Voith BTG MEK-3000 Bedienungsanleitung

User Manual

MEK-3000

Rotating Consistency Transmitter

The contents of this document are subject to revision without notice due to continued progress

in methodology, design, and manufacturing. BTG shall have no liability for any error or

damages of any kind resulting from the use of this document.

reproduced, translated or converted into electronic or machine-readable form

without written permission of BTG Instruments AB.

Original Instructions

BTG Instruments AB, 2021

Table of contents

Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Product Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.3 Type Plate Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.4 CE Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.5 Communication Platform CPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.5.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.5.3 Type Plate Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5.4 CE-Declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.5 Supplier's Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Process Site Selection for Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Dilution Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3 Process Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.1 MEK-3000 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3.2 Weld-in Saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3.3 Measuring Chamber with Weld-in Stud . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.4 Measuring Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.5 Sensing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3.6 Propeller and Hub recommendations . . . . . . . . . . . . . . . . . . . . . . . . 29

II User Manual MEK-3000 M2071/8en © BTG 2021

4 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.2 Saddle / Weld-in Stud / Measuring Vessel Installation . . . . . . . . . . . . . . 32

4.2.1 Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2.2 Weld-in Stud for Ø180 mm Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2.3 Measuring Vessel with Saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.2.4 Weld-in Stud for Ø270 mm Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2.5 Measuring Vessel for Ø270 mm Flange. . . . . . . . . . . . . . . . . . . . . . . . . 41

4.3 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.3.1 Check Mechanical Sealing Movability . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.3.2 Mount the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.3.3 Mount / Dismount the Dirt Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.4 Mounting of Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.4.1 Inspection Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.5 Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.5.1 Flushing Water Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.5.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.6 Communication Platform CPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.6.1 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.6.2 Cabling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.6.3 Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.6.4 Backup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.6.5 RS-485 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5 Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6 Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.1 Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.1.1 Regular Maintenance of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 67

6.1.2 General Maintenance Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.2 Service Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.2.1 Removing the Transmitter from the Pipe . . . . . . . . . . . . . . . . . . . . . . . 68

6.2.2 Changing O-rings and Sealings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.2.3 Changing the Electronics Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.2.4 Changing Sensing Element and Propeller/Hub . . . . . . . . . . . . . . . . . . . 71

6.2.5 Changing the Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6.3 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

6.3.1 Calibration Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.1 HCM-8000 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.2 FCM-8000 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.3 Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

7.4 Raw Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7.5 Life Cycle Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

7.6 Pulp Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.7 MEK-3000 Documentation Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

8 CPM Operation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1.1 Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1.2 User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1.3 How to Read This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.1.4 Parameter Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.2 Menu Structure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.2.1 Measurement/Sample Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.2.2 Calibrate Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.2.3 Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.2.4 Diagnostics Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.2.5 Backup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3 General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.3.1 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.3.2 Calibration Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.3.3 Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.3.4 Check Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.4 Measurement/Sample Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

8.4.1 View Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8.4.2 View Instrument Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8.4.3 View/Edit Basic Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.4.4 Take Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

IV User Manual MEK-3000 M2071/8en © BTG 2021

8.5 Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

8.5.1 View Calibration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

8.5.2 View Correlation Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.5.3 Basic Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

8.5.4 Lab Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

8.6 Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

8.6.1 General Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

8.6.2 Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

8.6.3 Sensor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

8.7 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

8.7.1 Life Cycle Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

8.7.2 Configure Alarm Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

8.7.3 Configure Warning Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

8.7.4 View Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

8.8 Backup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8.8.1 Store Data on a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8.8.2 Restore Data from a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

8.8.3 Format Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

8.8.4 Store Data and Log Tables on Memory Card . . . . . . . . . . . . . . . . . . . 136

8.8.5 Configure Logging Update Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

9.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

9.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

9.3 Sensing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

9.4 Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

9.5 Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

9.6 CPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9.6.1 CPM-1400 with HCM/FCM-8000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9.6.2 CPM Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Important Information

This user manual contains all necessary instructions for installation, operation,

maintenance, and basic service of the MEK-3000

NOTE!

Always read the safety instructions before installation and service of the

Analyzer!

The instrument is operated using the CPM communication platform.

For guidelines on how to navigate and configure the CPM, see the CPM

Operation Guide enclosed as appendix with this manual.

Recycling

Recycle the instrument and all replaced parts according to local, first and

foremost national, laws and regulations. Contact BTG to get detailed

information on how to disassemble and recycle the instrument safely.

BTG should have no liability for any error or damage of any kind due to

disassembly or recycle work done.

Important Information

2 Important Information, MEK-3000 - Rev. A © BTG 2021

Safety Instructions

1 Safety Instructions

General

All BTG products(1) are designed according to Sound

Engineering Practice and for the Pulp and Paper

Industry.

These Safety Regulations are based on a risk analysis

carried out in accordance with the requirements of

relevant CE directives in order to comply with European

standards for CE marking.

This document provides general safety instructions that

apply when operating with BTG products to reduce the

risk of accidents. A BTG product is not hazardous in

operational mode if these Safety Regulations are

adhered to.

These Safety Regulations MUST be read before

installing any BTG product. Be careful to follow the

safety routines when installing the product, when

removing the product for service, and when carrying out

service on the product.

Use warning signs for safety information!

Mounting parts, such as measuring vessels and weld-in

studs, are dealt with in accordance with the pressure

vessel standards of specific countries.

Always take precautions when handling equipment in

pressurized pipes.

All installation, operation, service, and other handling

must be carried out by trained and authorized personnel

and according to valid standards.

Personnel must familiarize themselves with the

potential hazards indicated on the product they are

working on to understand which instructions apply. If

questions arise regarding safety instructions, contact

BTG for clarification.

For personal and functional safety: Use only parts that

have been manufactured or approved by BTG.

Local Regulations

First and foremost National Regulations must be

adhered to followed by any Local Regulations.

The National and Local Regulations supersede this

document. Should neither the National nor Local

Regulations cover a particular point within this

document, then the Regulations set out in this

document should be adhered to.

Target Group

The target group for this document is all personnel who

work with products delivered by BTG. These personnel

must familiarize themselves with the instructions in this

document.

Competence Requirements

It is presumed that all personnel who work on products

delivered by BTG have the necessary education,

training, experience and competence required to adapt

actively the personal safety requirements and the

protective measures to their work situation.

English language is typically used for all product

information provided by BTG Instruments AB, thus it is

required that the target group should have sufficient

knowledge in English language in order to understand

all product information, including in particular safety

related information.

How to read the Safety Instructions

The following conventions are used in a BTG manual:

DANGER!

A DANGER! admonition is used when there is a hazard

with a risk for injury or possible death to a person.

WARNING!

A WARNING! admonition is used when there is a risk

for damage to program, device, machine, sampler and

so on.

CAUTION!

A CAUTION! admonition is used when there is a risk of

system failure, service interruption, disturbances to

plant operation, a measuring application and so on.

The admonitions above are hierarchic. A DANGER!

admonition includes the possibility of both a WARNING!

and a CAUTION! admonition.

(1) Theterm "product"isused inthisdocument asa general

reference to Instruments, machine parts, or equipment.

Safety Instructions

4 Safety Instructions - Rev. A © BTG 2021

Safety Regulations

The symbols below are examples of danger signs found

in instructions, manuals, and on products delivered by

BTG.

Safety Regulations for Installation and

Service

Always turn off all power and other supplies before

performing any service or maintenance on the

product.

All welding or bolting must take place in accordance

with current standards and regulations.

All handling of electrical units must take place in

accordance with current standards and regulations.

Use approved lifting gear during installation to prevent

injury. Ensure that the equipment is anchored solidly

during installation.

If a motor with rotated parts are switched on, there is

risk of injury by crushing or cutting if the cover has been

removed. Take care when working close to a propeller

and a sensor if these are exposed.

Take every professional precaution before servicing. Do

not wear gloves or rings which may get caught in the

machinery! Use approved protective clothing during

installation and service to prevent injury.

Before removing a product from a measuring chamber

or opening an inspection cover, check carefully that the

line is empty.

Hot or corrosive liquid flowing out under pressure

may cause serious chemical burn injuries!

Take care when opening the cover of a electronic box

with built-in power supply unit.

This contains live parts which may cause electric

shocks.

Live parts are protected against normal contact

provided that the connections are made correctly.

When a product is exposed to dangerous basic or acidic

corrosive media, it should be removed from the pipeline

regularly for inspection. Replace any damaged seals. If

pressurized parts on a product or a weld-in stud have

corroded, check that the material is correct for the

application.

Leakages may cause personal injury or damage to

equipment due to corrosion or burning!

Beware of high temperatures during installation and

service to prevent injury.

DANGER

Hazardous voltage

in the equipment

DANGER

Crushing

DANGER

Cutting

DANGER

CHECK PIPES!

Risk for corrosive,

toxic, or aggressive

liquids or gases

with high pressure or

high temperature.

DANGER

Use protective

clothing

DANGER

High

emperatureT

DANGER

Risk for personal

injury and

possible death

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