OUL00489 V2.0 EN - Metso TS Owner's Manual - …valveproducts.metso.com/documents/cct/products/Metso_TS/Manuals...A temperature sensor (Pt-100) is installed inside the connecting pipe

Metso Total Solids Transmitter

Installation, Operating& Service manual

OUL00489 V2.0 EN

Table of contents

Warnings & safety information

Introduction 71.

Measurement principle.....................................71.1.Parts of the device...........................................71.2.

Construction 92.

Metso TS-FT....................................................92.1.Sensor electronics .........................................102.2.Transmitter Central Unit (TCU) .....................102.3.

Installing 113.

General principles..........................................113.1.Choosing the installation site.........................113.2.Installation dimensions...................................133.3.TCU and its shield..........................................163.4.Electric connections ......................................163.5.

Setting up 194.

Checking the hardware..................................194.1.Installing.........................................................194.2.Checking the cable connections....................194.3.Checking electric operation............................194.4.Configuration and calibration.........................194.5.

User interface and operating 215.

Operating unit, TCU.......................................215.1.Operating diagram.........................................225.2.

Configuration 236.

Configuration menu........................................236.1.Choosing and scaling the output signal.........236.2.User settings..................................................236.3.Device info ....................................................246.4.Setting date & time.........................................246.5.

Calibration 257.

About calibration............................................257.1.Sample taking................................................257.2.Entering laboratory results.............................257.3.Offset correction.............................................267.4.Calibration and sample history ......................267.5.

Diagnostics 278.

Diagnostics menu...........................................278.1.Error table......................................................278.2.Diagnostics values.........................................278.3.Diagnostics limits...........................................288.4.

Special functions 299.

Special functions menu..................................299.1.Chemical compensation.................................299.2.Sensitivity correction .....................................329.3.Recipes .........................................................339.4.

Troubleshooting 3510.

Troubleshooting procedures .........................3510.1.Effect of process conditions onmeasurement.................................................35

10.2.

Self-diagnostics error messages ...................3710.3.

Replacing components 3911.

Sensor electronics..........................................3911.1.Antenna cables, FT-sensor............................4011.2.Antennas, FT-sensor......................................4111.3.TCU ...............................................................4211.4.

HART user interface 4312.

About the interface.........................................4312.1.Measurement.................................................4412.2.Configure........................................................4412.3.Calibrate.........................................................4512.4.Diagnostics.....................................................4812.5.

Recycling and disposal 4913.

Technical specifications

Spare parts

Installation, operating & service manual, OUL00489 V2.0 EN3Metso Total Solids Transmitter


Warnings & safety information

During installation, maintenance and service operations, remember thatthe sample line may contain hot sample or water – be careful!

Always check input voltage & frequency beforemaking any connections.Incorrect connections will damage the equipment! Always follow the ap-plicable electric safety regulations in all installation work!

Before any welding works in the vicinity of the devices, make sure thatoperating voltage is not connected!



1. Introduction1.1. Measurement principleThe operation of the Metso Total Solids Transmitter(Metso TS) is based on the measurement of microwavepropagation time.

Microwaves are a form of electromagnetic radiation,and their propagation velocity, or flying time, is depend-ent on the dielectric constant of the medium in whichthey travel. The flying time is calculated as follows:

c = speed of light in vacuumer = dielectric constant of the medium.

In water microwaves travel at a much slower speedthan in sludge. Thus the dry solids content can be cal-culated based on the time it takes the microwaves totravel through the measured mass.

The advantages of this measurement method are itsindependence on medium, insensitivity to flow rate,and single-point calibration.

1.2. Parts of the deviceThe device consists of the sensor unit (Fig. 2 or 3) andthe TCU operating unit (Fig. 1).

Fig. 1. Operating unit, TCU.

Fig. 2. Metso TS-FT.

Fig. 3. Metso TS-FT high-pressure model.


Notes


2. Construction2.1. Metso TS-FTThe Metso TS (Fig. 1) consists of the sensor unit andTCU operating unit. The sensor is available in six sizes,from FT50 - FT300, with pressure rating PN16.

With pressure rating PN100 the sensor is availablein three sizes in the range FT100 - FT200. The appro-priate model is selected according to the requiredpressure rating and the diameter of the process pipe.

The body of the flow-through sensor consists of apipe section that forms part of the process pipeline onceinstalled. Flush-mounted antennas are installed on op-posite sides of the sensor body, and measurement takesplace through the pipe. The sensor electronics housingis installed to the sensor body by means of a connectingpipe.

A temperature sensor (Pt-100) is installed inside theconnecting pipe. Antenna cables, installed in a protect-ive tube, run along the outside of the connecting pipeand connect to the electronics housing.

All wetted sensor and antenna parts are made of AISI316/316L. The antenna material is polished ceramic.

A

B

C

D

E

Fig. 1. Metso TS-FT: A - sensor electronics, B - sensorcable connector, C - antenna cable, D - temperaturesensor, E - microwave antennas.


2.2. Sensor electronicsSensor electronics of the FT model is shown in Fig. 3.The sensor electronics board is installed between around cover and a base. The electronics contains a mi-crowave transmitter and receiver, and the electronicsfor control, measurement and communciation.

When the electronics board is pressed on the baseplate, its snap-on connectors connect with the antennacable connectors on the base plate. Guide pins on thebase plate guide the connectors into position. Thetemperature sensor, and the supply power and serialcommunication lines from the TCU, are connected tothe connectors on the sensor electronics housing.

2.3. Transmitter Central Unit (TCU)The TCU is the operating terminal and calculation unitof the Metso TS. It is operated by means of the keypadand a four/line display. The TCU is delivered with ashield attached to it (Fig. 2).

Connections:– To sensor unit: operating voltage, RS485 serial

communication.– To current outputs (passive). In TCU Rev B and

greater: 2 current outputs.– To HART communicator (HART only in current

output 1).– RS232 connection to a PC (for service purposes).– Mains power.

Fig. 2. Operating unit, TCU.

A

B

C

D

E

Fig. 3. Sensor electronics: 1. Power cable connector, 2. Fastening screw, 3. Temperature sensor connector, 4.Guide hole, 5. Antenna cable connectors.


3. Installing3.1. General principlesThe sensor model is selected according to the size andpressure rating of the pipeline. Flow-through modelsare FT50/2", FT100/4", FT150/6", FT200/8 ",FT250/10" and FT300/12". These can be installed tothe following pipe flanges:

Standard model– DIN PN10– DIN PN16– ANSI Class 150– JIS 10K

High-pressure model– DIN PN100– ANSI Class 600– JIS 63K

For laboratory follow-up, it is important to use agood sampler (e.g. NOVE) and install it in accordancewith the Metso TS installation instructions.

NOTE: Before installing the process coupling / sensor,make sure that the process pipeline is empty and notpressurized, and that installation work can be carriedout safely!

3.2. Choosing the installation siteWhen choosing the installation point, pay attention tothe following:– Never install the sensor to the suction side of a

pump, or to a tower.– Free straight pipe section after any changes in the

pipeline profile.– Space for the sensor housing.– TCU must be installed close to the sensor. The

length of the normal sensor cable is 10 m (33 ft), a30 m cable (98 ft) is available as option.

Also pay attention to the following specifications:– Process temperature max. 100 °C (212 °F).– pH 2.5...11.5.– Recommended process pressure is 1.5 - 16 bar (22

- 232 psi) to eliminate the effect of air bubbles.– Conductivity according to sensor specifications.– Pressure rating of the sensor:

- FT models PN16/PN100

Inspecting the installation:– Make sure that the installation point and sensor po-

sition are in accordance with the instructions.– Make sure that the FLOW arrow on the sensor

housing is aligned with the process flow direction.– Protect the sensor and TCU from direct heat radi-

ation and direct sunlight.– Before start-up, make sure that the seals between

the Metso TS flanges and process flanges are cor-rectly installed and the mounting bolts tightened.

Sensor installation to a vertical and horizontal pipelineis illustrated in Fig. 1 and 2.


D

D

A B

Measuring line at a 90° angletowards the pump axis.

Measuring line parallel tothe previous horizontal pipe.

Fig. 1. Installing the sensor to a vertical pipeline: A - after a pump, B - after a horizontal pipe section.

2xD if Cs>8%

D

Min4xD Min2xD1xD ifCs>8%

Min4XD2xD if Cs>8%

Min2xD1xD ifCs>8%

DA B

If the section of horizontal pipe precedingthe sensor is >10xD, then the sensor isinstalled with its electronics casing on top.

Fig. 2. Installing the sensor to a horizontal pipeline: A - after a bend, B - after a vertical pipe section.


3.3. Installation dimensionsWhen installed, the sensor replaces a section of theprocess pipeline (Fig. 3 and 4). The installation dimen-sions are shown in Fig. 3 - 8. A sticker on the electron-ics housing indicates the correct installation directionin relation to the flow in the pipeline.

L

min. 500 mm (20")

Fig. 3. Metso TS-FT installation principle.

min. 500 mm (20")

L

Fig. 4. Metso TS-FT PN100 installation principle.

Fig. 5. Main dimensions FT50/2", FT100/4".





Fig. 8. Main dimensions FT100/4", FT150/6", FT200/8" PN100.


3.4. TCU and its shieldThe TCU is delivered with a protective shield attachedto it. Choose an easily accessible location, and mountthe shield on the wall with three screws.

When choosing the TCU installation point, remem-ber that the sensor cable is 10 m (~ 33 ft) long The di-mensions of the shield are shown in Fig. 9.

3.5. Electric connections

NOTE:Beforemaking connecting the power supplywires,make sure that thewires are not powered! Connect powerto the wires only after you have made and checked allconnections.

NOTE: If the TCU has been powered off for some time,the display will take some time to light up. This delay isperfectly normal, and the display will start working assoon as its internal backup battery has recharged.

Sensor cable

NOTE: In normal deliveries the sensor cable is alreadyconnected to TCU.

1. If the sensor cable is not connected, insert its openend (= cable end without connector) into theTCU's connection box, and connect it as shownin Fig. 11. Connection of protective shields:Intertwined shields of the twisted wire pairs(connector 3) to GND together with wire 2.- Sensor cable shield (wire 6) to connector 'SCSHIELD' (Sensor Cable Shield).

2. Lead the other end of the sensor cable to thesensor unit, and connect it to the connector on thesensor electronics base plate.

NOTE: Do not put the sensor cable on the same rack withpower cables (motor/pump power cables etc.).

232 (9.13")

70 (2.76")

31 (1.22")

236(9.29")

133 (5.24")

282(11.10")

Fig. 9. Installation dimensions of the TCU shield.


Mains powerConnect the mains power cable (90 - 260 VAC) to TCUthrough the left-hand conduit of the connector casing,and connect it to the terminal strip as shown in Fig. 11.

Current signal cablesTCU Rev B contains two current outputs. Current out-put 1 (CS+, CSIN) is hardwired to give the dry solidscontent signal. The user can choose either the processtemperature (°C/°F), process conductivity (mS/cm) orsolids content (TS% / g/l) to current output 2 (CS2+,CSIN2).

Insert the current output cables to the TCU connectorcasing through the inlets and connect them to the ter-minal strip as shown in Fig. 11.– Power supply wire to connector 'CS+' or 'CS2+'.– Current output wire to connector 'CSIN' or 'CSIN2'.

NOTE: The current output of the Metso TS is a passiveoutput and it requires an external power source. Theminimum supply voltage is dependent on resistance.

NOTE: In TCU Rev B, do NOT connect the shield of thecurrent output cable at the TCU! Connect it only at themill system end! In earlier versions (TCU Rev 0 and RevA) the instruction was that the shield should be connec-ted to connector ‘SHIELD’ at the TCU.

Fig. 10 shows the resistance as a function of inputvoltage. Resistance here means the total sum of allresistances (measurement, cables, power supply) in thecurrent loop.

1000

500

250

06 12 35 V2817

Ω

Operating region

Fig. 10. Load on TCU's current output.

TE

CS+

CSIN 250 Ω

90 - 260 VAC47 - 63 Hz

Channel

Power supply

Automation system

Input(4...20mA)

Sensor cable2x(2+1)x0.5+ shield

4 - 20 mA + HART (Dry solids content)4 - 20 mA (Process temperature/conductivity)

Fig. 11. Connections of the TCU.


Notes


4. Setting up4.1. Checking the hardware1. Make sure that the delivery is consistent with the

order.2. Make sure that the device has not suffered any

damage during transport.

4.2. InstallingInstall the sensor and TCU as instructed in Chapter 3of this manual.

4.3. Checking the cable connections1. Make sure that the power supply cable is correctly

connected.2. Make sure that the current outputs are correctly

connected.3. Make sure that the sensor cable is correctly con-

nected.

4.4. Checking electric operation1. Connect power to the system.2. Make sure that the TCU display lights up and

shows text. Normally the main display will soonappear. If a device has been replaced, the programmay ask the user to start calibration. In such cases,select calibration of the unit (Sensor elec-ronics/TCU) that was not replaced.

3. Allow the device to warm up for one hour beforestarting it up.

NOTE: If the TCU has been powered off for some time,the display will take some time to light up. This delay isperfectly normal, and the display will start working assoon as its internal backup battery has recharged.

4.5. Configuration and calibration1. Choose the language, temperature unit (Celsi-

us/Fahrenheit) and dry solids content unit (TS%or g/l) as instructed in Chapter 6.2.

2. Set the correct date and time to the device as in-structed in Chapter 6.4.

3. Scale the current outputs as instructed in Chapter6.1.

4. Calibrate the dry solids content as instructed inChapters 7.1 and 7.2.

After these procedures the Metso TS is ready to startmeasurment.


Notes


5. User interface and operating5.1. Operating unit, TCUThe sensor is operated with a TCU (Transmitter CentralUnit).

Number keys: Entering numerical data, selecting fromthe menus. In some displays the number keys can alsobe used to type letters. To enter letters, press a keyrapidly several times and the letters indicated on thekey will appear one after the other.

Sample: In the "Sample taking" function of the Calib-ration menu, pressing this button starts and stops takinga calibration sample. Pressing this key in the main menustarts and stops taking a follow-up sample.

Edit/Save: Press this button to go into editing mode.In editing mode, press this key to save data.

ESC: Exit from editing mode without saving. Togglingbetween main display and function menu.

Enter: Toggling between main display and info dis-play. In editing mode, jumping to the next edit field.

Back arrow: In editing mode, returning to the previouscharacter inside a field.

Forward arrow: In editing mode, moving to the nextcharacter inside a field.

Down arrow: Scrolling down in a display if there aremore than four lines (a downward-pointing arrow inthe bottom right corner of the display indicates thatthere are more lines). Scrolling the alternatives in anediting field.

Up arrow: Scrolling up in a display if there are morethan four lines (an upward-pointing arrow in the topright corner of the display indicates that there are morelines). Scrolling the available alternatives in an editingfield.


5.2. Operating diagramThe operating diagram is divided into four functionsand their submenus. The main sections are Calibration,Configuration, Diagnostics, and Special functions.

To access a menu from the main display, press ESCand then select the number of the desired function.

Press ESC to return to the previous level. If a displaycontains more lines than the TCU can show at a time(i.e. more than four lines), arrows in the top or bottomright corner of the screen indicate that the lines can bescrolled up or down with the down arrow or up arrowkeys.

TS FT200 POS-1234 1=C2=Tu

4=D

ENTER

3=Lab ValuesTS= 3.12%T= 56.7 CStatus=OK

1=Calibration2=Configuration

4=Special functions3=Diagnostics

% Range = 53.00 %mA = 12.48 mACabin T = 52.3 C

ESC

1

2

3

4

Meas Att= 45.6 dB

Sample takingEnter labOffset CorrectionCalibration HistorySample History

Output signal 1Output signal 2User SettingsDevice InfoSet Clock

Error LogDiag. valuesDiag. limits

Chemical CompensationTemperature CompensationSensitivity CorrectionRecipes

Fig. 1. Operating chart.


6. Configuration6.1. Configuration menuThe configuration menu contains the following func-tions:

1 = Output signal 12 = Output signal 23 = User settings4 = Device info5 = Set clock

6.2. Choosing and scaling the output signalIn the main display, press ESC to access the Operationsmenu. Configure the dry solids content output: choose1 and the following display will appear:

Low TS (4mA) = 0.0%High TS(20mA) =10.0%Filtering =1 sFault =3.75 mA

Press "Edit/Save" and enter values for the low andhigh solids content. If necessary, you can also changethe filtering time and choose how the current outputbehaves if the self diagnostics detects an error. The al-ternatives are setting the current output to a fixed value(either 3.75 mA or 22.5 mA), and freezing it to the lastvalue before the error situation.

If you wish to configure either process temperatureor process conductivity to current output 2, choose 2and the following display will appear:

Choose variable:Process temperatureLow (4 mA) = 0High (20 mA) =100

Press "Edit/Save". Select the variable with theup/down arrow keys, and then enter the low and highlimits for the selected variable. Press "Edit/Save" tosave.

6.3. User settingsIn the main display, press ESC to access the Operationsmenu. Choose "Configuration" -› "User settings" to seethe following display:

trend int:10 minpositio :POS-1234language :englishTS unit. : g/ltemp unit :Cpassword :NAkt siglev :ON

The display shows four lines at a time. Use theup/down arrow keys to scroll the screen. Press"Edit/Save", and you can then edit the following:

Trend int: Sampling interval of the trend table. Usethe up/down arrow keys to edit.

Position: Installation point of the sensor. In this fieldyou can type letters with the number keys. To get aletter, press a button rapidly several times so that theletters under that key run on the screen.

Language: Changing display language. Use theup/down arrow keys to select from the list.

Temp unit: Temperature unit, °C / °F. Use the up/downarrow keys to select from the list.

TS unit: Dry solids content unit, TS% or g/l.

Password: Choose whether or not a password is re-quired. Use the up/down arrow keys to select. If thepassword is activated, the program will ask for a pass-word when entering Edit mode and also before a calib-ration sample can be taken. The password is 3121. Thedefault setting is that a password is not in use.

Act.siglev: ON/OFF. When this setting is ON, thedevice will keep the signal level within a certain optim-um range. This may be necessary if process conductiv-ity varies a lot.


6.4. Device infoChoose "Configuration" -› "Device info" to see thefollowing display:

1 = Sensor Electronics2 = TCU

To see more detailed information on the sensorelectronics, choose "1=Sensor electronics".

Type: TS FT-xxxS/N : 123456HW Ver: 0001SW Ver: 0001

Type: Metso TS sensor type.

S/N: Serial number of sensor electronics.

HW Ver: Sensor electronics version number.

SW Ver: Version number of sensor electronics soft-ware.

To see the corresponding information on the TCU,choose 2=TCU.

6.5. Setting date & timeChoose "Configuration" -› "Set clock" to see the follow-ing display:

Date 26.09.10Time 12:14:53

The date and time set in this menu will be used inthe trend table and as the time stamp for calibrationsamples. The status line in the main display reads "Setclock" until the time has been set in this menu. Use the"Edit/Save" button to edit and save the time setting.


7. Calibration7.1. About calibrationThe Metso TS is factory-calibrated before delivery,which means that it will begin to measure dry solidscontent as soon as the power is switched on. Factorycalibration is done during the final testing, using cleanwater.

Re-calibration during device start-up is recommen-ded, to optimize the device settings for the actual con-ditions at the installation site.

To calibrate the device, take a dry solids contentsample and enter its laboratory result into the MetsoTS. Follow the instructions below, and the status lineon the display will change from "Factory calibration"into "OK".

The Calibration menu contains the following func-tions:

1 = Sample taking2 = Enter lab3 = Offset correction4 = Calib.history5 = Sample history

7.2. Sample takingIn the main display, press first ESC to access the Oper-ations menu, and then select "Calibration" -› "Sampletaking". Always when a sample is taken with a factory-calibrated device, it will adjust the measurement signalto the optimum level before taking the sample.

This may cause a small step change in the dry solidscontent measurement of the device. For this reason thedevice must not be used for dry solids content controlat this point.

The sample taking display looks like this:

Press sample-keyto start sampling.TS = 3.26 %status:Waiting

Now press the "Sample" button (on the right side ofthe display). The device begins to average the measure-ment result, and the message "Sampling" appears onthe status line. Take a calibration sample, and then pressthe Sample button again. The device stops the resultaveraging and shows the result on the display.

Sampling ready.average TS= 3.26 %min= 3.20%max= 3.33%T = 56.3 °C

In addition to the average dry solids content, the devicealso shows the minimum and maximum values duringthe sampling period, and the process temperature.

The minimum and maximum values indicate howmuch the dry solids content varied during the samplingperiod. The variation should be relatively small to en-sure that the obtained sample is reliable.

The sample data will go to the "Enter Lab" menu towait for the laboratory value. Press ESC to move backin the menu structure.

NOTE: Pressing the Sample button in themainmenuwillalso start measurement result averaging. However, theobtained sample cannot be used for device calibration -it is intended for reading the average result over a periodof time, for example for monitoring purposes.

7.3. Entering laboratory resultsWhen you have determined the dry solids content ofthe sample in the laboratory, press ESC in the mainmenu to access the Operations menu, and then select"Calibration" -› "Enter Lab". The following displaywill appear:

dd.mm.yy hh:mmTS =00.00%Lab =00.00%Chem =NaOHTS con =1.2mS/cmLab con =0.0mS/cm

The first line shows the sampling date and time inthe format dd.mm.yy, hh:mm. The second line showsthe dry solids content measured by Metso TS. Press"Edit/Save", and the cursor will appear in the field"Lab". Enter here the dry solids content result obtainedin the laboratory.

When calibrating the conductivity measurement,enter the laboratory result for conductivity in the field"Lab con", use mS/cm as the unit.

Press "Edit/Save" to save the values.

NOTE: The lines "Chem", "TS con" and "Lab con" areonly needed for chemical compensation (see section9.1).

The laboratory value of the sample can only beentered once in the "Enter Lab" menu. If necessary,you can perform offset correction for the dry solidscontent calibration as explained below ("Offset correc-tion").


7.4. Offset correctionIf laboratory monitoring indicates that the Metso TSmeasurement results are consistently too high or low,this can be corrected by offset correction of the calibra-tion.

Press ESC in the main menu to access the Operationsmenu, then select "Calibration" -› "Offset correction".The following display will appear:

Offset = 0.00 %Cum. offset = 0.00 %

Press "Edit/Save", and the cursor will appear in thefield "Offset". Enter the required offset correction valuein the field. For example, if the laboratory monitoringshows that the Metso TS result is 0.1% too high, theoffset correction should be - 0.1%. Press "Edit/Save"to save the values.

7.5. Calibration and sample historyCalibration historyThe calibration history table contains the last tenchanges made to the dry solids content calibration. Tosee the table, press ESC in the main menu to access theOperations menu, and then select "Calibration" -›"Calib. history". The following display will appear:

10.10.10 12:10:48Lab= 3.20 TS= 3.00Cum.offset=-00.00 %T=47.4C att= 40.2 dB

The first line shows the date (dd.mm.yy) and time ofthe calibration change. The second line shows theentered laboratory result (Lab) and the correspondingMetso TS measurement result (TS), if the calibrationwas made using a new sample. If only an offset correc-tion was made, the second line shows the laboratoryresult (Lab) and the offset change (Offs). The third lineshows the cumulative change resulting from the levelchanges.

Here you can see if the calibration has been re-peatedly corrected in the same direction or back andforth. The former alternative clearly indicates that thedevice measurement has been drifting. In the latter case,either there is a device error, or the laboratory analysesand the calibration based on these may be incorrect.

Sample historyThe sample history table contains the 30 latest calibra-tion and monitoring samples. Monitoring samples canbe taken by pressing "Sample" in the main menu, whilecalibration samples must be taken in the "Sample tak-ing" menu.

You can also use this table if you wish to read themeasured values for certain samples. To access thesample history table, go to Operations menu and press"Calibration" -› "Sample history".

10.10.10 12:10:48TS= 3.00att= 40.2 T=47.4C

…ENTER=for next

The first line shows the sample date and time. Thesecond and third line show the Metso TS measurementresults for dry solids content, measurement signal atten-uation, and process temperature.


8. Diagnostics8.1. Diagnostics menuThe diagnostics menu contains the following functions:

Error LogDiag. valuesDiag. limits

8.2. Error tableIn the diagnostics menu, select "1=Error table". If theself-diagnostics system has detected no errors, the dis-play reads "NO ERRORS". If errors have been detected,the first line of the display shows the timestamp whenthe error occurred, the second line shows when it ended,and the error type is shown on the third line.

If the error is still on, the ending timestamp is shownas '--'. The message "Shutdown" instead of the errorending stamp indicates that operating power wasswitched off when the error was still on. If the error isstill on when the power is connected on again, it willbe stored in the error table as a new error. The tablecontains the 10 most recent errors.

10.12.10 15:32:45--.--.-- --.--.--RLEV ALARM...ENTER=for next

8.3. Diagnostics valuesSelect "Diagnostics" -› "Diag. values", and the follow-ing display will appear:

Cab temp = 40.6 CMlev = 121 mVRlev = 214.4 mVMstab = 9.8Rstab = 2.1El drift = -2.4VCO drift = 3.2

This display shows the values of the following dia-gnostics measurements:

Cab temp: Temperature of sensor electronics.

Mlev: Measurement signal level.

Rlev: Reference channel signal level.

Mstab: Stability of the measurement channel signal.

Rstab: Stability of the reference channel signal.

El drift: Drift of the reference channel signal.

VCO drift: Drift of the signal generator.

Chapter 10 of this manual contains more detailedinformation on how this data can be utilized for service.


8.4. Diagnostics limitsSelect "Diagnostics" -› "Diag. limits", and the followingdisplay will appear:

Ctmp max =90 /OFFPtmp max =100.0 /ONPtmp min =0.0 /ONMlev min =10 /ONR.Lev min =100.0 /ONMstab max =20 /ONRstab max =2 /ONEldr abs =80.0 /ONVCOdr abs =50 /ON

The display shows the error limits for each dia-gnostics measurement, and its effect on the currentsignal (ON/OFF). To edit these limits press "Edit/Save"and enter a new error limit, or change the ON/OFFsetting with the up/down arrow buttons.

Even if the effect of a limit on the current signal isblocked by setting it OFF, an error message will stillappear in the status line of the main display, and errordata will also be stored in the error table.


9. Special functions9.1. Special functions menuThe Special functions menu contains the followingfunctions:

1 = Chemical comp2 = Temperature comp3 = Sensitivity corr4 = Recipes

9.2. Chemical compensationLarge variations in chemical content may cause errorsin the dry solids content measurement of the Metso TS.Compensation based on microwave attenuation meas-urement can be applied to eliminate these errors.

The use of chemical compensation is explained inthe following sections.

Entering laboratory values1. First take a sample as instructed in section 7.1.2. Determine its dry solids content and filtrate con-

ductivity at room temperature.3. Then go to the "Enter Lab" menu.4. Press "Edit/Save", and enter first the laboratory

result for the dry solids content. Pressing "Enter"scrolls the display down after the last line.

5. Then select the chemical type with the up/downkeys, and enter sample conductivity using mS/cmas the unit.

--------------------Sample 12.08-04TS = 3.00 %Lab TS= 0.00 %--------------------Chem = NaOHTS cond= 2.4 mS/cmLab cond= 0.0 mS/cm

If the conductivity meter gives the result as mS/m,divide the result by one hundred (e.g. 550 mS/m = 5.5mS/cm).

If the conductivity meter gives the result as uS/cm,divide the result by one thousand (e.g. 5500 uS/cm =5.5 mS/cm). If the conductivity meter gives the resultas umho/in, divide the result by 2500 (e.g. 25 000umho/in = 10 mS/cm).

Using the chemical compensationAfter entering the laboratory values select "Specialfunctions" -› "Chemical comp." and the following dis-play will appear:

--------------------Chem.comp: OFFComp. value= 0.00%Chem = NaOHLab cond =3.4 mS/cm--------------------

Press "Edit/Save", and the cursor will appear in thefield "Chem. comp". The text OFF indicates thatchemical compensation is not in use. Use the up/downarrow keys to change the text to ON and press"Edit/Save". The Metso TS then begins to use thechemical compensation.

The value "Comp. value" on the second line indicateshow much the chemical compensation subtracts fromthe actual measurement result. The third and fourthlines indicate the chemical and laboratory conductivityvalues entered by the user.


Temperature compensation correctionThe Metso TS compensates for the effect of temperat-ure by using a temperature measurement. If temperaturesensitivity is still observed in the measurement result,it can be eliminated by temperature compensation cor-rection. First determine the actual temperature depend-ence by means of laboratory monitoring. To ensurereliable results, both the sampling and laboratory ana-lyses must be accurate and reliable, and also the tem-perature range must be wide enough.

The results of laboratory monitoring are shown in aTS-Lab vs. Temp graph. If the TS-Lab points are on ahorizontal graph, the Metso TS measurement resultsshow no dependence on temperature. If the graph ishorizontal but are not at zero level, perform a levelcorrection to the calibration as instructed in section 7.3.

If the graph is not horizontal, the Metso TS measure-ment results show some dependence on temperature(Fig. 1). To eliminate this effect, enter a correctioncurve for the temperature compensation. Select "Specialfunctions" -› "Temperature comp", and the followingdisplay will appear:

Temp TS-Lab1. 0.00 0.002. 0.00 0.003. 0.00 0.004. 0.00 0.005. 0.00 0.006. 0.00 0.00

Press "Edit/Save". Then enter the correction curveas point pairs, Temp/TS-Lab. The Metso TS will usethis data to correct the compensation. Up to six pointpairs can be entered. In the case shown in Fig. 1 twopoint pairs are enough, and based on the results thesecan be selected for example as follows:

Temp TS-Lab1. 42.0 0.002. 48.1 0.103. 00.0 0.004. 00.0 0.005. 00.0 0.006. 00.0 0.00

Compensation is also successful outside the definedinterval such that the compensation curve is continuedbeyond the outermost points using the same slope.

TS-Lab vs Temp

-0,2-0,15-0,1-0,05

00,050,10,150,2

41 42 43 44 45 46 47 48 49 50

Temp (°C)

TS-Lab(%

)

Fig. 1. Determining temperature dependence.


Effect of new dry solids calibrationIf the Metso TS is re-calibrated with a new dry solidscontent sample after setting the temperature compens-ation correction, the device will make a level adjust-ment to the correction curve.

This level adjustment sets the effect of the correctioncurve to zero at the new calibration temperature. Forexample, if a new dry solids content calibration is madeusing a 45 °C sample, the device will make an approx-imately -0.05% level adjustment to the curve, and thecorrection curve would then look like this.

Temp TS-Lab1. 42.0 -0.052. 48.1 0.05

Changing the correctionIf temperature dependence is still observed after thecorrection, the easiest solution is to edit the existingdata points to correct the curve. The changes are thenadded to the already existing correction values.

For example, after the temperature correction curveand a new dry solids content calibration, the resultswould look like Fig. 2. The correction curve for 42°Cwould be increased by 0.03%, and the correction valuefor 48.1°C would be decreased by 0.02%, to give thefollowing correction.

Temp TS-Lab1. 42.0 -0.022. 48.1 0.03

TS-Lab vs Temp

-0,2-0,15-0,1-0,05

00,050,10,150,2

41 42 43 44 45 46 47 48 49 50Temp (°C)

TS-Lab

(%)

Fig. 2. Results of new dry solids content calibration.


9.3. Sensitivity correctionThe sensitivity of the Metso TS dry solids contentmeasurement has been set for municipal waste. If thedevice is used to measure some other materials, it maybe necessary to change its sensitivity. A graph is usedto determine the slope of a data set, and this value thenindicates the sensitivity of the Metso TS dry solidscontent measurement.

If the sensitivity of the device to the measured ma-terial is not known beforehand, laboratory monitoringis required. In order to determine the sensitivity withgood reliability, the laboratory results must cover alarge enough range of dry solids contents. The resultsof the monitoring are plotted in a graph, with MetsoTS on the vertical axis and Lab. dry solids content onthe horizontal axis.

In the example shown in Fig. 3 a linear regressiongraph is drawn through the data points. The slope ofthe curve equation gives the sensitivity of the measure-ment, in this case it is 0.89.

To correct the sensitivity, select "Special functions"-› "Sensitivity corr." and the following display willappear:

Input new sens.coeff = 1.00

Press "Edit/Save" and enter the sensitivity valueobtained from the graph, in this case it was 0.89. Press"Edit/Save" to save. If the sensitivity correction mustfor some reason be done a second time, remember totake into account the already existing correction set-tings. In practice this means that the sensitivity obtainedat the second time must be multiplied by the existingsensitivity coefficient, and the obtained new value isthen used as the sensitivity correction factor.

Example: in the previous example, if the sensitivitycorrection value obtained from repeated laboratorymonitoring is 0.9, the new sensitivity correction is then:0.89 x 0.9 = 0.8. If sensitivity correction must be can-celed, enter 1 as its value.

TS vs Lab y = 0,8932x + 0,291

22,22,42,62,83

3,23,43,63,8

2 2,2 2,4 2,6 2,8 3 3,2 3,4 3,6 3,8

Lab (%)

TS(%

)

Fig. 3. Determining the sensitivity of Metso TS measurement.


9.4. RecipesThe recipe function may be needed in special applica-tions where the measuring conditions vary so muchthat they cannot be covered with just one calibration.These changes may be for example– large changes in dry solids content that go outside

the measuring range of the device (±9…±15%, de-pending on sensor type),

– a change in the measured material, when the drysolids content sensitivity of the materials is verydifferent, or

– a large chemical change (e.g. different chemicaltype) that cannot be covered by chemical compens-ation.In such cases the device is calibrated and configured

separately for each different set of process conditions,and these are then saved as separate recipes. Each re-cipe can have its own dry solids content calibration,chemical compensation, temperature compensationcorrection, sensitivity correction, and current outputscaling.

Up to four recipes can be stored in the device. If therecipes are in use, the status line of the Metso TS maindisplay will show the recipe name instead of the usual"OK".

Choose "Special functions" -› "Recipes" to see thefollowing display:

--------------------1=Choose recipe2=Clear recipe--------------------

Using the recipesSelect recipes either manually from the TCU keypad,or automatically with the binary controls connected tothe TCU. Press "Recipes" -› "Choose recipe", and thefollowing display will appear:

--------------------Choose: OFF1.--------0000002.--------0000003.--------000000--------------------4.--------000000

Press "Edit/Save", and the cursor will appear in thefield "Choose" on the first line. Use the up/down arrowkeys to choose the recipe number (1, 2, 3 or 4) or the"Binary" selection. When "Binary" is selected, recipeis set by the TCU binary inputs Bin0 and Bin1 (seebelow, Recipe selection with binary inputs).

You can name the recipe as follows: move the cursorto the recipe with the "Enter" key, and then write therecipe name. Use the number keys to scroll the lettersunder each key. If the recipe is not named by the user,the program will use default names (RES01, etc). Savethe recipe selection and names with the "Edit/Save"key.

The date after a recipe name (ddmmyy) indicateswhen the calibration was last changed. The text "ON"after the date indicates which recipe is in use at themoment.

--------------------Choose: 11.RES01---150405 ON2.--------0000003.--------000000--------------------4.--------000000

When process conditions change so much that a newrecipe is needed, choose the next recipe as instructedabove, either manually or with the binary inputs.

--------------------Choose: 21.RES01---1504052.RES02---000000 ON3.--------000000--------------------4.--------000000

The software will store the calibration of the previousrecipe for the next one. If the date is shown as 000000,this means that the recipe in question has not been cali-brated with an own sample. Calibrate the recipe witha new sample as instructed in chapter 7, and the calib-ration date will then appear in the display.

If necessary, scale the current output as instructedin section 6.1 and also configure the special functionsas instructed in chapter 9. Configure recipes 3 and 4 inthe same way.


Clearing a recipeIf you wish to delete the data of a recipe, select "Re-cipes" -› "Clear recipe", and the following display willappear:

--------------------Clear recipe: 1

Press "Edit/Save" and then select the recipe with theup/down arrow keys. Press "Edit/Save" and the programwill ask for confirmation:

--------------------This action willClear recipe 1ENTER=ClearESC=Cancel--------------------

Press Enter to clear the recipe.

NOTE: You cannot empty the recipe that is currently inuse.

Recipe selection with binary inputsRecipes can be selected by using two digital controllines connected to the TCU's binary inputs. Up to fourrecipes can then be used.

Two recipes can be used if only one binary input isconnected. Choose "Binary" as the recipe selectionmethod (see above, Using recipes).

Choose: BIN1.RES01---150405 ON2.RES02---2204053.--------000000--------------------4.--------000000

Connect for example digital control lines from themill system to TCU's binary inputs BIN0 and BIN1,their ground to input BINGND. Choose the recipe withthe binary inputs as indicated in the following table.The recipe used at the moment is indicated by the text"ON".

BIN0 BIN1 Recipe0 0 11 0 20 1 31 1 4


10. Troubleshooting10.1. Troubleshooting proceduresMetso TS requires no scheduled maintenance. Thischapter contains instructions for possible fault situ-ations. The device has self-diagnostics that monitorscertain internal measurements and gives an error mes-sage if any of these is outside the allowed range. Self-diagnostics is able to detect clear faults that are usuallycaused by the sensor electronics.

Incorrect measurement results may also be causedby antenna leaks, contamination, defective antennacables, or some process variable that is disturbing themeasurement. These problems may not always be de-tected by the self-diagnostics system.

Sometimes the current output signal from the TCUis incorrect. The actual measurement may work cor-rectly but the signal sent to the mill system is wrong.Fig. 1 shows a troubleshooting diagram for differentproblem situations.

10.2. Effect of process conditions onmeasurement• AirIf the measured sludge contains air, this shows up inthe measurement as a too high dry solids content value.The air may be present in bubbles of different sizes.Small air bubbles dissolve in water at an approximately1.5 bar (22 psi) pressure, but large bubbles may causeproblems even at higher pressures. At worst the errormay be up to several % points of dry solids. Air is alsoa disturbing factor in the process, therefore the forma-tion of air bubbles should be prevented.

Metso TS

SLOW DRIFT/ERROR INDICATION

Contaminationof antennas

Antennaleakage

Check processconditions

Check self-diagnostic’serror messages

Sensorelectronics failure


A SUDDEN CHANGE INLEVEL WHEN PROCESSCONDITIONS ARE STABLE

REFERENCECHANNEL FAILURE


Fig. 1. Troubleshooting diagram


Mechanisms introducing air into the process– Air gets mixed into the sludge for example when

material drops from a conveyor into a tank or vat.If the tank level is low, the adding point is close toa pump, or the throughflow time of the tank is short,the air is not removed before the sludge flows outagain. The best way to bring material into a tank isto lead the flow in under the surface.

– Strong stirring while the level in the tank is low mayalso generate a whirl that sucks air into the material.

– Air may also be mixed in through a leaking joint onthe intake side of a pump.

– Dilution water is another source of air.– Air may begin to collect inside a pipe bend that

forms the highest point of a line. When this airpocket gets big enough, the flow through the pipewill eventually drag it along. This kind of an airpocked may cause a distinct peak in the dry solidscontent measurement.

– Foaming chemicals may generate air in the sludge.

• ChemicalsChemicals in the sludge may weaken the measurementsignal. A maximum conductivity limit has thereforebeen defined for each sensor type. If the process con-ductivity is over this limit, the measurement signal istoo weak and there is noise and errors in the measure-ment result. When the conductivity is very much abovethe limit, the measurement signal will disappear alto-gether. Variations in chemical content may cause smallerrors in measurement even within the conductivityspecification.

These errors can be eliminated by using the MetsoTS chemical compensation (see chapter 9).

• TemperatureTemperature affects the dry solids content measure-ment, and the temperature measurement of the MetsoTS is used to compensate for this effect. If temperaturedependence is observed in the measurement, it can beeliminated by the temperature compensation correction(see chapter 9).

• Antenna leakAn antenna leak causes the measurement signal toslowly drift either up or down. If a leak is detected,replace the antenna and also its antenna cable, as thecable may have got wet as well. A clear leak can beobserved by removing the antenna cover and checkingif water drips between the antenna and the connectedplugged to it.

• Antenna contaminationAntenna contamination causes the measurement resultto drift slowly upwards. If the antennas are periodicallycleaned, for example during a process wash, this errorwill disappear. The antennas are made of polishedceramic, and contamination may be caused by somesubstance that adheres to the surface. Checking theantennas for contamination requires a process stop, asthe device must be removed from the process.

• Sensor electronics failureA typical electronics failure shows up as a sudden levelchange in the measurement and a quick drop in thesignal level, when some component fails. A problemin the reference channel always means that the sensorelectronics is defective. The self-diagnostics systemhas an alarm limit for the reference channel signal, andthis ensures that obvious component failures are detec-ted.

Sensor electronics faults may even cause a smallerror or drift in the measurement result, if all of theother causes listed above can be excluded. In such acase, all self-diagnostic measurements may be withinthe allowed limits and thus the diagnostics systemcannot detect the problem.

Locating the source of the problem may requirecareful analysis of the device's internal trend and historytables and their comparison to the error results, if thedata exists (e.g. laboratory follow-up). This requiresprofound knowledge of the device and is typicallyperformed by Metso's service personnel.

• Reference channel faultSee the information above for Sensor electronics fail-ures.


10.3. Self-diagnostics error messagesThe self-diagnostics monitors the signals of the processmeasurement channel and the internal reference chan-nel. This system is able to detect clear device faults.When such a fault occurs, the system gives an alarmby either freezing the signal or by setting it to a user-selected value, either 3.75 or 22.5 mA.

However, if the measurement result drifts but noobvious device failure is observed, the self-diagnosticssystem may not be able to detect the situation. In suchcases it may be useful to compare the self-diagnosticsmeasurement results to the observed drift, and to lookfor any correspondences between these, in order tolocate the fault.

Cab temp: Temperature of sensor electronics. If thistemperature is continuously very high, faults are likelyto occur more frequently.

Mlev: Measurement signal level, mV. If the measure-ment signal level drops below the alarm limit, thereason may be either an electronics fault, an antennaleak, or very high conductivity of the measured sludge.In case of an electronics fault, usually also the referencesignal level Rlev has dropped below the alarm limit.

Rlev: Signal level of the internal reference channel,mV. If this signal level drops below the alarm limit,the problem is always in the sensor electronics.

Mstab: Indicates the stability of the measurementchannel signal; this reflects the effect of both sensorelectronics and the measured sludge. If the sensorelectronics is OK (see Rstab), the Mstab value indicatesif the process contains large air bubbles that may causemeasurement errors. Large air bubbles cause a higherMstab value, and too high dry solids content results.The Mstab level is also influenced by the dry solidscontent, and sensor model. When the dry solids contentis high, the Mstab value is higher than for lower solidscontents.

Rstab: Stability of the internal reference channel signal.The lower this value, the more stable the signal is.Rstab alarm is caused by a fault in sensor electronics.

El drift: Indicates the drift in the electronics delaymeasured by the reference channel. This value is elim-inated from the measurement channel by compensation,and thus any electronics drift will not cause errors inthe measurement result. The El drift alarm is causedby a fault in sensor electronics.

VCO drift: Indicates the drift of the signal generatorin the sensor electronics. This alarm is caused by a faultin sensor electronics.


Notes


11. Replacing components11.1. Sensor electronicsRemoving (Fig. 1)1. Unplug the sensor cable from the sensor base plate

to disconnect operating power.2. Remove the electronics cover.3. Disconnect the cable connector and temperature

sensor connector from the electronics, and bendthem to the side.

4. Remove the three mounting screws and lift thesensor electronics out of the housing by pullingevenly from the mounting screws.

NOTE: The sensor electronics is aligned in position bythree guide pins that keep it in place even when themounting screws are removed.

Installing1. Align the groove on one side of the electronics

with the connector in the base plate. Move theelectronics and at the same time press it gentlyuntil the guide pins on the base plate align withthe holes on the electronics. Press the electronicsevenly onto the base plate.

2. Fasten the three mounting screws of the sensorelectronics.

3. Connect the sensor cable and temperature sensorcable connectors to the electronics.

4. Replace the sensor cover.5. Plug the sensor cable to its connector on the base

plate.6. After the power is connected, the Metso TS may

ask you to choose calibration. Select:- TCU, if you have not replaced the TCU;- default calibration, if you have also installed anew TCU.

Fig. 1. Removing the sensor electronics.


11.2. Antenna cables, FT-sensorRemoving (Fig. 2 & 3)1. Remove the sensor electronics as instructed in

section 11.1 above.2. Unscrew the antenna cable inlet bushing from the

sensor base plate, and slide it down until the con-nector body at the end of the cable can be seen.

3. Hold the connector body in place with an 8mmwrench (e.g. SMA wrench) and at the same timeuse a 10mm box wrench to loosen the lock bush-ing on the other side of the base plate.

NOTE: Make sure that the connector body does not turnwhile you unscrew the lock bushing!

4. Open the four screws fastening the antenna coverin place, and remove the antenna cover.

5. Open the antenna cable SMA connector from theantenna end, use either an SMA wrench or anSMA adapter. With FT50/FT100, you also needto open two screws that fasten the cable bushing.

6. Remove the antenna cable from its mountinggroove, for example by prying off the casing tubewith a screwdriver so that the cable comes out ofthe groove at the antenna end.

7. When the cable casing tube is loose from thesensor body, carefully pull the connector on thebase plate out from its hole.

NOTE: Lift the cable holding by its casing tube, not bythe cable itself!

NOTE: Be careful not to damage the antenna cable con-nector on the base plate!

Installing1. Make sure that the Nylon seal ring is in place, on

the bottom of the antenna cable lead-throughthread on the base plate.

2. Carefully insert the antenna cable connector tothe hole on the base plate, and press the antennacable casing tube into the grooves. Make sure thatthe rubber collar at the antenna end fits into itscorrect place.

3. Using an 8mm wrench, hold the antenna cableconnector on the base plate in position. On theother side of the base plate, tighten the connectorlock bushing to 1 Nm torque using a box key at-tached to a Beltzer torque driver. Do not over-tighten the lock bushing, you may break it!

4. Slide the antenna cable inlet bushing down to thebase plate and screw it into the thread.

5. Using either an SMA wrench or an SMA adapter,screw the antenna cable connector into the antennaconnector, to the torque indicated on the wrench.For FT-50/FT-100: also screw in the two mountingscrews of the bushing.

6. Fasten the antenna cover with the four mountingscrews.

Fig. 2. Detaching the antenna cable, FT100.

Fig. 3. Detaching the antenna cable, other FT sensormodels.


11.3. Antennas, FT-sensorSee Fig. 4.

NOTE: Before starting the work, make sure that the pro-cess pipeline must be empty and unpressurized, so thatthe work can proceed safely!

Removing1. Remove the sensor electronics as instructed in

section 11.1 above.2. Remove the antenna cable as instructed in section

11.2 above.3. Remove the six mounting screws of the antenna

with a 5mm Allen key. For FT50/FT100: the an-tenna is mounted with six screws and sealingwashers.

4. Pull out the antenna from the hole and remove theO-ring.

5. Detach the antenna from the flange by openingtwo M4x12 screws.

Installing1. Fasten the antenna to the flange with two M4x12

screws and washers.2. Clean the sealing surfaces of the antenna installa-

tion hole, for example with isopropanol.3. Install a new O-ring against the shoulder on the

installation hole.4. Apply some Loctite 270 locking medium on the

six mounting threads of the flange.5. Make sure that the O-ring of the antenna flange

is in position, and install the antenna to the an-tenna coupling.

6. Using a 5mm Allen key, tighten the six M6x16mounting screws and their washers. Tighten to atorque of 8 Nm. For FT50/FT100: the antenna ismounted with six screws and sealing washers.

7. Install the antenna cable and sensor electronics inreverse order.

1.

2.

3.

4.

5.

6.7.8.

10.

9.

Fig. 4. Metso TS-FT construction: 1 - sensor cover, 2- sensor electronics, 3 - base plate assembly, 4 - ther-moelement (temperature sensor), 5 - sensor body, 6 -antenna seal, 7 - microwave antenna, 8 - antennaflange, 9 - antenna cable, 10 - antenna cover.


11.4. TCURemoving1. Switch off operating power to the TCU, and dis-

connect the power wires from TCU's terminalstrip.

2. Disconnect the sensor cable and system cable fromTCU's terminal strip.

3. Release the TCU from its shield.

Installing1. Fasten a new TCU to the shield.2. Connect the sensor cable, system cable and power

cable to the new TCU's terminal strip.3. Switch power on.

NOTE: It may take a couple of minutes before any char-acters appear on the TCU display. This is perfectly nor-mal: the internal back-up battery must recharge first be-fore the display begins to operate.

4. If the device asks you to choose calibration, select:– Sensor electronics calibration, if you have not re-

placed the sensor electronics,– Default calibration, if you have also replaced the

sensor electronics.


12. HART user interface12.1. About the interfaceHART® is a registered trademark of the HART Com-munication Foundation. HART communication is amethod for transmitting digital information betweenfield devices and host devices (e.g. HART communic-ator). The Metso TS uses the Metso Mircowave Con-sistency Transmitter (Metso MCA) device description.

To use the HART communication, a HART commu-nicator containing the Metso MCA command base isneeded. The %Cs reading of Metso MCA correspondsto the %TS values of Metso TS.

Connect the HART communicator parallel with thecurrent output line, for example to the HART connectorpins on the TCU front panel.

All the same operations can be performed using theHART user interface of the Metso TS and with theTCU. Operating diagram of the HART communicatoris shown in Fig. 1.

When the HART communicator is connected toMetso TS, the following display will appear:

MCA: MCA-1234Online1 Measurement2 Configure3 Calibrate4 Diagnostics

Measurement

Configuration

Calibration

Diagnostics

Range ValuesUser SettingsDevice InfoSensor ElectronicsTCUSet time

Take sampleEnter LabOffset correctionFillersCalibration historySample HistorySpecial Functions

Chemicals Comp.Temperature Comp.SensitivityRecipes

PV %CsProcess TempMeas AttConductivityAO mA% of RangeActive Recipe Trend Int

PositionLanguageTemp Unit

Diag historyDiag valuesDiag alarmsDigital inputsLoop test

Lab CsFiller %Clay %CaCO3 %Talc %TiO2 %ChemicalLab cond

Low RangeHigh RangeDampingAlarm Current

Poll addrManufacturerModelFinal Asbly numberTagMessageUniversal revDescriptor

Filler %Clay %CaCO3 %Talc %TiO2 %

Fig. 1. Operation menu of the HART communicator.


12.2. MeasurementThe "Measurement" menu shows the measurementresults from Metso TS:

MCA: MCA-1234Measurement1 Sensor Type FT2002 Cs 0.00 %Cs3 Prc Temp 57.3 °C4 Status OK5 Conductivity 2.43 mS/cm6 % of range 36.72 %7 mA 9.88 mA8 meas Att 32.4 dBRecipe # OFF

Sensor Type:

Cs: Measured dry solids content.

Prc Temp: Measured process temperature.

Status: Device status (OK, Alarm,...).

Cab Temp: Temperature of sensor electronics.

% of range: Value of dry solids current output, aspercentage of the total output range.

mA: Value of dry solids current output, in mA.

meas Att: Measured attenuation of microwaves in theprocess.

Recipe #: The number of the recipe in use (see section9.3).

12.3. ConfigureIn the "Configure" menu you can configure the MetsoTS current output and some other parameters, and viewdevice information.

MCA: MCA-1234Configure1 Range Values2 User settings3 Device info4 SENSOR ELECTRONICS5 TCU6 Set Clock

Range valuesLowRnge: Dry solids content result corresponding tothe low limit (4 mA) of the current signal.

UppRnge: Dry solids content result corresponding tothe high limit (20 mA) of the current signal.

Damping: Filtering time of the current signal.

Alarm cur: How the current signal behaves when self-diagnostics detects an error. Alternatives are 3.7 mA,22.5 mA, or Hold.

User settingsTrend Int: Sampling interval of the internal trend table.

Pos: Device position.

Lang: Language version of Metso TS.

Temp unit: Process temperature unit, °C / °F.


Device infoPoll Addr: HART address of the device.

Manufacturer: Manufacturer of the device (Metso).

Model: Device name.

Final asmbly num: Field device identification number.

Universal rev: Universal Device Description revisionsupported by the device.

Tag: Text entered by user, will be shown at the top ofthe screen, after device name.

Message: Text entered by user.

Descriptor: Text entered by user.

Sensor ElectronicsSensor type: Sensor model in use.

Sensor S/N: Serial number of sensor electronics.

Sensor HW rev: Revision number of sensor electron-ics.

Sensor SW rev: Revision number of sensor electronicssoftware.

TCUS/N A: First part of TCU serial number.

S/N B: Second part of TCU serial number.

HW rev: TCU revision.

SW rev: Revision number of TCU software.

Cal date: Final testing date of the TCU.

Cal ID: Initials of the person who did the final testing.

Set ClockDate: Date, in format dd/mm/yy.

Hours.

Minutes.

Seconds.

12.4. CalibrateThe Metso TS is calibrated with single-point calibra-tion. The "Calibrate" menu contains the commands forsampling and laboratory value entering.

You can also perform level correction, carry outsome special functions, and view calibration and samplehistory data. The "Calibrate" menu looks like this:

MCA: MCA-1234Calibrate1 Sample taking2 Enter Lab3 Level corr4 Filler5 Lab cal History6 Sample history7 Special functions

Sample takingUse this function to take a sample for single-point cal-ibration.

Move the cursor with the arrow keys to field "Sampletaking" and then press the arrow right to see the follow-ing display:

Press OK to startsample taking

ABORT OK

Press OK (F4). The Metso TS begins to average themeasurement result for a sample, and the display willlook like this:

Press OK to stopsample taking

ABORT OK

Take a sample and press again OK (F4). The MetsoTS reports the measurement result:

MCA:MCA-1234Sampling readyAverage Cs = 3.02 %Min: 3.01 % Max: 3.03 %T = 42.3 °C

ABORT OK

Press OK (F4) and the "Calibrate" menu appearsagain.


Enter LabUse this function to enter the laboratory value for thesample.

Move the cursor with the arrow keys to field "EnterLab" and then press the arrow right to see the followingdisplay:

MCA: MCA-1234Enter labLab CsFiller%KaolinCaCO3TalcTiO2ChemicalLab Cond

Lab Cs: Laboratory result for dry solids content.

Filler %: Not used in Metso TS.

Kaolin%: Not used in Metso TS.

CaCO3%: Not used in Metso TS.

Talc%: Not used in Metso TS.

TiO2%: Not used in Metso TS.

Chemical: Chemical type (only needed for chemicalcompensation).

Lab cond: Laboratory result for conductivity, mS/cm(only needed for chemical compensation).

NOTE: If the conductivitymeter gives the result asmS/m,divide the result by one hundred (e.g. 550 mS/m = 5.5mS/cm). If the conductivity meter gives the result asuS/cm, divide the result by one thousand (e.g. 5500 uS/cm= 5.5 mS/cm).

Offset corrUse this function to perform level correction on themeasurement result.

Move the cursor with the arrow keys to field "Levelcorr" and then press the arrow right to see the followingdisplay:

MCA: MCA-1234Set the offsetcorrection: [-10,10]

00

DEL ABORT ENTER

Enter the required value and press "ENTER" (F4).The HART communicator then sends the value toMetso TS.

Lab cal HistoryThis menu shows a history of device calibrations.

Move the cursor with the arrow keys to field "Labcal History" and then press the arrow right to see thefollowing display:

MCA: MCA-123423-04-10 10:32:09Lab = 3.00 MCA=3.10Cum offset = 0.00 CsT=53.2 C Att=49.3 dB

ABORT OK

The display shows the date and time of the calibra-tion, and the measurement result and laboratory valuesof the sample. You can browse the calibrations bypressing "OK" (F4). Press "ABORT" (F3) to exit fromthe menu.

Sample HistoryThis menu shows the history of samples taken with thedevice.

Move the cursor with the arrow keys to field "SampleHistory" and then press the arrow right to see the fol-lowing display:

MCA: MCA-123423-04-10 10:32:09MCA = 3.04 % CsAtt=49.3 dB T=53.2 C

ABORT OK

The display shows the date and time of the sample,and the measurement results. You can browse thesamples by pressing "OK" (F4). Press "ABORT" (F3)to exit from the menu.


Special functionsThe special functions include chemical compensation,temperature compensation correction, sensitivity cor-rection, and recipes.

Chemical compensationLarge variations in chemical content may cause errorsin the dry solids content measurement of the Metso TS.Compensation based on microwave attenuation meas-urement can be applied to eliminate these errors.

To use chemical compensation, make settings in twomenus. First select the chemical and enter the laboratoryresult for sample conductivity in the "Enter lab" menu.Remember to enter the conductivity value in mS/cm.

If the conductivity meter gives the result as mS/m,divide the result by one hundred (e.g. 550 mS/m = 5.5mS/cm). If the conductivity meter gives the result asuS/cm, divide the result by one thousand (e.g. 5500uS/cm = 5.5 mS/cm).

Then activate the chemical compensation in menu"Special functions -› "Chemicals compensation":

MCA: MCA-1234Chemicals CompChem. comp = OFFComp.value = 0.00 %Chemical = NaOHLab.cond = 2.45 mS/cm

ABORT OK

Change the setting in field "Chem.comp" from OFFto ON to activate chemical compensation. You can readthe chemical compensation value from the field"Comp.value".

This is the value that the chemical compensationsubtracts from the dry solids content result. The lasttwo lines show the chemical and laboratory conductiv-ity value entered in the "Enter Lab" menu.

Temperature compensation correctionIf temperature dependence is observed in the measure-ment results, a temperature compensation correctioncurve can be entered.

Determine the correction curve by using 2 - 6 pointpairs (temperature/dry solids content), and the MetsoTS will use the curve to correct the dry solids contentmeasurement results.

Determine the point pairs as instructed in section 9.1of this manual. Then enter the data points in menu"Temp Comp":

MCA: MCA-1234Temp Comp1 #1 °C 0.002 #1 % 0.003 #2 °C 0.004 #2 % 0.00…9 #5 °C 0.00

#5 % 0.00#6 % 0.00#6 % 0.00

Enter the temperature and dry solids content valuesfor the required number of points (#1...6). Then press"SEND" (F2) to send the data to Metso TS.

Sensitivity CorrectionThe sensitivity of the Metso TS dry solids contentmeasurement has been set for municipal waste. Themeasurement sensitivity can be edited if necessary, forexample if some other material will be measured.

If the sensitivity correction for the measured materialis not known in advance, determine the correction asinstructed in section 9.2 of this manual, and then enterthe correction in menu "Sens. Corr".

MCA: MCA-1234Sens Corr

1.001.00

DEL ESC ENTER


RecipesThe recipe function may be needed in special applica-tions where the measuring conditions vary so muchthat they cannot be covered with just one calibration.

These changes may be for example– large changes in dry solids content that go outside

the measuring range of the device (±9…±15%, de-pending on sensor type),

– a change in the measured material, when the drysolids content sensitivity of the materials is verydifferent, or

– a large chemical change (e.g. different chemicaltype) that cannot be covered by chemical compens-ation.In such cases the device is calibrated and configured

separately for each different set of process conditions,and these are then saved as separate recipes.

Each recipe can have its own dry solids content cal-ibration, chemical compensation, temperature compens-ation correction, sensitivity correction, and currentoutput scaling. Up to four recipes can be stored in thedevice.

The "Recipes" menu looks like this:

MCA: MCA-1234Recipes1 Choose: OFF

In field "Choose", set the required recipe. Alternat-ives:– OFF: recipe function is not in use (default),– 1, 2, 3, 4: choose the recipe number,– BIN: recipe selection with binary inputs.

Choose a recipe, then calibrate the device and scalethe current output for the recipe. Take the other recipesinto use in the same way.

When the setting "BIN" is used, connect for exampledigital control lines from the mill system to TCU'sbinary inputs BIN0 and BIN1, their ground to inputBINGND. Choose the recipe with the binary inputs asindicated in the following table.

BIN0 BIN1 Resepti0 0 11 0 20 1 31 1 4

12.5. DiagnosticsThe "Diagnostics" menu contains the following func-tions:

MCA: MCA-1234Diagnostics1 Diag History2 Diag Values3 Diag Alarms4 Digital Inputs5 Loop test6 Clear Logs

Diag History: The ten most recent self-diagnosticsalarms, with beginning and ending times.

Diag values: Measured values of the diagnostics vari-ables (see section 8.2).

Diag Alarms: Alarm limits of the diagnostics variables,and setting alarms on and off (see section 8.3).

Digital Inputs: Status of TCU binary inputs BIN0 andBIN1.

Loop test: Forcing the output signal to a certain value.

Master Reset: TCU reset. Similar to powering off,does not erase calibration.

Status, Status nxt: Status of diagnostics variables(alarm on / off).


13. Recycling and disposal

When sorted by material, nearly all parts of the device can be recycled. A materials list is delivered with thedevice. Upon request, the manufacturer will provide more detailed instructions for recycling and disposal. Thedevice may also be returned to the manufacturer for recycling and disposal against a separate fee.


Notes


04.04.2011 1 (1)

Metso Total Solids Transmitter(Metso TS) Technical specification

© Metso Automation Manufacturer reserves the right to changes without prior notice.

SensorMeasurementMeasuring range.............. 0–35 % TS (if > 35 % TS, please

consult with Metso Automation)Repeatability ................... ± 0.01 % TSSensitivity ........................ 0.001 % TSFiltering ........................... 1–99 s

Process conditionspH-range ......................... 2.5–11.5Temperature.................... +0–100 °C (+32–212°F)Pressure:- Minimum recommend. ... > 1.5 bar (> 22 psi), no free air- Maximum ...................... 16 bar / 100 bar (232 / 1450 psi)Vibration .......................... max. 20 m/s2, 10–200 Hz

Environmental conditionsTemperature.................... -20 – +70 °C (-4 – +158°F),

protect from direct heat sourcesHousing class .................. IP65 (NEMA 4)

ConnectionsOperating voltage,communication ................ cable from TCU

MaterialsWetted parts .................... AISI 316, AISI 316L, CeramicSeals............................... Viton, Simrit 483

Operating unit TCUConnectionsCable to sensor ............... length 10 m / 33 ft

(option 30 m / 98 ft)Operating voltage ............ 90–260 VAC / 0.1 A

Connections to mill systems- analog outputs ............... 2 current outputs (4–20 mA):

dry solids content + processtemperature/conductivity(selectable)

- HART® ......................... 12–36 VDC- binary inputs .................. 2 x 12–28 VDC/10 mA, isolated

Connections to PC (start-up, service)DTM for FieldCare™ ........ HART®PC connection (service) ... RS-232Profibus PA

Environmental conditionsTemperature .................... 5–50°C (+41–122°F)Housing class .................. IP65 (NEMA 9)

Dimensions & weightw x h x d .......................... 232 x 282 x 133 mm

(9 1/8" x 11 1/8" x 5 1/4")

Weight ............................. 2 kg (4.5 lbs)

Conductivity limits and sensor weights:

Conductivity max. (mS/cm) Weight, kg(lbs)30°C 50°C 70°C

Metso TS FT-50/2" 25 25 25 8.5 (18.7)Metso TS FT-100/4" 18 16 13 10.0 (22)Metso TS FT-100/4" PN100 18 16 13 38 (83.8)Metso TS FT-150/6" 13 12 10 13.5 (29.8)Metso TS FT-150/6" PN100 13 12 10 78 (172)Metso TS FT-200/8" 13 11 9 17.0 (37.5)Metso TS FT-200/8" PN100 13 11 9 126 (277.8)Metso TS FT-250/10" 13 11 9 24.5 (54)Metso TS FT-300/12" 10 9 7 29.0 (63.9)

14.02.2011 1 (2)

Metso Total Solids Transmitter(Metso TS) Spare parts & Service kit


Metso TS spare parts1 Sensor Cover OUL00480 12 Sensor Electronics OUL00469 13 Assembly Set FT OUL00271 14 Thermoelement Assembly FT OUL00178 15 Seal Ring OUL00294 26 Microwave Cable FT-50/2" PN16 OUL00420 2

FT-100/4" PN16 OUL00114 2FT-100/4" PN100 K06594 2FT-150/6" PN16 / PN100 OUL00118 2FT-200/8" PN16 / PN100 OUL00194 2FT-250/10" PN16 OUL00197 2FT-300/12" PN16 OUL00216 2

7 O-Ring 23.4x3.5 Viton OUL00198 28 Microwave Antenna AISI 316L OUL00046 29 Antenna Cover FT-150/6", FT-200/8", FT-250/10", FT-300/12" OUL00189 2

FT-50/2", FT-100/4" OUL00180 1 / 2FT-50/2", antenna on attenuator side OUL00422 1

Attenuator 10 dB FT-50/2" OUL00428 1Gasket FT-50/2", FT-100/4" OUL00213 2

10 Screw DIN912-M6x16 A4-70 OUL00185 1211 Washer DIN127-B6 A4 5060013 1212 Screw DIN84-M4x12 A4 5160015 413 Washer DIN127-B4 A4 5060011 1214 Screw DIN84-M4x8 A4 5160025 8

2 (2)

Metso Total Solids Transmitter(Metso TS) Spare parts & Service kit


Metso TS service kit OUL00512Accessory case OUL00513 1Manual OUL00489 1Sensor Electronics OUL00469 1Operating Unit TCU (TS) OUL00471 1Thermoelement Simulator OUL00350 1Simulation Cable OUL00334 1SMA Torque Wrench Modified A4611042 1SMA Torque Wrench Adapter OUL00407 1Torque Driver 1/4" OUL00349 1Box Key 10 mm, 1/4" for Driver OUL00409 1Thread Locking Compound Loctite 270 83200021 10 mlInstant Glue Loctite 480 8360019 20 gSpare Part Set Metso TS-FT: OUL00352 1

O-Ring 14.3x2.4 Simrit 483 8060036 5O-Ring 23.4x3.5 Viton OUL00198 5O-Ring 33x2.62 Viton OUL00182 5O-Ring 56.2x3.0 Viton OUL00184 5Seal Ring 16x10x1 Polyamide OUL00294 10Seal Washer U6.7x11.0x1 OUL00183 5Lock Washer DIN127-B4 A4 5060011 5Lock Washer DIN127-B6 A4 5060013 5Rec Countersunk Screw DIN965-M3x12 OUL00094 5Slothead Screw DIN84-M4x8 A4 5160025 5Slothead Screw DIN84-M4x12 A4 5160015 5Socket Head Screw DIN912-M6x16 A4 OUL00185 5

OPTIOT:Microwave Cable FT-50/2" PN16 OUL00420

FT-100/4" PN16 OUL00114FT-100/4" PN100 K06594FT-150/6" PN16 / PN100 OUL00118FT-200/8" PN16 / PN100 OUL00194FT-250/10" PN16 OUL00197FT-300/12" PN16 OUL00216

Thermoelement Assembly FT OUL00178Microwave Antenna AISI 316L OUL00046

Metso Automation Inc., Kehräämöntie 3, P.O.Box 177, FI-87101 Kajaani, FinlandTel. +358 20 483 120, fax +358 20 483 121, www.metso.com/automation

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 the right to alter the contents of this document without prior notice.Modbus is the trademark of Modicon Inc.

Copyright © September 2011Metso Automation Inc.Documentation: JT-Tieto OyTranslation: Marjo Nygård

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