OPERATING AND SERVICE MANUAL MDS E-S CAN Monitor Divert E-Scan System Designed and Manufactured by THE ELECTRON MACHINE CORPORATION 15824 CR 450 West PO Box 2349 Umatilla, FL 32784-2349 111206 (352)-669-3101 FAX: (352)-669-1373 E-Mail: sales@electronmachine.com http://www.electronmachine.
The Electron Machine Corporation MDS E-SCAN Introduction Increasing emphasis on recovery boiler safety in pulp and paper manufacture requires highly accurate, reliable instrumentation at prescribed points in the process. In particular, the prevention of furnace explosions resulting from the introduction of low solids liquor into the furnace has been a subject of recent study by industrial insurance companies.
The MPR E-Scan is a microprocessor driven critical angle refractometer. It is used to measure the refractive index of process fluids which directly correlate with customer request for dissolved solids. It is equipped with a broad range of diagnostics to aid in fault isolation without the use of special test equipment. The instrument is calibrated before leaving the factory and should not need recalibration unless some modification is made to the sensing head.
Table of Contents 1. MDS E-Scan Installation......................................................... 9 1.1 Site Selection............................................................................... 9 1.2 Power Requirements ................................................................... 9 1.3 Installation of Sensing Heads.................................................... 10 1.4 Steam Purge Attachment .......................................................... 11 1.
4. MPR E-Scan Information...................................................... 31 4.1 Technical Description ................................................................ 31 4.1.1 Sensing Head ........................................................................................31 4.1.1.1 Optics ...........................................................................................31 4.1.1.2 CCD Linear Array ...................................................................32 4.1.1.3 Signal...
6. 7. Monitor Problem Analysis................................................... 53 6.1 Procedures................................................................................. 53 6.2 Trouble Shooting Chart ............................................................. 53 Monitor Information................................................................. 54 7.1 Console Technical Description.................................................. 54 7.1.1 7.2 Monitor Specifications ...................
MDS E-SCAN MPR E-SCAN /INSTALLATION 1. 1.1 MDS E-Scan Installation Site Selection The MDS E-Scan cabinet can be mounted in any area where ambient conditions allow personnel to remain for extended periods and is suitable for the atmosphere and service conditions normal to a recovery boiler installation. A vortex cooler or a cooling fan is supplied with the cabinet to prevent excess heat buildup. The cabinet should be kept closed to maintain environmental resistance. 1.
MDS E-SCAN 1.3 MPR E-SCAN /INSTALLATION Installation of Sensing Heads Sensing Head The sensing heads are attached to the process line by Isolation Valves. These adapters must not be placed in an area where vibration is severe or excessive. They should be installed a minimum of six feet apart to prevent interaction of the purges. The adapter should be oriented to place the head in a horizontal plane to assure that deposit buildup and air pocket creation will be minimal.
MDS E-SCAN 1.4 MPR E-SCAN /INSTALLATION Steam Purge Attachment The steam purge valve must be similarly mounted to the adapter with a minimum of 6" and a maximum of 18" from the steam port on an adapter preferably with 1/4" tubing. It is essential that NO LEAKS be present in this line that could allow evaporation of liquids, thereby plugging the purge line. Steam Purge Connections – for liquids which exhibit a tendency to “coat” Steam pressure must be at least 50 psi (3.
MDS E-SCAN MPR E-SCAN /INSTALLATION 1.5 Cooling System Requirements When supplied with a vortex cooler a clean and dry air supply of the proper pressure (approximately 90 PSI at 8 cubic ft/min.) is required. If equipped with the cooling fan option the console must be mounted in a controlled environment. 1.6 Start-Up Turn power on. Allow sufficient time for the sensing head to stabilize at the process temperature. It is recommend that no adjustments be made for at least 15 minutes after start-up.
MDS E-SCAN MPR E-SCAN OPERATION 2. MPR E-Scan Operation This equipment is designed for continuous operation and may be left on for extended periods of time. 2.1 The Operator’s Panel The Operator’s Panel or Front Panel consists of a display and a 20-button touch pad, which form the interface between the operator and the instrument. The display consists of a 640 x 480 pixel LCD screen, which provides the operator with various messages.
MDS E-SCAN MPR E-SCAN OPERATION 2.1.2 Button Touch Pad Function Chart Scrolls cursor horizontally to the left and also used to initiate editing of calibration voltages in the calibration table, and temperature values in the compensation table. Scrolls cursor horizontally to the right and also used to initiate editing of all system parameters excluding those accessed by the LEFT ARROW. Scrolls cursor vertically in the “Up” direction. Scrolls cursor vertically in the “Down” directio n.
MDS E-SCAN 2.2 MPR E-SCAN OPERATION Normal Mode 2.2.1 What Normal Mode Does In normal mode the system displays the following information: • • • • • • • • Name of the current product being measured along with an associated unit number. Software version number. Current time and date. On-line SOLIDS measurement. On-line temperature in Degrees Fahrenheit and Centigrade. Alarm points for measurement. Error status for system measurement, communication and voltage levels.
MDS E-SCAN MPR E-SCAN OPERATION 2.2.3 The Menu Options in Normal Mode Normal mode is entered by default, upon power up. To gain access to other system features select the MENU button on the Front Panel Touch Pad. Note: The screen names and set points below are just an example, they will vary from application to application.
MDS E-SCAN 2.2.4 MPR E-SCAN OPERATION Overview of Menu Options CALIB (Password required) option allows the operator to enter calibration set points. This consists of calibration limits, measurement, temperature compensation, and analog zero adjustment. Since a complete calibration is performed in advance by EMC, it would be a rare condition for the operator to access calibration measurement and temperature compensation.
MDS E-SCAN 2.3 MPR E-SCAN OPERATION/CALIBRATION Calibration Selection (Note: To access calibration enter password “0000") Calibration Mode Screen The calibration menu contains four menu options: 1. Limits - This option contains the system limits for alarms, purge cycle, analog output and filter weight. 2. Meas. - This option allows entry to the calibration measurement routine.
MDS E-SCAN MPR E-SCAN OPERATION/CALIBRATION Measurement Alarm Divert : If the measurement falls below this limit, a system alarm is activated. An error message will appear in the status window in normal mode, and the divert alarm relay will be turned off to activate a divert to the Monitor. Measurement Alarm Low: If the measurement drops below this limit, a system alarm is activated. An error message will appear in the status window in normal mode, and the low measurement alarm relay will be turned on.
MDS E-SCAN MPR E-SCAN OPERATION/CALIBRATION Min. Purge Temperature: This value determines the point below which a steam purge will not be allowed. Selecting the “Meas.” option from the calibration menu results in the following display: Calibration Measurement Screen The calibration measurement table is created when you place actual solution samples to be measured on the sensing head and then save the desired measurement reading for that sample along with the current measurement voltage.
MDS E-SCAN MPR E-SCAN OPERATION/CALIBRATION Selecting the “Temp.” option from the calibration menu results in the following display: (Circulation bath with temperature adjustment and pump is needed for temperature compensation.) (Not normally used on the MDS-E-Scan system.) Calibration Temperature Screen This is the temperature compensation table. The “VALUE” column represents the compensation values, and the “DEG. C” column represents the temperatures at which those compensations occurred.
MDS E-SCAN MPR E-SCAN OPERATION/CALIBRATION The final option of the calibration menu is “Anlg. 0" which activates the following display: Analog Zero Adjustment Screen The analog zero adjustment is used to correct for any shifts in the measurement voltage.
MDS E-SCAN MPR E-SCAN OPERATION/CALIBRATION Note: If the process measurement changes after the sampled reading is recorded then the final adjusted reading will not reflect the lab reading. However, since the adjustment is calculated from the recorded sampled reading, the final reading will be accurate and will not require further manual adjustment. Thus the lab reading should only be thought of as the desired reading if the process is stable.
MDS 2.5 E-SCAN MPR E-SCAN OPERATION/ DIAGNOSITIC SELECTION Diagnostic Selection The Diagnostics menu contains the following options : Diagnostics Mode Screen 1. Voltages - This displays all pertinent system voltages such as: measurement voltage, temperature voltage, and lamp voltage. 2. Relays - This allows the operator to toggle system relays for testing or troubleshooting purposes. The toggled relays can be visually checked by examining the relay LEDS on the interface board.
MDS E-SCAN MPR E-SCAN OPERATION/ DIAGNOSITIC SELECTION The “Relays” option activates the following display: Diagnostics Relay Screen There are eight total relays, two of which are used as inputs coming from the Monitor and two are unused. The other four relays are activated when either measurement alarms are occurring or when purging.
MDS E-SCAN MPR E-SCAN OPERATION/ DIAGNOSITIC SELECTION NOTE: The information displayed at the bottom gives the operator the output resolution, which is useful when editing the output values for analog load calibration. The “Time/Date” diagnostic option activates the following display: Diagnostics Time/Date Screen This menu enables the operator to set the system time and date. System Time: This is the time displayed in military format in normal mode.
MDS 2.6 E-SCAN MPR E-SCAN OPERATION/ PURGE SELECTION Purge Selection Purge Mode Screen Selecting the “Purge” option from normal mode adds purge information to the current display. When purging, the ‘H’ system indicator (measurement hold) is displayed to the far right of the displayed reading, and the measurement voltage as well as the current purge mode is displayed at the bottom. The timing information for purging is set in the calibration limits menu.
MDS E-SCAN MPR E-SCAN OPERATION/ PURGE SELECTION 2.7 Configuration Section Display Unit Number This is used to identify refract #1 or #2. Selecting unit number requires a “0000” password.
MDS E-SCAN MPR E-SCAN OPERATION / PROBLEM ANAYLSIS 3. 3.1 MPR E-Scan Problem Analysis Procedures The following analysis procedures are meant to aid in isolating MPR E-Scan failures down to the board, or in the case of the sensing head--device level. Board or device replacement with a fast turnaround is available from EMC. These abbreviations are used: I/O Main E-Scan I/O board Conditions analog voltages for digital microprocessor.
MDS 3.2 E-SCAN MPR E-SCAN OPERATION / PROBLEM ANAYLSIS Trouble Shooting Chart SYMPTOM POSSIBLE CAUSE No display, failsafe LED off. No display, backlighting. Fuse blown. Power supply failure, check ±15vdc and 5vdc. No display and failsafe LED on. Display failure. Video cable failure. Display on but is garbled. CPU failing, Display or Video cable failure Buttons do not respond properly. Connector from overlay to I/O board not, or improperly mated with J5. Front panel overlay defective.
MDS E-SCAN MPR 4. 4.1 E-SCAN INFORMATION MPR E-Scan Information Technical Description 4.1.1 Sensing Head The MPR E-Scan uses an LED as a light source and utilizes state of the art CCD (charge coupled device) technology to accomplish scanning the reflected light returned from the prism. 4.1.1.1 Optics Light radiated from the LED passes through the prism surface to be reflected off mirror 1 to the prism-to-process interface.
MDS E-SCAN MPR E-SCAN INFORMATION 4.1.1.2 CCD Linear Array The linear array used in the E-Scan includes 2048 individual photo sites. Each of these photodiodes independently measures the incident radiation between scan intervals and stores an electrical charge, which reflects the measured intensity. At the end of this interval the shift gate is activated and the charges are simultaneously transferred into the shift register.
MDS E-SCAN MPR E-SCAN INFORMATION The signal is passed through circuitry to develop a DC voltage, which is related to the ratio of the time of A to B. This voltage is sent to the console to be processed by the microprocessor and displayed in the customers preferred units of measurement. Filtered CCD Signal 4.1.2 Console The console is constructed of molded fiberglass polyester to give protection in harsh environments. 4.1.2.
MDS E-SCAN MPR E-SCAN INFORMATION 4.1.2.3 IB (interface board) for external connection The interface board is located on the back wall of the console. Most external connections are made to connectors that plug into this board. The only exceptions are optional features that require connections to optional available connectors located on the side of the console. 4.1.2.4 Power supply The power supply is located in the top of the console and serves as a hold down clamp for the analog output modules.
MDS E-SCAN MPR E-SCAN INFORMATION 4.1.2.7 CPU Card The CPU card is found plugged into the PC/104 bus connectors of the I/O card. Ampro CoreModule 430 PC/104 CPU/VGA Card The CPU card operates with a microprocessor running at 133 MHz. The CPU card has a built- in flash hard disk drive, which contains the operating software, parameters and calibration points for the system. The processing power of the MPR E-Scan is performed by the microprocessor on the CPU core module.
MDS 4.2 E-SCAN MPR Refractometer Specifications Accuracy Span Repeatability Sensitivity Stability Response time Console Head +/- 1% of span or .000075 R.I., whichever is greater .0015 R.I. minimum .132 R.I. maximum .5% of span or better .5% of span or better No recorded drift /24 hour period. 250m.s. to 15 min. <500m.s. for .0015 R.I. change with 90% recovery on .015R.I. span.
MDS E-SCAN M ONITOR OPERATION 5. Monitor Operation This equipment is designed for continuous operation and may be left on for extended periods of time. 5.1 The Operator’s Panel The Operator’s Panel or Front Panel consists of a display and a 20-button touch pad, which form the interface between the operator and the instrument. The display consists of a 640 x 480 pixel LCD screen, which provides the operator with various messages.
MDS E-SCAN M ONITOR OPERATION 5.1.2 Button Touch Pad Function Chart Scrolls cursor horizontally to the left. Scrolls cursor horizontally to the right and also used to initiate editing of all system parameters. Scrolls cursor vertically in the “Up” direction. Scrolls cursor vertically in the “Down” direction. ENTER Used to select all cursor items and to save edited data. Esc Used to abort to previous operation without saving edited data.
MDS E-SCAN 5.2 M ONITOR OPERATION Normal Mode 5.2.1 What Normal Mode Does The Normal Mode of operation consists of the following information: • • • • • System time, date and software version number. Current solids readings from the MPR E-Scan units. Current time until next purge for the MPR E-Scan units. System status for the MPR E-Scan units. System status for the Monitor. 5.2.
MDS E-SCAN M ONITOR OPERATION +15 VOLT ERROR: This indicates that the plus 15 volt supply is outside the allowable 10% tolerance levels, which means it is either below +13.5 volts or above +16.5 volts. -15 VOLT ERROR: This indicates that the minus 15 volt supply is outside the allowable 10% tolerance levels, which means it is either above -13.5 volts or below -16.5 volts.
MDS E-SCAN M ONITOR OPERATION PURGE MISSED : This indicates that the steam solenoid relay was not activated during the purge operation and therefore the purge did not occur. PURGE INVALID : This indicates that either the steam solenoid relay was activated during a non-purging operation or there is an open- line condition. PURGE NOT ACTIVE: This is caused by not having purge cycle times set. This alarm flashes above the alarm box and does not take the refractometer off line. ISO.
MDS E-SCAN M ONITOR OPERATION SYSTEM: This status field is used to monitor many system functions and to issue warnings instead of errors so that the operator can be notified of problems that are not fatal but need to be addressed. The following warnings can be displayed in this status field: CHK LAMP VOLTAGE: This indicates the lamp voltage in a sensing head is above 4.0 volts. CAUTION- If lamp voltage reaches 4.2 volts the refractometer will be taken out of service.
MDS E-SCAN M ONITOR OPERATION 5.2.4 The Menu Options in Normal Mode Normal mode is entered by default, upon power up. To gain access to other system features select the MENU button on the Front Panel Touch Pad. Note: The readings below are just an example, they will vary from application to application.
MDS 5.3 E-SCAN M ONITOR LOG SELECTION Log Selection Log Mode Screen The logs menu contains four menu options: 1. ERR/WARN LOG This option allows the operator to view a log containing a history of system errors and warnings. Each log entry contains the error/warning message along with a time and date stamp. 2. PURGE LOG This option allows the operator to view a log containing a purge history.
MDS 5.4 E-SCAN M ONITOR CONFIGURATION SELECTION Configuration Selection The configuration menu contains two menu options: Configuration Mode Selection 1. STATES This allows the operator to set up the Monitor for either a 1 unit or 2 unit divert configuration. The operator can also enable/disable trending which is used as a divert prediction indicator. 2. LIMITS This allows the operator to enter set points for all system limits, such as trending, comparator, and temperature limits.
MDS 5.5 E-SCAN M ONITOR CONFIGURATION STATES SELECTION Configuration States Selection The first configuration option, “States”, activates the following display: Configuration States Selection One Unit Divert will allow the Monitor to activate the divert relay when (1) MPR E-Scan unit contains a solids reading below the divert point with no alarm present.
MDS 5.6 E-SCAN M ONITOR CONFIGURATION LIMITS SELECTION Configuration Limits Selection The next configuration option, “Limits”, activates the following display: Configuration Limits Screen Using the Front Panel arrow buttons, the operator can scroll through and edit selected system limits. In this example, Comparator Span % can now be changed using the RIGHT ARROW button. Comparator Span %: This x represents the maximum percent of solids readings difference that is allowable.
MDS 5.7 E-SCAN M ONITOR DIAGNOSTICS MODE SELECTION Diagnostic Mode Selection The Diagnostics menu contains the following options: Diagnostics Mode Screen 1. Voltages: This displays all pertinent system voltages for both MPR E-Scan units as well as the Monitor. 2. Relays: This allows the operator to toggle system relays for testing or troubleshooting purposes. The toggled relays can be visually checked by examining the relay LEDS on the Monitor /MPR EScan interface board. 3.
MDS 5.8 E-SCAN M ONITOR DIAGNOSTIC VOLTAGES SELECTION Diagnostic Voltages Selection The “Voltages” option results in the following display: Diagnostics Voltages Screen U1 Meas: The voltage produced when measuring a solution sample. It is used by MPR E-Scan unit 1 to obtain an interpolated value from the calibration table that will reflect an accurate displayed solids reading. U1 Temp: A voltage that produces the process temperature readout on MPR E-Scan unit 1 as follows: (Voltage - .5v) * 50 = Deg.
MDS E-SCAN M ONITOR DIAGNOSTIC VOLTAGES SELECTION U2 Meas: The voltage produced when measuring a solution sample. It is used by MPR E-Scan unit 2 to obtain an interpolated value from the calibration table that will reflect an accurate displayed Solids reading. U2 Temp: A voltage that produces the process temperature readout on MPR E-Scan unit 2 as follows: (Voltage - .5v) * 50 = Deg. C. U2 Lamp: A nominal voltage needed to maintain a signal of proper amplitude for MPR E-Scan unit 2 light source.
MDS 5.9 E-SCAN M ONITOR DIAGNOSTIC RELAY SELECTION Diagnostic Relay Selection The “Relays” option activates the following display: Diagnostics Relay Screen There are eleven total relays, six of which are inputs. Four input relays are activated by the MPR E-Scan units when the Isolation Valves are closed or when there are purge failures. One input is activated by pressing the reset button attached to the door of the MDS E-Scan cabinet.
MDS E-SCAN M ONITOR DIAGNOSTIC TIME /DATE SELECTION 5.10 Diagnostic Time/Date Selection The “Time/Date” diagnostic option activates the following display: Diagnostic Time/Date Screen This menu enables the operator to set the system time and date. System Time: This is the time displayed in military format in normal mode. System Date: This is the date displayed in normal mode. 5.11 Print Selection This dumps all logs to the printer for permanent hard copy output.
MDS E-SCAN MONITOR PROBLEM ANALYSIS 6. 6.1 Monitor Problem Analysis Procedures The following analysis procedures are meant to aid in isolating Monitor failures down to the board. Board or device replacement with a fast turnaround is available from EMC. These abbreviations are used: I/O Main Monitor I/O Board Conditions analog voltages for digital microprocessor. CPU CPU Card Microprocessor, plugs into the I/O board. IB Most external connections are made to this board.
MDS E-SCAN MONITOR INFORMATION 7. 7.1 Monitor Information Console Technical Description The console is constructed of molded fiberglass polyester to give protection in harsh environments. Display The LCD (liquid crystal display) has a pixel count of 640 by 480 to give very sharp resolution. The display is suitable for both graphics and text information.
MDS E-SCAN MONITOR INFORMATION 7.1.1 Console Cards IB (interface board) for external connection The interface board is located on the back wall of the console. Most external connections are made to connectors that plug into this board. The only exceptions are optional features that require connections to optional available connectors located on the side of the console. Power supply The power supply is located in the top of the console and serves as a hold down clamp for the analog output modules.
MDS E-SCAN MONITOR INFORMATION 7.3 Features • Continuously monitors both refractometers and associated equipment, looking at all vital signals per unit to determine whether the displayed solids should be considered valid. • Removes from service either refractometer whose associated signals do not meet a prescribed tolerance. An alarm will actuate, identifying the refractometer and circuit at fault.
MDS 7.4 E-SCAN MONITOR INFORMATION Specific Functions (Dwg. A-11585) Note: 58% +2% noted below are industry standards but may vary depending upon the application. The Monitor is capable of performing the following functions: 1. Monitor the (+15), (-15) and (+5) supply voltage of each refractometer independently. Should either refractometer's supply voltages exceed a predetermined safe operating voltage range with a minimum and maximum limit of ±10%: a.
MDS E-SCAN MONITOR INFORMATION 7. Monitor the isolation valve position. A partially closed or closed valve will initiate steps (a), (b) and (c). 8. Compare meter outputs. Should a difference of 2% solids or greater exist between refractometer readings, an alarm will be activated. 9. Monitor the supply voltages of the Monitor. Should either supply fail, an alarm will be activated. 10.
MDS 7.5 E-SCAN MONITOR INFORMATION Trouble Shooting Guide and Truth Table (For unit configured for two refractometer divert.) (X) Refrac removed from service (Y) Refrac remaining in service now solely responsible for diversion. Diversion will occur if reading drops below 58% due to low solids or alarm being activated which would remove unit from service. (Alarms shown on next page.
MDS E-SCAN MONITOR INFORMATION Condition for either Refractometer (1) or (2) Alarms Activated Liquor Diversion Loss of power to both refracs. 1,2,3,5,8 Will divert Failure of both refracs which would activate both alarms. any combination Will divert Refrac (1) and (2) indicates solids below 58%. Will divert Loss of power to both refracs & Monitor. Will divert Additional Notes 7.5.1 Error Alarm Conditions Alarm Condition 1 Refract Power Supply out of tolerance.
MDS E-SCAN MONITOR INFORMATION 7.5.2 Warning Alarm Conditions Alarm Condition 8 System Warning. * Check lamp voltage, indicates lamp voltage in either sensing head is about 4.0Vdc. See maintenance section 8.5. * Check purge log, ind icates successful purge after second or 3 attempt. Purge log contains duration of steam time needed. * Check analog solids, indicates direct voltage derived solids does not agree with RS-232 solids readings.
MDS E-SCAN SERVICE 8. 8.1 Service EMC Warranty The Electron Machine Corporation warrants that the equipment manufactured by EMC is free of defects in material and workmanship. Should such fault appear within one year of date of shipment from our factory, the Electron-Machine Corporation will repair or replace the defective part upon its prepaid return to Umatilla, Florida USA. (This warranty does not apply to equipment which has been tampered with or abused). 8.
MDS E-SCAN 8.4 SERVICE Spare Parts 8.4.1 How to Order Parts Orders for parts should be addressed to: Technical Services Department The Electron-Machine Corporation P O Box 2349 Umatilla, FL 32784-2349 Purchase orders should include the model number and the serial number of the equipment that the part is to be used with, in addition to the part number or drawing number and the chassis number.
MDS 8.5 E-SCAN SERVICE Maintenance MDS E-Scan Monitor Divert System Periodic Inspection Checklist We recommend the following checks be performed at least on a monthly basis under normal operation. § Desiccant condition: The desiccant seen through the view plug on the sensing head should be light orange when effective and clear when no longer effective. The desiccant can be renewed by heating to approximately 250°F (121°C) until it recovers its original color.
MDS 8.6 E-SCAN SERVICE Caution CAUTION When removing the sensing head from an operating line , do not assume that the line is empty or that the isolation or bypass means is working properly . If an EMC isolation valve is used, be sure its travel is not limited by any external attachments or other interference and the valve is closed tightly. No pressure should be felt on the head as the mounting nut is being removed. ANY PRESSURE FELT WHEN THE NUT IS LOOSENED MUST BE INVESTIGATED BEFORE PROCEEDING.
MDS E-SCAN SERVICE -Notes- 66
MDS E-SCAN DRAWING LIST 9.
