sensor the microwave anten nas are mounted on the sensor body which is installed via a coupling into the process pipe On the end of the sensor there is a probe antenna and on the base there is a flushmounted antenna In addition on the end of the sensor body there is a Pt 100 thermoelement The antenna cables and the Pt 100 sensor cables run through the inside of the sensor to the sensor electronics Figure 3 shows the sensor s construction drawing The material of the wetted metal parts is AISI316L with options of titanium or hastelloy The antenna ma terial is polished ceramic
67. r is 170 mm If necessary shape the process coupling curvature radius of installation surface to the shape of the pipe Place the process coupling in line with the hole and weld four adhesion welds around the seam Weld a continuous weld around the seam Installing the deflector plate Check that the sealing ring is in the groove of the flange Set the deflector plate into the process coupling such that the plate curves toward the sensor Put the mounting clamps screws and nuts into place and tighten to a finger tightness Point the plate toward the sensor with e g a monkey wrench Tighten the mounting clamp screws 170 6 70 FLOW 5 14404 EN Align with the sensor FLOW Fig 16 Metso MCA F Sensor deflector plate installation guide A Saddle B Deflector plate Metso Mircowave Consistency Transmitter Installation operating amp service manual 00298 V2 2 EN 4 Setting Up 4 1 Mechanical Inspection 1 Check that the delivery content corresponds to what was ordered 2 Check that
68. rarily in the uppermost mounting hole so that the base plate will stay in place while the microwave cables are being mounted Use pointed pliers to take hold of the body of the microwave cable connector that is on the base plate side Push the threaded part of the connector far enough into the hole in the base plate so that the cable s clamping bush and O ring start turning in the thread Hold the connector body in place with an 8mm set wrench and use a 10 mm box key attached to the Belzer Torque driver to tighten the clamping bush of the antenna cable from the opposite side of the base plate to 1 Nm torque Repeat the same steps for the other connector Push the base plate all the way against the sealing Apply locking medium Loctite 270 to the threads of the base plate s five free mounting holes and put M6 lock washers and M6x20 Allen screws into the threads Tighten the screws to 8 Nm torque Place the thermoelement cable into the groove in the base plate and tape it into place with thin tape Install the sensor electronics as described in Chapter 11 1 10 11 12 13 14 Metso Mircowave Consistency Transmitter 47 95198 d K a zu Gf Qs Ae l Fig 3 Removal diagram for antenna cables of other FT Sensor models Installation operating amp service manual OUL00298 V2 2 EN 11 3 Antenna Cables FT Sensor NOTE Before
69. s disturb ances to the process itself so the formation of air bubbles should be avoided Air formation mechanisms Air is mixed with pulp for example when it is dropped into the stock tank If the level in the stock tank is low if the point of impact in near the pump or if the flow through time in the tank is low then air is not able to escape properly from the pulp be fore the pulp is forced into a departing flow The best way to put pulp in the tank is to run the input pipe under the level of pulp in the tank In addition a strong stirring at a low surface level can cause a whirl that causes air to be mixed into the pulp Air may also become mixed into the pulp through a leaking joint on the pump s intake side The dilution water may also contain air and cause air bubbles in the pulp Air can build up in bends in dilution or pulp pipes if the bends are at the highest spot in the production line In such cases an air pocket is formed and continues to grow in a bend in a pipe When the air pocket is large enough it begins moving with the flow in the pipe air mass such as this may cause a momentary error in consistency measurements Air may be generated in the pulp through foaming caused by chemicals as well SLOW DRIFT ERROR INDICATION electronics failure A SUDDEN CHANGE IN LEVEL WHEN PROCESS CONDITIONS ARE STABLE
70. sated for with chemical compensation In these cases each process condition has its own calibration and configuration performed This calibra tion and configuration is saved as its own recipe In addition to consistency calibration for each recipe you can set chemical compensation temperature consist ency correction sensitivity correction and current output scaling You can save a maximum of four recipes If a recipe is in use MCA indicates this by showing the name of the recipe on the main display status line instead of the OK text that is normally shown In Special Functions menu select 4 Recipes The following display appears 1 2 1 1 1 Using Recipes You can select a recipe either manually using the keypad or with a binary control lines attached to the TCU In Recipes menu select 1 Select recipe The following display appears Select rec OFF em 000000 2 000000 000000 000000 Metso Mircowave Consistency Transmitter 39 Press the Edit button to make the cursor appear in the Select field in the first row Use the up and down ar rows to select the desired recipe number 1 4 or the Binary selection method If you select Binary then the recipe is determined by the TCU binary inputs 0 and Binl refer to section 9 4 subsection Selecting the Recipe with Binary Inputs You may name the reci
71. tched off for a long time it may take a few minutes for text to appear on the dis play This is due to the charging of the device s internal back up battery Sensor Cable NOTE In a normal delivery the sensor cable is already connected to the TCU 1 Insert the end of the sensor cable that has no con nector into the TCU connector casing through the inlet and connect it as shown in Figure 15 The protective shields are connected as follows Twisted pair lines intertwined protective shields cable 3 are connected to adaptor GND together with cable 2 The sensor cable s protective shield cable 5 is connected to adaptor SC SHIELD Sensor Cable Shield Bring the sensor cable to the sensor unit and con nect its adaptor to the adaptor in the base plate of the sensor electronics NOTE Do not place the sensor cable on cable shelves that contain cables of motors pumps or other electrical Fig 13 TCU shield mounting dimensions Metso Mircowave Consistency Transmitter 20 cables 232 9 13 133 5 24
72. that the mounting location and position are in accordance with the installation instructions Check that the flow arrow on the sensor casing is pointing in the direction of flow Protect the sensor and the TCU from direct heat sources and sunlight Metso MCA F Before operating the sensor check that the process coupling s mounting clamp is se curely tightened Metso MCA FT Before operating the sensor check that the sealing between the MCA flanges and pro cess flanges are properly installed and that the mounting nuts are tightened Sensor installation to a vertical and horizontal pipeline is illustrated in Fig 1 5 Installation operating amp service manual OUL00298 V2 2 EN Min2xD 1xD if Cs gt 8 Min2xD 1xD if Cs gt 8 towards the pump axis Measuring line at a 90 angle i Measuring line parallel to the previous horizontal pipe Fig 1 Metso MCA F Installation on a vertical pipe A after a pump B after a horizontal pipe A Min2xD B If the section of horizontal pipe preceding the sensor is gt 10xD then the sensor is installed with its electronics casing on side Fig 2 Metso MCA F Installation on a horizontal pipe A after a ver
73. the device was not damaged in trans port 4 2 Installation Install the sensor and TCU according to the instructions in Chapter 3 4 3 Cabling Inspection 1 Check that the power supply is connected cor rectly 2 Check that the current output is connected cor rectly 3 Check that the sensor cable is connected correctly Metso Mircowave Consistency Transmitter 4 4 Electrical Inspection 1 Connect the electronics to the power supply 2 Check that text appears on the TCU display Normally the main display appears but in connec tion with replacing a device you may be asked to select calibration In such a case select calibration of the unit Sensor Electronics TCU that was not changed 3 Allow the device to warm up one hour before starting it up NOTE If the TCU has been switched off for a long time it may take a few minutes for text to appear on the dis play This is due to the charging of the device s internal back up battery 4 5 Configuration and Calibration 1 Select the language and temperature unit Celsius Fahrenheit according to Chapter 6 3 2 Set the device date and time according to Chapter 6 5 3 Scale the current output according to Chapter 6 2 4 Calibrate the consistency according to Chapters 7 1 and 7 2 After you have completed these procedures Metso MCA is ready to measure consistency Installation operating amp service manual OUL00298 V2 2 Notes Metso Mircowave
74. tical pipe B after a bend in the pipe Metso Mircowave Consistency Transmitter 14 Installation operating amp service manual OUL00298 V2 2 EN a a a o x 55 Q 5 N xu A 526 dE S o Isi UI Measuring line at a 90 angle l Measuring line parallel to towards the pump axis the previous horizontal pipe Fig 3 Metso MCA FT Installation on a vertical pipe A after a pump B after a horizontal pipe A D B Minzxp E 1xD if m Cs gt 8 ill OT Min2xD 1xD if Cs gt 8 FLOW THEE If the section of horizontal pipe preceding the sensor is gt 10xD then the sensor is installed with its electronics casing on top Fig 4 Metso MCA FT Installation on a horizontal pipe A after a bend in the pipe B after a vertical pipe Metso Mircowave Consistency Transmitter 1 5 Installation operating amp service manual 00298 V2 2 EN Fig 6 Metso MCA FT installation directly after a pump Fig 5 Metso MCA FT installation directly after a pump M
75. twork connection NOTE When you connect power supply cables make sure that the cables are disconnected from the power supply NOTE Connect the cables to the power supply only after you have checked all connections Refer to Chapter 3 5 Installation operating amp service manual OUL00298 V2 2 EN 13 3 Installation Guide Upgrade Kit for MCAi MCAi Display Unit Disconnect the power supply MCAi Sensor Remove the Sensor Cover from the power supply cables coming into the Remove the cable connections from the Field Con device Open the connector casing cover Figure 2 nection Board Pull the cables out through the inlet bushings and remove the cables Figure 4 Fig 2 Fig 4 Remove the cable connections Pull the cables out through the inlet bushings Remove the PT 100 adapter from the Field Connec Remove the Display Unit and shield Figure tion Board Figure 5 3 HART ee t vum a gt gt Pt 100 adapter t Fig 5 Fig 3 Metso Mircowave Consistency Transmitter 60 Installation operating amp service manual OUL00298 V2 2 EN Remove the microwave cables from the sensor electronics with an SMA wrench figure 6 Remove the cable inlet bushing from the base plate Figure 8 Fig 6 Remove the 4 mounting screws and lift the electron ics off Figure 7 M
76. urement result av erage over the desired period of time for monitoring purposes for example Installation operating amp service manual 00298 V2 2 EN 7 2 Entering Laboratory Results When you have determined the sample s laboratory consistency press the ESC button to move from the main menu to the Operations menu Select Calibration Enter Lab after which the following menu appears dd mm yy hh mm MCA 00 00 SCS Lab 00 00 SCS Filler 0 00 SCS Y The first row shows the sample s date and time in the following format dd mm yy hh mm The second row shows the consistency measured by Metso MCA Press the Edit button to make the cursor appear in the Lab field In the Lab field enter the calibration sample s laboratory consistency If the pulp contains fillers enter in the fourth row in the Filler field the filler amount which shows the proportional amount of filler as a percentage of the overall consistency If the pulp does not contain filler press the Save button to save your changes If you enter a value larger than zero in the Filler field use the down arrow to move to the following lines Enter the proportional amount of each filler component If the filler consists for example entirely of kaolin enter 100 as the value of kaolin Press the Save button to save your changes NOTE The lines Chem MCA con and Lab con are needed only for the chemicals compensation chapter 9 1 NOTE The value
77. user interface as on the device s TCU user interface Figure 1 shows the HART Communic ator operation menu When you connect HART Communicator to Metso MCA the following menu appears MCA MCA 1234 HART Communicator is connected in parallel to the current output e g to the connector pins on the front panel of the TCU Measurement Configuration Calibration Diagnostics 1 Online Measurement Configure 2 3 4 PV Cs Process Temp Meas Att Conductivity AO mA 96 of Range Active Recipe Calibrate Diagnostics Low Range High Range Damping Alarm Current Trend Int Position Language Temp Unit Poll addr Manufacturer Model Range Values User Settings Final Asbly number Device Info Sensor Electronics TCU Set time Take sample Enter Lab Tag Message Universal rev Descriptor Lab Cs Filler 96 Clay 96 CaCO3 Offset correction Fillers Talc 96 TiO2 96 Calibration history Sample History Special Functions Diag history Diag values Diag alarms Digital inputs Loop test Chemical Lab cond Filler 96 Clay 96 CaCO3 Talc 96 TiO2 96 Chemicals Comp Temperature Comp Sensitivity Recipes Fig 1 HART Communicator operation menu Metso Mircowave Consistency Transmitter 51 Installation operating amp service manual OUL
78. ve Cable FT 150 6 OUL00194 Microwave Cable FT 200 8 00197 Microwave Cable FT 250 10 00216 Microwave Cable FT 300 12 OULO00178 Thermoelement Assembly FT 00100046 Microwave Antenna AISI 3161 Metso Automation Manufacturer reserves the right to changes without prior notice Page 3 4 Metso MCA Service kits amp spare parts Spare parts MCA FT Part Order Code Description Pcs 1 100278 Sensor Cover 1 2 00100051 Sensor Electronics 1 3 00100271 Assembly Set 1 4 OULO00178 Thermoelement Assembly FT 1 5 00294 Seal Ring 2 00100420 Microwave Cable FT 50 2 2 00100114 Microwave Cable FT 100 4 2 6 OULOO0118 Microwave Cable FT 150 6 2 OULO00194 Microwave Cable FT 200 8 2 OULO00197 Microwave Cable FT 250 10 2 0000216 Microwave Cable 300 12 2 7 OULO00198 O Ring 23 4x3 5 Viton 2 8 OULO00046 Microwave Antenna AISI 316L 2 OUL00189 Antenna Cover FT 150 FT 200 FT 250 FT 300 2 OULO00180 Antenna Cover FT 50 FT 100 FT 50 1 100 2 9 00100422 Antenna Cover FT 50 attenuator side 1 OULO00428 Attenuator 10 dB FT 50 1 OUL00213 Gasket FT 50 FT 100 2 10 00185 Screw DIN912 M6x16 4 70 12 233778 Screw DIN912 M6x20 A4 70 FT 50 FT 100 8 11 5060013 Washer DIN127 B6 A4 12 12 5160015 Screw DIN84 M4x12 A4 4 13 5060011 Washer DIN127 B4 A4 12 14 5160025 Screw DIN84 M4x8 A4 8
79. ve button to save the new value If you have to perform the sensitivity correction a second time for some reason you have to take into ac count the existing sensitivity correction This is done by multiplying the new defined sensitivity by the exist ing sensitivity coefficient and entering this result for the new sensitivity coefficient value For example if the sensitivity is defined again to be 0 9 after the cor rection of the previous example the new sensitivity coefficient is calculated 0 9 x 0 89 0 8 If you want to cancel the sensitivity correction write 1 for the sensitivity coefficient value MCA vs Lab y 0 8932x 0 291 3 8 3 6 34 A 28 26 24 22 2 2 22 24 26 28 3 32 34 36 38 Lab 90 Fig 3 Calculating MCA measurement sensitivity Metso Mircowave Consistency Transmitter 38 Installation operating amp service manual 00298 V2 2 EN 9 3 Recipes The Recipe function may be necessary in special functions in which measurement conditions change so much that one calibration cannot cover it Such a change may be e g change in consistency greater than the device measurement range 9 15 depending on the type of sensor A change in the measured material since different materials have different consistency sensitivity or A large chemical fluctuation e g change of chem ical type that cannot be compen
80. wer right corner of the display indicates that you can scroll down You can also use the down arrow to scroll between edit field options Up arrow Use the up arrow to scroll up if there are more than four lines An upwards pointing arrow in the upper right corner of the display indicates that you can scroll up You can also use the up arrow to scroll between edit field options Fig 1 TCU display Installation operating amp service manual OUL00298 V2 2 EN 5 2 Operations Menu The operations menu is divided into the functions Cal Use the ESC button to return to the previous level If ibration Configuration Diagnostics and Special the menu in view on the display has more than four Functions and their respective submenus lines i e more than fits on the display at one time an Use the ESC button to access the function menu arrow appears in the upper or lower right corner of the from the main display In the menus you can use the display to indicate that you can scroll up or down with number of the desired function to continue the up arrow or down arrow MCA FT200 POS 1234 ESC 1 Calibration Cs 3 12 Dogs seen T 56 7C deco um STATUS OK Specia unctions ENTER A 1 Range 53 00 Sample taking mA 12 48 mA Enter lab Cabin 52 3 gt Offset correction Meas Att 45 6 dB Filler Calib history Sample history Output signal 1 Output signal 2 User settings Device
81. which appears as a slow upward or downward drift In case of leakage you must change the antenna and the an tenna cable as well because the cable may also have gotten wet In FT sensor models a clear case of leakage can be detected by removing the antenna cover and checking whether water drips from between the antenna and the connector that is connected to it In the Fork Sensor a clear case of leakage can be detected by removing the sensor electronics and checking whether water has accumulated in the connect ing pipe Antenna Contamination Antenna Contamination causes an upward drift in the measurement If the antenna is cleaned periodically e g as a result of being washed or changing the wood species then the error disappears The antenna is made of polished ceramic so contamination may be caused by some material that is adhering to this surface Checking for antenna contamination requires a break in the process and removal of the device Metso Mircowave Consistency Transmitter 42 Pieces of string etc wrapped around Fork Sensor body The Fork Sensor is inserted into the pipe and therefore it is not recommended to install it in a position in which the pulp may contain strings or other such materials which could become wrapped around the Fork Sensor If these materials do become wrapped around the sensor body the measurement drifts upwards The speed of the drift is directly dependent on how rapidly these materia

Metso MCA - Installation, Operating & Service manual

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Metso MCA - Installation, Operating &amp; Service manual

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Metso MCA - Installation, Operating & Service manual