INSTRUCTION MANUAL

KC/5 Rotating Consistency Transmitter

W41040300 V2.2

March 2005

This manual W41040300 V2.2 is applicable for KC/5 firmware V1.03 or higher (KC/5 transmitters delivered since November 2004) Manual: many pages, print new manual. Software changes : V1.02V1.03: Start-up procedure added to Calibration menu (In-air torque) V1.03V1.04: Reset of Output Filter after the process stop Possible to edit Friction alarm limit in Factory Settings Added Power supply min. and max. temperature to Data Log Decreased Autoreverse timing, now minimum times 5seconds after each 1 minutes V1.04V1.05: Corrected Year in Data Log, V1.04 displayed Year sometimes wrong

KC/5 Safety Notice!

Severe Injury may result if the following Instructions are not followed exactly!
Kajaani Process Measurements KC/5 has been designed to make it safe to use at all times. The standard retractable version of KC/5 can be used in applications where less than 10 bar (150 psi) line pressures exist. A special, non-retractable model is available for higher pressures. The KC/5 is shipped to you in completed sub-assemblies. All safety related components are checked, and verified to work correctly, before the product is shipped from our factory. The customer is responsible for the correct installation of the KC/5 into the process line by following the procedures outlined in this KC5 Instruction Manual (included with each KC/5 shipment). It is imperative that the Locking Ring which is part of installation hardware is properly tightened every time the sensor is inserted into the process. If the KC/5 Sensor is not securely locked into place by the Locking Ring according to Instruction Manual there is possibility that sensor will vibrate excessively and may back off from process. In case the Jack Assembly has damaged or Seal Sleeve Assembly is not secured and the Locking Ring is not secured there exists the possibility that the KC/5 Sensor may be propelled out of the line by the line pressure and there exists potential for injury. People near the unit may be injured. KC/5 Sensor must be securely locked into place by the Locking Ring after every time the sensor is removed and re-inserted into process, or after the Seal Sleeve Assembly is disassembled and reassembled. Anyone who works on the KC/5 must follow all instructions in the Instruction Manual, and in this Safety Notice, to eliminate any chance for injury when working on the KC/5. The Locking Ring ( H41040131V1.0) and the Jack Assembly (A41040175V1.0) are critically important to the safe use of the KC/5 transmitter. They both must be attached, and securely tightened in place, while the sensor is inserted into the process line. While the Gate Valve is open the Sensor can be withdrawn from the line by slightly loosening the Locking Ring. Then the Jack can withdraw the Sensor from the process so the Gate valve can be closed. Only after the closed Gate Valve has isolated the line pressure from the withdrawn Sensor, is it safe to loosen the Jack Assembly and remove the Locking Ring. It is critically important to make certain that the Locking Ring and the Jack Assembly are secured according to the procedures as outlined in this Instruction Manual (Chapter 3.5.) and before attempting to re - insert the Sensor into the process line. Note! Make sure all Bolts and Nuts are tightened properly before opening the gate valve.

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Table of contents
1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 Introduction ..................................................4 Contact information......................................4 Unpacking and inspection............................5 KC/5 system description ..............................6 Measuring principle......................................6 Sensing element ..........................................8 General notes ..............................................8 Selecting the optimum measuring site.........9 Dimensions and clearance requirements of the sensor ..............................................11 3.1 Process connections..................................12 3.2 Installing the installation cone....................12 3.3 Installation to a BTG MEK process connection..................................................13 3.4 Installing the gate valve assembly .............14 3.5 Insertion of the sensor ...............................16 Preparing for insertion .......................................16 Inserting the sensor ...........................................16 3.6 Flange Installation PN25............................19 3.7 Seal water connection ...............................19 3.8.1. Low pressure water flushing....................19 3.8.2. Self contained seal water system............20 3.8 Insertion depth adjustment ........................21 3.9 Installation of the display unit.....................21 4.1 Display unit connections ............................22 4.2 Sensor unit connections ............................23 5.1 Operation of the KC/5-operator interface ..23 5.2 Menu structure ...........................................24 5.3 Set-up ........................................................28 6.1 Calibration menu........................................29 6.2 In-Air torque ...............................................30 6.3 Single-point calibration ..............................30 6.4 Zero adjustment .........................................30 6.5 Sampling procedure...................................30 6.6 Changing calibration parameters...............31 6.6.1. Manual adjustment ..................................31 6.6.2. Transmitter calculated parameter change.....................................................31 7.1 Regular maintenance of the KC/5..............32 Seal water reservoir (optional, in case mill seal water not used)........................................32 7.2 Maintenance menu ....................................32 7.3 Motor controls ............................................34 7.4 Troubleshooting .........................................35 7.5 Removing the KC/5 sensor........................36 7.6 On-line sensitivity check ............................36 7.7 Checking the functionality of the KC/5.......37 7.8 Torque sensitivity calibration .....................37 7.9 Cleaning the sensing element ...................38 7.9.1. Cleaning the sensing element from wrapped up material by reversed rotation ....................................................38 March 2005 7.9.2. Cleaning the sensing element manually. 38 7.10 Replacing elastic shield, rod seal and needle roller bearing ................................. 39 7.10.1. Removing elastic shield ........................ 39 7.10.2. Removing rod seal and needle roller bearing.................................................... 39 7.10.3. Installing elastic shield, rod seal and needle roller bearing ............................... 40 7.11 Replacement of the mechanical seals ...... 41 7.11.1. Removing front mechanical seal........... 42 7.11.2. Removing rear mechanical seal ........... 43 7.11.3. Installation of front and rear mechanical seals .................................... 43 7.12 Electronics................................................. 45 7.13 Replacing Sensor Board ........................... 47 7.14 Replacing Optics Board ............................ 48 7.15 Replacing Power Supply Unit.................... 48 7.16 Replacing Connection Board .................... 49 7.17 Replacing LC Display Board ..................... 50 Appendix 3.1.: Standard Installation Cone, PN10 Gate Valve .................................... 53 Appendix 3.2.: Standard Installation Cone, PN16 Gate Valve .................................... 54 Appendix 3.3.: BTG Adapter, PN10 Gate Valve55 Appendix 3.4.: BTG Adapter, PN16 Gate Valve56 Appendix 3.5.: Standard Installation Cone, PN25....................................................... 56 Appendix 3.6.: BTG Adapter, PN25.................. 58 Appendix 3.7.: Sensor Front Assembly, PN16SS .................................................. 59 Appendix 3.8.: Moment shaft and motor assembly ................................................... 60 Appendix 3.9.: ISO-torq Adapter installation..... 60 Appendix 4: Spare parts kit, recommended spare parts ................................................ 62 Appendix 5: Model selection table .................... 63 Appendix 6: Technical specifications................ 64

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1. Introduction
1.1 Introduction
The KC/5 is a new generation rotating consistency transmitter. It is a robust design consistent with the needs of the pulp and paper mill environment. It provides the user with an accurate reading of pulp consistency for use in many control applications. In order to get the best results from the KC/5 transmitter, please read this manual carefully. The information provided in this manual will help you to better understand the installation requirements, set-up procedures, and operation of the KC/5 rotating consistency transmitter. By reading and understanding this information your facility will be will best be able to optimum the performance of KC/5 transmitter.

1.2 Contact information

Europe, Asia and South America: Kajaani Process Measurements Ltd. PO BOX 94 FI 87101 Kajaani, Finland Tel: +358 8 633 1961 Fax: +358 8 612 0683 E-mail: kpm@prokajaani.com Japan: Kajaani Process Measurements Ltd., Japan Branch Office K. Doi 4-444-5 Nishimiyashita Ageo-shi, Saitama-Ken 362-0043 Japan Tel: +81 487 776 7695 Fax: +81 487 776 8469 Mobile: +81 90 7633 8960 E-mail: k.doi@prokajaani.com Please find your local supplier on internet address www.prokajaani.com North America: Kajaani Process Measurements Inc. 636 U.S. Route 1, Box # 4 Scarborough, ME 04074, U.S.A Tel: 207 883 1095 1 800 consist (266 7478) Fax: +1 207 883 1104 E-mail: kpmusa@prokajaani.com

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1.3 Unpacking and inspection

Note: When unpacking the KC/5, check for any damage and verify the contents against the packing list. Please report any damage or missing items immediately, so that they can be promptly repaired and/or replaced as necessary. The standard system contains following items (See figure 1-1): Gate Valve Ass'y, PN 10 A41040224V1.0

Sensor A41040157V1.0

Display Unit A410400179V1.0 Or Gate Valve Ass'y, BTG A41040159V1.0

Interconnect Cable A41040095V1.0 Insertion Jack A41040175V1.0

Instruction Manual W41040300V1.0

Figure 1-1. KC/5 standard system components

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1.4 KC/5 system description

The KC/5 consists of the sensor unit with mounting assembly and the display unit (See figure 1-2). There are four different sensor installation alternatives: 1. KPM Standard Installation Cone with Gate Valve and installation jack. 2. BTG MEK adapter with Gate Valve and Installation Jack. 3. Flange installation with KPM Installation cone without Gate valve and Installation Jack. 4. Mounting bracket for mounting on open vessel (i.e. stuff box or saveall drop chest). The installation cone is welded to the process pipeline. The DN80 (3) gate valve is mounted to the installation cone. Sensor probe is inserted into the process by the heavy duty scissor jack which is mounted to the gate valve assembly. The display unit is connected to the sensor unit by a 10 m (33) long shielded 10-conductor cable (maximum length available is 30 m). The cable includes a connector that can be quickly coupled to the sensor unit. Display unit is powered by 85-264 VAC/47-63 Hz and supplies 12/48 VDC to the sensor. All external electrical connections are made in the display unit (4 20 mA analog output, binary inputs). The sensor motor can be interlocked with stock pump running information (pump) via binary input in display unit.
Gate Valve Insertion Jack Sensor

KC/5 Display Unit

Pipe Locking Ring Installation Cone Drain Valve Seal Sleeve

110/220 VAC

4 - 20 mA/HART Grade Selection Interlocking

Figure 1-2. The KC/5 sensor unit with the display unit.

1.5 Measuring principle

The KC/5 sensor rotates sensing element (see fig. 1-3) in the pulp slurry. Slurry resists the movement and to overcome this resistance a torque force has to be applied. The higher the consistency, the greater is the resisting force. KC/5 measures the torque and converts measured torque value to consistency. KC/5 uses direct drive servo motor. Stator is mounted in the sensor body and the rotor of the motor integrated in drive shaft. There are no drive belt or gear boxes in KC/5 design. Two optical discs are rotated by the motor. One (drive) disc is attached to the drive shaft. Another (moment) disc is coupled to the drive disc with coil springs. The moment disc is mounted to the moment shaft the sensing element is in the opposite end of moment shaft. March 2005 W41040300 V2.2 Page 6 of 66

When drive shaft starts rotating, the springs force the moment disc to follow. Depending on the consistency of the slurry where sensing element rotates the force resisting movement varies. With higher resisting force the springs stretch more and the moment disc lags farther behind the drive disc. With less resistance discs follow closer to each other. The discs rotate at the same speed but there is angular phase difference (angle of lag). The angle of lag is directly proportional to the applied torque.

Figure 1-3. Measuring principle The lag angle is detected by high resolution optical sensor. Measurement electronics converts the optical signal to a calibrated torque reading. The system covers the full range of torque from zero torque (no torque applied to the sensor element) to the maximum of 1200 milliNewtonmeters [mNm] (170 ounce-inch). The measuring sensitivity is factory calibrated using standardized torque measurements. Thus each KC/5 has same sensitivity making them interchangeable. Torque is generated by shear force when a rotating sensing element cuts through a moving fiber network (See figure 1-4). As the curve shows, the torque generated by a rotating sensing element is not linear with consistency, but rather it increases more steeply at higher consistencies. The measurement algorithm within the KC5 linearizes the relationship between consistency and the torque. The KC/5 calculates then the output consistency as follows: C% = S * M + Z Where: C = S M Z Consistency = = = Slope Measurement signal (linearized torque reading) Zero offset

Slope (S) and offset (Z) are grade specific. KC/5 comes with seven pre-calibrated consistency curves that fit most applications in the mill. One additional user defined grade is for special applications.

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100

Torque curvature gets steeper with increasing consistency

Torque [mNm]

Linearized measurement signal Reading in water at 0%

0 0

Reading "in air"

Consistency [%]

Figure 1-4. Relationship between torque and consistency.

1.6 Sensing element

KC/5 transmitter is provided with the paddle type sensing element as standard (See figure 1-5). The paddle-style sensing element is stream-lined and is less likely to pick up stringy debris as are typically encountered in unscreened recycle and broke-line applications. Sensitivity of shear force measurement is directly proportional to the amount of cutting surface of a sensor element. The paddle-style element has very large cutting surface area providing excellent sensitivity. (4-pin element is used only in special applications.)
4-pin 8-pin paddle

Figure 1-5. Sensing elements

2. Location and installation requirements

2.1 General notes
The KPM transmitters are designed and manufactured to provide accurate and reliable measurements over a long period of time. Correct installation will ensure maximum performance and minimum cost of ownership. March 2005 W41040300 V2.2 Page 8 of 66

 Avoid installing the transmitter around heavy vibration sources (e.g. cavitating or unbalanced pumps). The KC/5 has two seal water options, Mill seal water or integrated seal water reservoir. Mill seal water is recommended in applications with fillers and with recycled pulp. Install a reliable sampling valve close to the transmitter. Poor sampling leads to inaccurate calibration and underperformance of the measurement. KPM KS- samplers provide consistent and reliable solution for any sampling application.

2.2 Selecting the optimum measuring site

It is important to properly locate the instrument. The site should both 1: optimize the performance of the instrument as well as 2: provide clear access for maintenance. KC/5 rotating type transmitter is installed in the installation cone. The insertion depth of the sensing element is adjustable. At lower consistencies element is recessed well outside the main pulp flow. At medium consistency element is inserted closer to the process. See fig. 3.10. Minimum straight pipe sections for transmitter: Low consistency 1.5 8%: Calming length Lbefore = 3 * D or 1 m (3 feet) whichever is longer Calming length Lafter = 1 * D Medium consistency 8 16%: Calming length Lbefore = 1.5 * D or 0.5 m (2 feet) whichever is longer Calming length Lafter = 1 * D

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x = Distance between the sensor unit and the sampling valve is about 500 - 1500 mm (20 - 59") 45 Lafter x Alternative position Sensor unit Tank Dilution water * Lbefore L = Straight line to pipe elbow, valve or pump Valve Valve

Sampling valve

Sampling valve

Sensor unit

Lab sample

Installation location rules: 1. The axis of the sensor and the pump shaft should be perpendicular to each other. 2. Align pump shaft with valve stem. 3. Respect straight pipe section.

Fig.2-1. Installation in a vertical pipe.

Lbefore

Lafter x

Sensor unit Sampling valve L = Straight line to pipe elbow, valve or pump Dilution water * x = Distance between the sensor unit and the sampling valve is about 500 - 1500 mm (20 - 59")

Tank

Valve Lab sample

Installation location rules: 1. Align pump shaft with valve stem . 2. Respect straight pipe section.

Fig.2-2. Installation in a horizontal pipe.

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2.3 Dimensions and clearance requirements of the sensor

510 mm (20.1") 316 mm (12.4") 194 mm (7.6")

300 mm (11.8")

Figure 2-3. Dimensions of the KC/5 sensor.

BTG Measuring Vessel

KPM Installation Cone

140 mm (5.5")

460 mm (18")

510 mm (20")

510 mm (20")

660 mm (26")

200 mm (8")

510 mm (20") 750 mm (30")

375 mm (15") 690 mm (27")

Figure 2-4. Clearance requirements of the KC/5 sensor Note: Care should be taken to ensure the sensor is readily accessible for service. At the point of installation, the user should leave a minimum of 750 mm (30) clearance perpendicular from the pipe at the point of installation (See figure 2-3), or 690 mm (27) from the edge of a BTG weld-in stud.

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3. Sensor unit and display unit installations

3.1 Process connections
There are 3 alternative process connections: 1. KPM installation cone. Preferred process connection. See 3.2 for installation instructions. 2. Existing BTG measurement chamber. Does not require any welding. Adapter to fit gate valve and the sensor to existing measurement chamber. 3. Bracket for mounting to open vessel of weir.

3.2 Installing the installation cone

1. Verify that the curvature of the cone fits properly over the outer diameter of the pipe. 2. Cut the cone (unless cut already by Kajaani Process Measurements) so that the distance from flange to outer surface of pipe is 60 mm/ 2,4. 3. Cut a hole in the side of the pipe to match to the shape of the cone as shown in figure 3-1. To prevent fiber debris from collecting on the edge of the cut-out, ensure the edges of the hole are ground smooth. Debris collected at this location can interfere with proper measurement (See appendix 1). 4. Place the cone over the hole in the pipe. Verify that the hole is centered with respect to the cone. Fillet weld around the entire perimeter of the cone to attach the cone to the pipe. (See welding drawing appendix 1).

Curvature of cone must match that of existing pipeline Center cone over cut - out and fillet weldaround entire perimeter 355.6 mm (14") radial clearance needed aroundcenterline for gate valve Cross-sectional view of the installation cone Existing pipe line Cut hole into pipeline to match with the shape of the cone

2.4 0.1 inch

60 2

Cut the installation cone to same radius with existing process line

6" x 4" sch 10s AISI 316L

215 8.5"

155 6.1"

Figure 3-1. Cone installation. March 2005 W41040300 V2.2 Page 12 of 66

3.3 Installation to a BTG MEK process connection

Bolt the KC/5 adapter assembly to BTG weld-in stud or measuring vessel.

Figure 3-2. Adapter assembly for BTG weld-in stud.

Figure 3-3. Installation to weld-in stud or measuring vessel.

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3.4 Installing the gate valve assembly

Note: The gate valve is installed in different position for horizontal and vertical process pipes. In a horizontal pipe the gate valve is in upright position and in a vertical pipe it is placed in horizontal position.
Gate Valve Guide Pins (4) Installation Cone Bolts (4) Mounting Flange Nuts (4)

Insertion Guide

Gaskets Seal Assembly Lock Ring

Figure 3-4. Gate valve assembly, horizontal pipe.

Figure 3-5. Gate valve assembly, vertical pipe. In vertical pipe installation all the parts from the installation cone to the mounting flange are rotated 90 degrees compared to the position in figure 3.4. The direction of the seal assembly remains the same. See figure 3-4, 3-5 and appendix 3. 1. Slip the flange guide ring inside the cone flange March 2005 W41040300 V2.2 Page 14 of 66

2. Screw the four guide pins to the cone flange 3. Screw the 4 stud bolts into the cone flange. Leave them slightly loose for easier positioning of the mounting flange 4. Check that the gaskets are properly placed in the gate valve 5. Position the gate valve with the help of the guide pins (mounted in the gate valve) onto the installation cone. Horizontal position in vertical pipe, vertical position in horizontal pipe. 6. Place the mounting flange assembly (flange with seal sleeve and lock ring preassembled) on stud bolts. Tighten the slightly loose stud bolts (see step 3) and fix the mounting flange to its place. Note: if needed, turn seal sleeve/locking ring until jack mounting holes are horizontal and Radial locking Bolt is accessible. If necessary, change location of 2 Insertion Housing Bolts. Note: Make sure the orientation of the locking ring is so that the Radial Locking Bolt can be tightened with allen key. See Fig 3.6.

Figure. 3.6. Radial locking Bolt orientation. Safety Warning: Jack and Locking Ring must be secured and attached in place after inserting the sensor as per chapter 3.7. Note: Remember to close the gate valve before re-pressurizing the process pipe. 7. Test the gate valve installation for leakages at process pressure. 8. Check that the O-rings are in place inside the seal sleeve. Lubricate the O-rings using Vaseline or silicone grease. This reduces the sliding friction between the O-rings and the external sealing surface. Mounting the insertion jack Once the gate valve assembly has been installed and tested under process pressure, the system is ready for mounting the jack. Install the jack over the seal sleeve with 2 bolts provided. Lock the bolts with locking pins. Note: The jack is always installed in vertical position independent of gate valve position.

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Mounting Bolts to Seal Sleeve

Mounting Bolts to Sensor

Figure 3-7. KC/5 insertion assembly.

3.5 Insertion of the sensor

Preparing for insertion
1. Check that the inside of seal sleeve is free of dried pulp and debris. Remove any material inside 2. Check that the O-ring inside the seal sleeve are secure and undamaged 3. Lubricate O-ring surfaces with grease to reduce friction

Inserting the sensor

If the sensor has previously been in use make sure the sensing element and seal sleeve inside are clean. Every time the KC/5 is taken out of line, the seal sleeve and sensing element should be rinsed with clean water to remove any pulp and debris. Note: To prevent the sensing element from pushing against the gate valve, make sure that the jack is in fully open position. 1. With the gate valve still in the closed position, lift and slide the KC/5 unit into the seal sleeve until the bolts in the jack can be mounted to the sensor body. (See figure 3-7). The jack must be completely open. 2. Fasten sensor probe to the insertion jack with two bolts and insert the locking pins to prevent the bolts from turning by vibration. 3. Connect the seal water to the sensor. 4. Connect the interconnect cable to display unit. 5. Check that the jack is fully open before switching on power to KC/5 Display Unit. 6. Switch power on and make in-air torque to tune the torque to zero (see 6.2). Note: sensing element has to rotate freely inside seal sleeve. Any pulp/debris will interfere with measurement 7. Switch power off from Display Unit. 8. Open the gate valve. 9. Jack the sensor in until the insertion depth adjustment ring stops against the locking ring. 10. Fasten the locking screw to lock the sensor safely into its measurement position.

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Seal Sleeve

Jacking Screw

Jack Bolt Hole

Seal Water Outlet

Locking Ring

Depth Adjustment Ring

Seal Water Inlet

Figure 3-7. Insertion of the sensor unit.

Safety Check after each insertion to the process line

Safety Warning: Jack and Locking Ring must be secured and attached in place after re-inserting the sensor. The locking ring secures that the sensor does not come accidentally out from the process and that the sensor doesnt vibrate inside installation parts. Excessive vibration can damage the jack and the sensor. It is important the Locking Ring is securely tightened.

Figure 3-9. Locking ring of the Sensor The KC/5 sensor locking ring has to be tightened securely following way: 1. Make sure the orientation of the Locking ring is so that the Radial Locking Bolt can be tightened with allen key, if not, rotate the Locking ring on the Insertion Housing so that the Radial Locking Bolt is accessible. 2. Tighten the Radial Tightening Bolt of the Locking Ring.

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Figure 3-10. Radial locking of the Locking Ring.

3. Tighten the Locking Ring Fastening Bolts to lock the sensor to the Insertion Housing assy.

Figure 3-11. Fastening the Locking Ring to the Insertion Housing. Note: Locking ring has to be tightened every time the sensor is installed after maintenance.

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3.6 Flange Installation PN25

Note: The standard model of the KC/5 is designed for use below pressures of 16 bar (240 psi). There is special PN25 model of the transmitter available. Note: Standard KC/5 gate valve is designed for use below pressures of 10 bar (150 psi). 16 bar gate valve available as an option. At pressures above 16 bar, the gate valve assembly can no longer be used. For pressures above 16 bar (up to maximum of 25 bar (375 psi)), the sensor is bolted to the cone.

Figure 3-12. Flange Installation, max PN25.

3.7 Seal water connection

KC/5 drive shaft is equipped with mechanical seals (double seal, tandem sealing system). The seal manufacturers recommend flushing of seals with water to extend the seal life. The water provides flushing, lubricating and heat transfer. KC/5 has two alternatives for seal flushing 1. Low pressure water flushing. 2. Self contained seal cooling and lubrication system (reservoir)

3.8.1. Low pressure water flushing

It is recommended to connect flushing water if the water quality is good enough to keep the seal water system clean. Mechanical seals last longer with seal water when pulp contains fillers. The rate of flow is limited by the flow regulator. Make sure that seal water flow can be checked and monitored easily. Recommended water pressure is 1.0 -10 bar (15 -150 psi), max. particle size 200 m. Flow is 0.5 l/min (0.13 US gal/min) to 2.0 l/min (0.5 US gal/min) within specified pressure. Connect the seal water to the male fitting of the sensor using flexible reinforced plastic tube. Flexible tube must be used to facilitate the move of the sensor. Install a shut-off valve close to the transmitter. Connect another reinforced plastic tube to the outlet, and draw it to the floor drain and fasten it just above the floor outlet so that the flow can be observed. It is a mandatory to install an anti-siphon prevention tube to prevent siphon phenomena in case of seal water loss.

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Reinforced flexible plastic tube Anti-siphon tube 8/6 mm Elbow fitting

Flow regulator 0,5 - 2 l/min 0,13 - 0,5 gpm Valve

Open flow to channel

1 - 10 bar 15 - 150 psi

Figure 3-13. Low pressure water flushing arrangement.

3.8.2. Self contained seal water system

The self containing cooling liquid system is optional. This approach is recommended if water quality is poor. The cooling water reservoir is mounted in the insertion jack and connected with flexible tube to the seal water inlet. Volume is 1 liter (1/4 US gallon), use drinking water to fill the reservoir if ambient temperature stays above 0C (+32F). If freezing conditions are possible, use glycol/water mixture 50/50% Water reservoir is emptied when ever tubes to the sensor are decoupled. Refill the reservoir before power to the sensor is turned on.

Figure 3-14. Self contained seal water system.

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3.8 Insertion depth adjustment

KC/5 sensor can be installed at adjustable depth into the process. To move the depth adjustment ring, loosen the set screws, slide the adjustment ring to desired position and relock the set screw again. Figure 3-10 gives most commonly used values. Unless specified in the order, KC/5 comes with standard depth adjustment for KPM Installation Cone. With MEK adapter sensor need to be fully inserted. Depth adjustment becomes useful if flow pattern or consistency profile changes for one reason or another. By inserting the sensing element deeper inside one can avoid the layer where consistency profile varies.

A Depth adjustment A: KPM Cone 68 mm BTG Adapter 0 mm

Figure 3-15. Insertion depth adjustment.

3.9 Installation of the display unit

The display unit can be located anywhere near the sensor unit so that it can be easily accessed by mill personnel. Connection cable standard length is 10 m (33). Protection class of the display unit enclosure is IP66 (NEMA 4X). Mount the display unit to the wall with four (4) screws.

150 6.9"

6 1/4"

195 7.7"

400 15.7" 350 11.8"

200 7.9"
Figure 3-16. Dimensions of the display unit.

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4. Electrical connections
4.1 Display unit connections
The display unit has two functions: to supply 12/48 VDC power to the electronics/direct drive motor, and to serve as an easy-to-use interface. It is connected to the sensor unit via 10 m (33 ft) cable. Connections are shown in figure 4.1. Wire the display unit as follows: 1. Open the box cover. The connectors are in the connection board. 2. Install the interconnect cable coming from the sensor unit and 4 - 20 mA cable coming from DCS to terminals as shown in figure 4.1. The 4-20mA can be powered by sensor (default) or by DCS, see fig 7.14 how to change the setting. Note, if powered by DCS polarity is reversed (- pin 12, + pin 13). 3. Connect 220/110 VAC (85-264 VAC)

Grade selection codes Grade pin 14 15 16 SW HW TMP CTMP GW Recycle Eucalypt User def 0 1 0 1 0 1 0 1 0 0 1 1 0 0 1 1 0 0 0 0 1 1 1 1

+ -

Analog input 4 - 20 mA

DCS

Binary Output

+24 VDC Grade selection

Sampler

+24 VDC

Binary Output

+24 VDC Process stop

Binary Input

Display unit

+24 VDC Alarm

S AMPLE

ES C

Sensor Connections shield current loop + current loop sensor supply +12 VDC sensor supply GND RS485 A RS485 B pwm motor supply + motor supply -

ENTER

DCS Connections

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1 2 3 4 5 6 7 8 9 10

Interconnect cable 10 m (33')

shield current loop + current loop grade 0 + grade 1 + grade 2 + grade shield sample + sample shield process stop + process stop alarm on alarm GND alarm off

ON

OFF
2 3 4 5 6 7 8 9 10 1

110/240 VAC 50/60 Hz

Sensor unit

Figure 4.1. Electrical connections.

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4.2 Sensor unit connections

Sensor unit is connected to display unit via supplied interconnect cable. All the internal connections are factory made. 1. Couple the seal water tubes, see fig 3-8. Water must be present on seals before power is connected to the system. 2. Plug in the quick connector at motor end of the cable.

5. Operating and setup instructions

5.1 Operation of the KC/5 operator interface
All the functions of the KC/5 are easily configured through the clear screen (See figure 5.1). Operation of KC/5 is menu driven. The arrow keys allow movement between the menus. The menu structure is divided into three main function blocks: Calibration, Set-up and Maintenance. The Factory Settings can be used to change some default parameters in special cases. The menu structure of the KC/5 user interface is shown in the next chapter.

SW

Cs: 3.5 % OUT 15.4 m A

4 3 5

Figure 5.1. The KC/5 user interface. 1. The display is 2 lines high x 16 characters in length. Main display shows both consistency value in percent and the analog output in mA. Display also shows current grade in the left upper corner. Menu display returns to main display automatically if not operated in 30 seconds. 2. Sample key. When activated, a 30 second countdown timer starts to show so as to identify when to take the sample. The display unit stores date, time and the measured consistency value averaged over 30 seconds time in its memory for later comparison to the lab values. This way it is easy to identify laboratory samples so that it corresponds in time to the consistency readings of the sensor unit. 3. Arrow keys - Arrow keys are used to move between menus, move cursor, or change values. Please refer to menu structure for more information about the arrow keys. 4. Esc key - press to cancel changes and/or return back to the previous menu. 5. Enter key - press to accept data and input changes.

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5.2 Menu structure

SW Cs 0.00 % Out 4.0 mA

ENTER PASSWORD 000

APPEARS IF PASSWORD OTHER THAN 000 PASSWORD IS SET IN SET-UP MENU. (PASSWORD 633 WORKS ALWAYS)

CALIBRATION

Change zero and slope

Zero: Slope:

xx.x xx.x

Old zero: Enter new

xx.x

xx.x

Old zero: New zero

xx.x xx.x

Old slope: Enter new

xx.x

xx.x

Old slope: New slope

xx.x xx.x

SET UP

Lab values

0000-00-00 Csxx.x

0:00 DIF 00.00

Enter lab value

0000-00-00 Csxx.x

0:00 LAB 00.00

MAINTENANCE

0000-00-00 Csxx.x

0:00 DIF 00.00

Delete sample enter confirms

FACTORY SETTINGS (requires password 633) Calibration calculation x sample ok enter continues S: xx.xx std. error: Z: xx.xx x.xx

Start up

In-Air torque

Element must be in air

Result xxx Enter confirms

Edit In-Air Offset xxxx

Edit In-Air Offset xxx mNm

Target Cs

ENTER TARGET Cs:

xx:x %

S= Z= Enter confirms

Edit Target Cs xx:x %

Edit Target Cs

xx:x %

S= Z= Enter confirms

Note! If in-air torque offset value have been edited since last Target Cs the target Cs cannot be edited.

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CALIBRATION

SET-UP

GRADE: SW LOCAL CONTROL

Grade: XXX S: XXX Z: XXX

EDIT GRADE NAME

GRADE: S: X.XX

SW Z: XX.X

GRADE: S: X.XX

SW Z: XX.X

MAINTENANCE

LOW LIMIT: xx.x %

OLD LIMIT: ENTER NEW:

XX.XX XX.XX

FACTORY SETTINGS (requires password 633)

HIGH LIMIT: xx.x %

OLD LIMIT: ENTER NEW:

XX.XX XX.XX

OUTPUT FILTER: XX s

EDIT FILTER: XX s

SET CLOCK year-mo-dd hh:mm

EDIT DATE & TIME year-mo-dd hh:mm

GRADE SELECTION MODE: LOCAL

SELECT MODE: REMOTE

MENU LANGUAGE: ENGLISH

SELECT LANGUAGE ENGLISH

ELEMENT TYPE: 8-PIN

SELECT ELEMENT 8-PIN

ERROR OUTPUT CURRENT: NO EFF.

SELECT ERROR CURRENT: 3.50 mA

PRC.STOP OUTPUT CURRENT:

SELECT PRC.STOP CURRENT: 4.00 mA

PASSWORD 000

EDIT PASSWORD 000

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SET-UP TEXTPROM FIRMWARE VERSION VERSION HART ID

MAINTENANCE

DEVICE IDENTIFICATION

DEVICE TYPE: KC/5

SERIAL #

TAG

FACTORY SETTINGS (requires password 633)

CHECK ON-LINE SIGNALS

OPTIC: CPU: FRICTION

XXC XXF YYC YYF x.x Nm

POWER:xx.xV / xx C MOTOR: xx.xV / y.y A BINARY INPUT STATUS: OOOO RAW: xxxxxx SPD: xxx.x RPM N:xxxx M: xxxx T: yyyy Cs: xx.x%

DATALOG SINCE yyyy-mm-dd hh:mm

Cs min: Cs max:

xx.x % xx.x %

mNm min: xxxxx mNm max: xxxxx OPTIC xx C OPTIC xx C MIN: yy F MAX: yy F Date Time Value Duration Date Time Value Duration

>1 Nm SHOCK XX COUNT <-100 mNm SHOCK XX COUNT RESET LOG DATA ENTER CONFIRMS TORQUE SETUP LOW TORQUE xxxxxxx / xx mNm

EDIT LOW BRAKE xxx mNm VALUE:

APPLY xx mNm TORQUE BRAKE EDIT RAW VALUE xxxxxx

RESULT: xxxxxxx ENTER CONFIRMS EDIT

xxxxxx
RESULT: xxxxxxx ENTER CONFIRMS EDIT

HIGH TORQUE xxxxxxx / xx mNm

EDIT HIGH BRAKE xxx mNm VALUE:

APPLY xx mNm TORQUE BRAKE EDIT RAW VALUE xxxxxx

xxxxxx

SIGNAL SIMULATION

Cs SIMULATION

SET Cs: xx.x % OUT xx mA

mNm SIMULATION

xxx SET mNm: Cs xx.xx% xx.xx mA

2 3

CHECK ALARMS (XX)

Alarm 1

RESET TO FACTORY DEFAULT VALUES

PRESS ENTER TO CONFIRM RESET

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FACTORY SETTINGS

PASSWORD (633) EDIT SN XXXXXXXX 8-PIN

SERIAL NUMBER: XXXXXXXX

DEFAULT ELEMENT PADDLE CURRENT OUTPUT CALIBRATION

SELECT DEFAULT: PADDLE EDIT VALUES S: xxxx Z: xxx

4-PIN

DISC ALIGNMENT LIMIT XXXXXXX

DISC ALIGNMENT LIMIT XXXXXXX 1 9

CHECK TEMP COMP FACTORS

TEMP FACTOR 0 0C xx

EDIT FACTORS 0-9 XXX.XmNm XXC

MOTOR CONTROLS

RPM SET POINT: XXX MOTOR DIRECTION: CW AUTO REVERSE 0s / 0 min CONTROL LOOP SPEED: 30

RPM SET POINT: XXX MOTOR DIRECTION: CW SET AUTO REVERSE XXXs / XXX min CONTROL LOOP SPEED: 30 CCW

TEMP SENSOR DIAGNOSTIC

157/187/ORG ID: 1059736B0008012

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5.3 Set-up
Check that the sensor unit is inserted into the process; seal water, the interconnect cable and power cable to the sensor unit are connected. Turn on the switch in display unit. The motor starts running unless process stop input is activated. In normal cases the steps in KC/5 set-up check list (Appendix 3) are sufficient. Select grade The user can change grade manually or by binary inputs from a remote device. The current grade selection mode (local or remote) is shown below the menu name. Each element has a predefined S (Slope) and Z (Zero) parameters for 8 different pulp grades (SW, HW, CTMP, TMP, GW, RECYCLE, EUCALYPT and USER DEF).
Sensing Element: Grade: SW HW TMP CTMP GW Recycle Eucalypt User def Paddle (Standard) S Z 2.7 -4.8 2.9 -6.1 2.7 -7.0 2.9 -9.0 2.6 -5.5 2.5 -5.0 2.5 -4.7 2.0 -5.0 4-pin S 2.9 3.2 2,9 3.2 2.8 2,7 2.7 2.0 Z -6.5 -8.2 -8.1 -10 -7.0 -6.0 -5.2 -5.0 8-pin S 2.7 2.9 2.7 2.9 2.6 2.5 2.5 2.0 Z -4.8 -6.1 -7.0 -9.0 -5.5 -5.0 -4.7 -5.0

Table 6.1. Default values for S and Z. Grade names can be edited (See menu structure, section 5.2). Edited grade names remain in use until the factory reset is done - then default names of chosen language are taken into use. The factory default values are stored by sensing element and by furnish permanently in the KC/5 memory. When the KC/5 is set up for the first time the factory default values are selected for use. User can change these parameters during the calibration and KC/5 will use the latest parameters for each grade. Select low limit of measurement span The low limit setting can be adjusted between 0.00 and 19.99 %/Cs. This value corresponds to output current 4 mA. Low limit must be smaller than high limit. Select high limit of measurement span The high limit can be adjusted between 0.00 and 19.99 %/Cs. This value corresponds to output current 20 mA. High limit must be larger than low limit. Output filter The user can filter out process noise, or abnormal spikes, from the output signal with this function. Filtering time is expressed as seconds (default = 10 s). Set clock Date and time are given in yyyy-mm-dd hh:mm format. Grade selection mode The user can select between local (default, changed from the keypad) or remote grade selection through binary inputs. Select menu language Selectable languages are English (default) and Finnish. Grade names will change to desired language by factory reset. Select sensing element March 2005 W41040300 V2.2 Page 28 of 66

The user selectable sensing element types are 8-pin, paddle (default), and 4-pin. The user has to select the element that is installed on the sensor. Error output The user can select desired function in case of the KC/5 detects error. There are following options: NO EFF: measured value is outputted even through the value of output can be erroneous (default). 3.5 mA: analog output goes to 3.5 mA during error. 22 mA: analog output goes to 22 mA during error. FREEZE: output freezes on the last accepted measurement value. See more information from chapter 7.2 - Check alarms. Process stop output If process stop input is activated the KC/5 sensor motor stops running. The user can select how the output behaves in this case. Alternatives are: 4.0 mA: analog output goes to 4.0 mA during stoppage. 20 mA: analog output goes to 20 mA during stoppage. FREEZE: output freezes on the last accepted measurement value.

6. Calibration
Separate calibration is required for each selected sensing element and pulp type. KC/5 can be calibrated against laboratory by taking samples or by choosing default values from the sensor memory. Initial calibration of KC/5 consists of following steps: A. IN-AIR TORQUE ZEROING: Sensing element is run in air. Torque turned to read zero. B. SINGLE-POINT CALIBRATION: KC/5 tunes calibration parameters S (Slope) and Z (Zero) based on one laboratory sample (Start up procedure). C. CALIBRATION: Fine tuning of the calibration using multiple points is described in chapters 6.4-6.6 In normal cases the steps A-B are sufficient.

6.1 Calibration menu

Consistency calibration is made by linearized curve. Cs = S x M + Z Cs=Consistency, S = Slope, M = Linearized measurement and Z = Zero. Change zero and slope: The user can review and adjust the Z and S values from this display setting. Zero Z can be adjusted from 99.99 to +99.99. Slope S can be adjusted from 0.00 to +19.99. Lab values: The user can review the last 10 samples stored in the memory; sampling times, measured values, and lab values. Through this display the new lab values are entered or old values edited. Samples can be removed by delete function. Calibration calculation: KC/5 can be requested to calculate new Z and S values based on minimum of 3 sets of stored calibration data. Recommendation: Use of a spreadsheet program (e.g. Excel) is recommended on calibration over the instrument aided calculation. Spreadsheet provides better visualization of the data points for example calibrated range and to remove outliers (unreliable samples) from calibration data. March 2005 W41040300 V2.2 Page 29 of 66

6.2 In-Air torque

Before inserting the sensor into the process, perform the in-air torque in calibration menu, start-up (chapter 5.2) : 1. Connect seal water and the interconnect cable to the sensor. 2. Turn on the power to start motor while the sensing element can rotate freely in air 3. Go to In-Air Torque in calibration menu. Press ENTER to initiate the procedure. KC/5 adjusts automatically torque measurement (T) to zero by changing the offset value. Display shows how much torque offset was required. Confirm the torq reading (T) from Maintenance menu, On-line signals that it displays close to zero. 4. For special cases Torque offset can be edited. In case where sensor can not be taken out from process and sensing element is rotating in water then edit mode is needed to adjust T value close to 5.

6.3 Single-point calibration

Target Cs procedure in Start up menu is a quick way to get a new unit running. 1. Go to "target Cs" menu while KC/5 is measuring in the process. 2. Type in assumed consistency and press ENTER. KC/5 adjusts calibration parameters S (Slope) and Z (Zero) to match with given consistency. 3. Take sample and make lab analysis to verify the given consistency. 4. If lab Cs differs more than 10 % from given Cs, go to "edit target Cs" and change the originally given Cs to correct value and repeat tuning by ENTER. 5. Continue calibration fine tuning by taking steps described in 6.5-6.7

6.4 Zero adjustment

After initial calibration described in chapter 6.2-6.3 only zero adjustment (offset change) is usually needed. This is done by changing Z value. 1. Take the sample. 2. Read the transmitters consistency reading. 3. Make lab analysis. 4. Adjust Z to make lab and transmitter reading match. Example: KC/5 reading Lab result 3.2% 3.5% If old Z = -7.0 New Z = -6.7

New Z = old Z + 0.3

6.5 Sampling procedure

Laboratory samples can be taken and stored in KC/5 memory by following procedure: 1. Press SAMPLE button. The display shows SAMPLING TIME LEFT XXs. During the 30 sec countdown the KC/5 averages 30 seconds worth of the measurement value and stores the data together with sampling time in the calibration data memory. 2. You must take the sample during the 30 second count down to match the stored data. 3. KC/5 displays the measured value Cs %, linearized measurement M and the MIN-MAX reading. MIN MAX value indicates process stability during the sampling time. If the consistency value is unstable during the sampling time, the sample drawn may not reflect the real consistency value and may not be reliable for calibration. In this instance sampling should be repeated. Measured value is accepted and

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4. 5.

stored in memory by pressing ENTER or automatically after 5 minutes when the display returns to main display. By pressing ESC the sample is discarded and display returns to the main menu Analyze the sample in laboratory Enter laboratory results into KC/5 memory following way: a. Select Lab values from Calibration menu. The display shows latest sampling time with measured averaged value and delta consistency (DIF) over the sampling time. ENTER button scrolls between DIF, Lab Cs%, or M values. If DIF is over 1 % Cs this sample is rejected from calculations b. Scroll with or buttons to reach proper sample data. Time serves as an clear identification for the samples c. Press button to select desired data. Menu prompts ENTER LAB VALUE. Enter by button, feed in the lab value, and press ENTER to confirm the fed lab value or ESC to discard it d. If sample data is not acceptable (e.g. large swing in consistency during sampling) go to DELETE SAMPLE mode and press ENTER to discard the sample values

6.6 Changing calibration parameters

There are two possible ways of adjusting the calibration values: 1. Change Z and S manually. 2. Ask KC/5 to calculate a new Z and S based on stored calibration data.

6.6.1. Manual adjustment

Manual adjustment means Zero and Slope adjustment manually by changing Z and S under Calibration menu. Recommended way to calculate calibration parameters is using a spreadsheet program (e.g. MS Excel). Contact KPM for a copy of spreadsheet compatible with Excel.

6.6.2. Transmitter calculated parameter change

When minimum of 3 laboratory samples have been collected and results entered into KC/5 memory, the transmitter can be asked to calculate calibration parameters. To activate the calculated parameters requires user acceptance. Select Calibration menu and go to Calibration calculation by pressing The display shows # SAMPLES OK ENTER CONTINUES. # must be 3 or higher otherwise transmitter refuses to calculate parameters. In case # is less than 3 display shows Invalid Samples 3. Press ENTER to calculate new S and Z with the aid of laboratory samples. The display shows the new values, and estimated error of calibration. Please check that S is at realistic level, typically 1,5 -5.0. Limits to enter new value are 0.0 19.99. If the result is unrealistic, please use spreadsheet to visualize and troubleshoot calibration data. 1. 2. 4. 5. Press ENTER button to accept the new calibration parameters and program will automatically return to the main menu. Press ESC to retain old values.

Note! KC/5 requires minimum of 3 laboratory samples to calculate calibration parameters. Calibration data is stored in a stack of 10 data pairs. It works on FIFO principle. When calculating calibration parameters KC/5 uses all the data in the memory at that time. Estimated error of calibration indicates the reliability of calibration data and can be used to judge if calculated parameters are acceptable or not.

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7. Maintenance
7.1 Regular maintenance of the KC/5
Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the sensor as per chapter 3.7. KC/5 does not require any scheduled regular maintenance other than checking the seal water flow. Normally seal water flow should be 0,5 2l/min (1/8 gal/min) from outlet or the seal water tube. In case of the seal water reservoir, water level should be 30% - 70% full.

Seal water reservoir (optional, in case mill seal water not used)
The mechanical seal generates heat and needs cooling and lubrication. The seal water reservoir provides water for the seal in case mill seal water cannot be used. It is recommended to turn KC/5 motor off during longer process outages. The seal water reservoir should be checked on a routine basis. Initially this should be done every other week to determine usage rates. The reservoir should be kept at a minimum of 30% full. If fibers appear in the reservoir drain out the old water and refill seal water reservoir. Fibers can plug fluid veins and prevent seal fluid circulation. Note! It is normal for mechanical seal to have some leakage. Seal water can become cloudy when fibers, fines or fillers mix with water. This is normal and causes no harm.

7.2 Maintenance menu

By means of the maintenance menu a user can evaluate the performance of the unit, or behaviour of the process. Device identification: The user can view following product information: device type serial number tag number firmware version. textprom version Hart ID The tag number can be edited by the user. All other information is in the permanent memory. Check on-line signals: The user can view following values in real time: sensor temperatures (optics and CPU) in Celsius and Fahrenheit friction [Nm] power module output voltage and temperature (V) (C) motor voltage and current (V) (A) binary input status (O = open, I = Closed) raw-signal from sensor (RAW) motor speed (RPM) (SPD) torque (N) temperature compensated torque (T) linearized measurement signal (M) consistency measurement (Cs % = Slope x M + Zero). Displayed Torque (N) is the sum of measured torque + torque offset. March 2005 W41040300 V2.2 Page 32 of 66

Data log since: The user can view following data: Cs min/max mNm min/max optics temp min/max the number of abnormal shocks (hits) on the sensing element (high and low force corresponding < 100 mNm and > 1 Nm). The time since the last reset is shown with the data. The data logs can be cleared in the Reset Log Data menu. Torque setup: Used to bench calibrate the sensor after service. Calibration is performed using a torque brake and zero level is set when sensing element is spinning freely in air. 1. Set Low Torque, when in air, set 0,0 mNm 2. Perform Low Torque set up 3. Set High Torque value specific for the torque brake used. 4. Perform High torque set up Low torque: Displays the existing low torque calibration numbers raw value and used torque. Torque value can be edited. Can be used to re-zero the sensor signal while element is spinning freely in air. New low torque calibration value is accepted by pressing ENTER button. Calibration is cancelled by ESC. High torque: Displays the existing high torque calibration numbers raw value and used torque. Torque value can be edited. Recalibration requires user acceptance (ENTER). Signal simulation: The output signal (4 to 20 mA) can be checked by this function. The simulated output current corresponds to the consistency value and output scaling. Simulated signal can be entered either as Cs-% reading (CS simulation) or as mNm (Torque simulation) corresponding to 0-999 mNm. Check alarms: Current active alarms (count of alarms shown in brackets). User can view following internal alarm flags: Alarm name Temp sensor error Temp too high Temp too low Pr. Eeprom empty Gap too small Gap too big Torque setup err Cs>high limit Cs<low limit No signal Motor jam Motor Problem Power over temp. High friction Power problem Possible cause Temperature sensor failure. Sensor overheating, >80 C Temp < 0 C (32 F) EEPROM, optics board failure; loose wire The optical discs out of alignment, check spring The optical discs out of alignment, check spring Torque set up failed; sensitivity out of limits Consistency over set range Consistency below set range Optics board failure, discs overlapping, loose wire Too high friction; seal tight, bearing worn out Motor RPM < set value; bearing, power supply Power supply to motor overheating Friction >1,5Nm; bearings or seal damaged Power supply, Hall-sensors of motor,connection cable Action Temp compensation not used Temp compensation not used Temp compensation not used Temp compensation not used Output set to alarm mode Output set to alarm mode Output set to alarm mode Output to 20 mA Output to 4 mA Output set to alarm mode Output set to alarm mode Output set to alarm mode Output set to alarm mode Output set to alarm mode Output set to alarm mode

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Error messages: In addition to alarms KC/5 shows several messages which are explained below: Message Invalid samples Slope too high Invalid Cs AUTO RVS Possible reason Lab result isnt given. Consistency variable more than 1 Cs % during sampling. Less than 3 sample. Calculated slope in calibration is bigger than 19.99. Result will be discarde Editing of consistency in torque tuning denied S or Z has been changed see 5.4 Motor runs counter-clockwise in auto-reverse mode

Reset to factory default values: The user can reload the default values of the S (Slope) and Z (Offset) for all pulp grades. Default values are shown in the table 6.1. The other parameters returned to factory set-up are: the original sensing element type, output filtering, and local grade selection mode. Grade names will be changed to defaults of the chosen language.

7.3 Motor controls

These functions are under Factory settings-menu. Password 633 is required to enter. Change rotation speed: The user can change RPM of the motor within 300-650 RPM. Display shows set speed, actual speed, and torque value. By pressing Enter the set value becomes permanent speed. Measurement sensitivity and signal to noise ratio improve when rpm is increased. As a rule of thumb: Cs range <3% 38% 6 10 % Rotation speed 600 rpm 420 rpm 550 rpm

Change rotation direction: The user can change the rotation direction of the motor. Normal direction is clockwise (CW) when looking from the motor end of the sensor. Counter clockwise direction is marked as CCW. Direction change can be used e.g. to remove wrapped material from sensing element without taking sensor out from the process. Reverse torque reading is shown as indication only. One can use the reading to determine if sensing element dislodged foreign particles. Exit from motor controls menu returns the direction automatically back to CW (normal measurement direction = clockwise). Auto-reverse Direction change can be made manually or automatically at set frequency. The user sets time how long and how often motor is run counter clockwise. Reverse run can be set to 0-120 seconds (5 sec increments) every 0-180 minutes (10 min increments). If reversed rotation time is 0 seconds, auto-reverse mode is off. Auto-reverse is interrupted or delayed if -sample button is activated -display is not in main display (someone operating KC/5) Interrupted or delayed auto reverse run is started in 1 minute after returning back to allowed condition. March 2005 W41040300 V2.2 Page 34 of 66

Output signal is frozen when auto-reverse is activated. Auto-reverse can be used e.g. in recycled pulp applications with some foreign material in the line. This material can get attached on the sensing element. Reversed rotation can often dislodge material without removing the sensor from the line and cleaning the sensor head.

7.4 Troubleshooting
Trouble shooting of modern electronics is limited to locating the faulty unit and replacing it. To locate faulty component use diagnostics features of the KC/5 software Maintenance / Check on-line signals section. Check following first: 1. Motor is running (RPM is as set). 2. Friction is less than 1 Nm. (FRICTION) 3. Motor voltage is 24 48 VDC (POWER) If not, use wiring layout drawing (figure 7-14) to locate faulty component. Check following voltages: AC/DC Power supply outlet voltage is 482VDC, measure from Connection Board. Motor Supply voltage is 24 48 VDC, measure from Connection Board and from Sensor Board. Sensor Supply Voltage is 12 VDC 1 VDC, measure from Connection Board and from Sensor Board. The following is a list of problems and potential solutions.
Problem A. Motor is not running Potential source of problem & solution 1. Check that the process stop binary input is not activated (if active main display reads Process stop) 2. Check the power switch in display unit is ON 3. Check fuse in the display unit and reset if needed. (fig 7.14, 7.17 & 4.1) 4. Check that drive shaft is not jammed If jam is reason alarm message reads motor jam Check from on-line signals if motor tries to start (motor current) Rotate drive shaft from sensing element and try if it helps If not, replace mechanical seal or bearing assembly 5. Check power to the motor. See figure 7.14. (pins 9 & 10) If there is no power to the motor replace AC/DC power unit. If power ok change sensor board (See section. 7.13). 1. Sensing element needs to be re-aligned (See section 7.10). Or damaged one changed 2. If gate valve has been closed while sensing element is inside it, the moment shaft might also be bent. Check straightness of the head of the moment shaft. Replace moment shaft if not straight.

B. Erratically spinning sensing element.

C. Seal water reservoir has a Refill reservoir to line level using good quality water. low fluid level. D. Seal water is dripping from drain hole E. No RS485 signal. If the rear seal of dual seal system has failed, seal fluid will leak out of the drain channels. Replace rear seal immediately (See section 7.12) 1. Check the connector from sensor electronics to display unit. 2. Check the cable connections at pin 6 and 7 of Display Unit connector board 3. Replace the Sensor Board 1. Take out KC/5 unit and check that sensing element is clean. If not clean proceed as described in section 7.9 2. Check that area between sensing element and drive shaft does not have a build-up of hard debris. Clean if necessary (See section 7.9 -7.10). 3. Sensing element is spinning erratically (See section problem B).

F. Raw output reading is erratic

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7.5 Removing the KC/5 sensor

Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the sensor as per chapter 3.7. Turn power switch OFF in the display unit. 1. Unplug the interconnect cable (See figure 7.1) 2. Close seal water line 3. Loosen the seal assembly locking ring 4. Jack the sensor to fully extracted position until jack stops 5. Close the gate valve 6. Open the drain valve in the mounting flange (verifying gate valve has good seal) 7. Disconnect the seal water hose connectors 8. Remove the locking bins and mounting bolts holding the sensor in the jack 9. Remove the sensor Note! Hold the sensor so that the sensing element does not rest on locking ring when pulling out the probe. This may bend the sensing element and the moment shaft and cause severe damage.
Gate Valve 5 Insertion Jack 4 Sensor 9

6 Pipe 1 Locking Ring 3 Mounting Bolts 8

Drain 7 Valve

Figure 7-1. Removing the KC/5 sensor.

7.6 On-line sensitivity check

KC/5 sensitivity can be checked with torque brake while the sensor is running in the process. The torque brake can be ordered from KPM. Order code is A41040222. 1. 2. 3. Open the Check Torque cap at the end of the sensor to get access to the torque socket Check the torque setup value from the torque brake (KPM brake 85 mNm). Connect torque brake to the socket. This can be done without stopping the motor. W41040300 V2.2 Page 36 of 66

March 2005

4. 5. 6. 7.

Hold torque break firmly against the socket while avoiding contact between shaft and case Read the torque value from maintenance menu, on-line signals Reading should increase about the same than the brake set value from the no-brake level. If not, proceed as per section 7.7. Close the Check Torque cap tightly

Figure 7-2. Sensitivity check with torque brake

7.7 Checking the functionality of the KC/5

Remove the sensor from the process (see section 7.5) 1. Check the elastic protective shield and clean the front end of the probe 2. Place the KC/5 sensor unit horizontal and the sensing element free for rotation. 3. Connect seal water to the sensor 4. Connect the interconnect cable 5. Turn on the power switch in the display unit. The sensing element should spin rotating counter-clockwise, as seen looking at the front of the element. 6. The sensing element spinning in air provides the no-torque reading. When properly calibrated, the notorque (N) output reading should be -2 +2 plus the torque offset (Offset can be checked from Torque setup). 7. If not, clean the front end behind the sensing element and check the elastic silicone shield for possible damage. 8. If cleaning did not help perform torque sensitivity calibration (see section 7.8)

7.8 Torque sensitivity calibration

Torque calibration is done by applying torque on the sensing element. KC/5 is factory calibrated using 85 mNm (12 ounce-inch). Low torque value (0 mNm) is measured while the sensing element is spinning in air. 1. Place sensor unit on the work bench with the display unit next to it. 2. Position the KC/5 so that the drive shaft is horizontal. 3. Connect seal water to the sensor Note! When the KC/5 transmitter is operated in air, the mechanical seal will heat up if seal water is not connected. This can damage the seal. Make sure there is fluid in the reservoir or connect water line to the seal water connector of the sensor. 4. Switch power ON in the display unit. 5. Select torque setup in maintenance menu and type in the high torque value to be used. Press ENTER and place torque brake to the torque socket (See figure 7-2). Press ENTER to initiate

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the calibration. After a while calibration raw value appears in display. ENTER accepts the new number, ESC cancels. 6. Repeat above with low torque value (sensing element rotating freely in air).

7.9 Cleaning the sensing element

7.9.1. Cleaning the sensing element from wrapped up material by reversed rotation
Sometimes piece of debris can stick on the sensing element or a strip of plastic or piece of wire wrap around the element. This will distort the measurement. Rotation direction change sometimes helps to shake off debris or remove strips. 1. Go to motor controls under factory settings. Select motor direction block, display reads CW = clockwise. Select CCW = counter clockwise rotation direction. 2. Press ENTER and direction is reversed. Display returns to show RPM and T. 3. Let element run in reverse direction for a while. At the moment debris is released the T value should have a step like change. 4. Return back to normal rotation direction and check if T value has changed from the original level. If not, repeat reversed rotation run few times until T reading indicates the removal of foreign particle.

7.9.2. Cleaning the sensing element manually

Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the sensor as per chapter 3.7. The sensing element must be free to rotate with reference to the drive shaft. This twisting action is the essence of the torque measurement. If hardened debris or chemical additives build up on elastic shield or in the region between the sensing element and the shield, it can cause the sensing element to lock-up on to the end of the shaft. This can cause a loss of sensitivity, and in the worst case, cause the output to be frozen at a constant reading. To clean, proceed as follows: 1. Remove sensor from the process line (See section 7.5). 2. Remove the sensing element by unscrewing the fixing screw (See figure 7-3). 3. Remove shield locking ring, if needed, for cleaning 4. Clean and remove any build-up on the sensing element, elastic shield, and the area in between. 5. Check condition of elastic shield; if cut or broken replace with a new one (See section 7.10) 6. Reattach the sensing element to the moment shaft and tighten the fixing screw.

Figure 7-3. Sensor head and the shafts. March 2005 W41040300 V2.2 Page 38 of 66

7.10 Replacing elastic shield, rod seal and needle roller bearing
Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the sensor as per chapter 3.7. If the elastic EPDM shield has punctured it has to be replaced. KC/5 elastic shield replacement set contains the parts which are recommended to be replaced. Content of Elastic Shield Replacement Set A41040302V1.1 Order Code Type H41040158 Elastic Shield 2650016 Rod Seal 2750001 Needle Roller Bearing 2700015 O-ring 19.1x1.6 FPM

7.10.1. Removing elastic shield

1. Remove the sensing element (See figure 7-3). 2. Open the screws in the shield locking ring and remove the ring. 3. Open the set screws in the shield cover and remove the shield cover. Elastic shield comes out with the cover (see figure 7-4b).

Figure 7-4a. Sensor head

Figure 7-4b. Removing the elastic shield.

7.10.2. Removing rod seal and needle roller bearing

1. Pull out moment shaft bushing using two screw drivers (figure 7-5a) 2. Remove the seal washer to get access to the rod seal (figure 7-5b).

Figure 7-5a. Removing moment shaft bushing March 2005

Figure 7-5b. Removing seal washer Page 39 of 66

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3. Remove moment shaft bushing (figure 7-5c) . Remove the needle roller bearing by turning sensor head downwards and moving moment shaft radially (figure 7-5e). Check the condition of the needle roller bearing (figure 7-5d). Replace the bearing if needed.

Figure 7-5c. The rod seal location Figure 7-5d. Location of the needle roller bearing

Figure 7-5e. Removing the needle roller bearing 4. Clean the moment shaft of any dried material. Pay extra attention to area under the rod seal.

7.10.3. Installing elastic shield, rod seal and needle roller bearing
1. 2. 3. 4. 5. Install the needle roller bearing. Use silicone oil as lubricant. Install a new rod seal from the shield replacement set inside the moment shaft bushing. Replace the old moment shaft bushing O-ring with a new one from the replacement set Reinstall the seal washer. Note that the bevelled side is facing the rod seal. (see figures.7-5b,c) Slide the assembled bushing over the moment shaft and push all the way down to the drive shaft

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Figure 7-6. Installation of the moment shaft bushing and the seal washer. 6. Assemble a new elastic shield into the shield cover. Pull the shield over the drive and moment shafts. To lessen the friction, wet the shaft surfaces (weak soap water). Push -do not twist - the shield cover all the way until the shield cover stops against the drive shaft. 7. Tighten the set screws on the shield cover (see figure 7-4a) 8. Place the shield locking ring on top of the elastic shield do not fasten the screws yet. 9. Reattach sensing element to the moment shaft and tighten the fixing screw 10. Lift the shield locking ring until it rests against the sensing element and fasten the screws

7.11 Replacement of the mechanical seals

Safety Warning: Jack and Lock Ring must be secured and attached in place after re-inserting the sensor as per chapter 3.7. KC/5 uses dual mechanical seals in tandem mode. The seal water is guided between the front (process side) and rear (motor side) seals. The front seal prevents pulp from getting inside the KC/5 probe housing. The rear seal keeps seal water from getting to drive shaft bearings. The seals are manufactured according to DIN 24960 standard and are commonly stocked items. Front seal (process side) Rear seal (motor side) 2650017 2650018 Order Code Type Bellows Seal T502, SiC/EPDM 2650005 Stationary Seat C606/25, SiC/EPDM Bellows Seal T502, SiC/FPM 2650007 Stationary Seat T6/25, SiC/FPM

Note: Rear seal (motor side) is recommended to be replaced with the front seal (process side) if rear seal has been in service more than 3 years. Estimated life time of a mechanical seal is 5 years. Rear mechanical seal should be replaced if 1. seal water/fluid is dripping from the draining duct 2. at the time of replacing the front mechanical seal the rear seal has been in service over 3 years 3. the rear seal has been in service for 5 years

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Figure 7-7. Location of the draining duct.

7.11.1. Removing front mechanical seal

1. 2. 3. 4. Remove first the sensing element and the elastic shield (section 7.10.1 and figure 7-4) Remove the front bellows seal by lifting it with symmetrically placed screw drivers (figure 7-8a) Release stationary seat by removing the locking ring (4 screws) (figure 7-8b) Remove the front stationary seat with help of two screw drivers (figure 7-8c)

Figure 7-8a. Removing the bellows seal.

Figure 7-8b. Removing the locking ring.

Figure 7-8c. Removing the stationary seat with 2 screw drivers.

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7.11.2. Removing rear mechanical seal

1. Anchor the sealing cover to a bench vice with lock ring and break sleeve from the installation assembly (or with Sealing Cover Removal Tool H41040314 V1.0). and rotate the sensor head open completely.

Figure 7-9. Opening the sealing cover 2. 3. 4. 5. Open two set screws and remove Seal Locking Ring (see figure 7-10). Remove the bellows seal by lifting it with symmetrically placed screw drivers. Open the 4 screws of the seat adapter holding the rear stationary seat. Remove the rear stationary seat from seat adapter by pushing forwards.

Figure 7-10. Removing the rear mechanical seal 6. Wipe the drive shaft clean and check that the draining duct is open.

7.11.3. Installation of front and rear mechanical seals

Wipe the drive shaft clean with soap water before installing the rear stationary seal. Note: Use clean water or soap water to reduce friction when installing seals. Wet surface reduces friction between the seal and the drive shaft. Do not use oil, grease or alcohol. 1. Install seat adapter with 4 screws. Install the adapter so that seal water ducts are not blocked.

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2. Push the stationary seat into seat adapter with polished side facing up. Use your hands to press the stationary seal into place 3. Push the rear bellows seal on top of the stationary seat with polished face down

Figure 7-11. Rear seal compression adjustment. 4. Place the seal locking ring on top of the bellows seal and adjust the seal compression by pressing the ring. Set installation length to 27 mm 0.5 mm from the top of the seat adapter to the bottom of the ring (see figure 7-11). 5. Lock the locking ring with 2 set screws 6. Apply little bit of graphite grease (e.g. molykote) to the sealing cover threads. 7. Install the sealing cover. Anchor the sealing cover to a bench vice with locking ring and brake sleeve (or with Sealing Cover Removal Tool H41040314 V1.0) and fasten the sensor head (see figure 7-9). 8. Place the front stationary seat on the sealing sleeve with the polished side facing up. Use your hands to press the mating ring into place (see figure 7-8c) 9. Install the locking ring and fasten the 4 screws (see figure 7-8b)

Figure 7-12. Installing front seal. 10. Slide the front bellows seal over the drive shaft. Compress front seal to its shortest dimension

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Figure 7-13. Installing shield cover. 11. Install the shield cover and the elastic shield (see fig 7-13). Push do not twist the shield cover as far as it goes. Fasten 3 set screws. Uncompress front sealing spring until it reaches the shield cover. Now installation length is correct. 12. Place the shield locking ring on top of the elastic shield. Leave screws loose 13. Reattach the sensing element to the moment shaft and tighten the fixing screw. 14. Lift the shield locking ring until it rests against the sensing element and fasten the locking ring screws

7.12 Electronics
KC/5 electronics contains the following replaceable boards/units Order Code 1. Optics Board A41040062V1.0 2. Sensor Board A41040070V1.0 3. Connection Board A410402202V1.0 4. AC/DC Power Supply 3100003 5. LC Display Board A41080023V2.0 Trouble shooting of modern electronics is limited to locating the faulty unit and replacing it. To locate faulty component use diagnostics features of the KC/5 software Maintenance / Check on-line signals section. Check following first: 1. Motor is running (RPM is as set). 2. Friction is less than 1.5 Nm. (FRICTION) 3. Motor voltage is 24 48 VDC (POWER) If not, use wiring layout drawing (figure 7-14) to locate faulty component. Check following voltages: AC/DC Power supply outlet voltage is 482VDC, measure from Connection Board. Motor Supply voltage is 24 48 VDC, measure from Connection Board and from Sensor Board. Sensor Supply Voltage is 12 VDC 1 VDC, measure from Connection Board and from Sensor Board.

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JP1: Current output mode Motor drive

Jumper position: Passive

Active (default) Sensor Board Motor supply 24-48VDC J7 _

1
1 2 3 4 5 9 8

Optical disk

J1
9

Photo detector Optics Board

6

+
7 6

7 6

8 9

1 2 3

Measurement signal Commutation pulses

Quick Connector

Interconnect Cable

AC/DC Power supply

48 VDC

Mains Connector 85-264 AC in Connection Board Resettable fuse Quick Connector pin Sensor Board J7 J1 8 9 3 1 6 7 5 2 1

Signal Shield Current Loop + Current loop Sensor Supply (+12V) Sensor Supply GND RS 485 A RS 485 B PWM Control (pulse) Motor Supply + Motor Supply GND

Connn. Board J1 1 2 3 4 5 6 7 8 9 10

Interconnect Cable wire shield white brown green yellow grey pink blue black + gray/pink violet + red/blue

Sensor Cable wire

1 2 3 4 5 6 7 8 9

white brown green yellow grey pink blue black + gray/pink violet + red/blue

Figure 7-14. Wiring layout. March 2005 W41040300 V2.2 Page 46 of 66

7.13 Replacing Sensor Board

Refer to figure 7-15. To change the sensor board, proceed as follows: 1. Remove the KC/5 sensor from process line (See section 7.5). 2. Open the back of the enclosure by opening the 4 screws 3. Remove Plastic insulation cover 4. Disconnect the cable connectors (3 pcs) on the Sensor Board. 5. Unscrew the six screws which attach the measurement board to the end housing. 6. Uncouple the Sensor Cable wires on the board 7. Replace with a new board. Note the orientation of connectors (fig 7-15). 8. Reconnect the cables on the board.

7-15. Sensor electronics. March 2005 W41040300 V2.2 Page 47 of 66

7.14 Replacing Optics Board

Refer to figure 7-16. 1. Open the small cover on side of the sensor housing, see fig 7-15. 2. Disconnect the optics cable connector on the optics board 3. Open 4 mounting screws and remove the board 4. Install a replacement board 5. Align the board so that the optics disks are in the middle of the alignment slot (see figure 7-16) 6. Connect the cable

Figure 7-16. Optics Board Alignment

7.15 Replacing Power Supply Unit

Disconnect AC power supply to Display Unit before starting the replacement work Power supply unit provides 48 VDC operating voltage to the motor and 12 VDC for display and measurement electronics. 1. Disconnect AC supply to Display Unit 2. Disconnect the cables between the connection board and the power supply unit and remove the mounting screws (4 pcs) and the mounting bars (2 pcs), figure 7-17. 3. Mount a new unit and reconnect the cables

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Figure 7-17. Display Unit.

7.16 Replacing Connection Board

Disconnect AC power supply to Display Unit before starting the replacement work 1. Disconnect AC supply from Display Unit 2. Disconnect 110/220 VAC mains power wires from the connection board 3. Remove the power supply unit (see section 7.15) 4. Disconnect all the cables, open the 4 mounting nuts of the board and the screw fastening the regulator on the heat sink (fig 7-17) 5. Remove the board 6. Mount a replacement board 7. Install the screw fixing the regulator on the heat sink. Note the insulation pad between the heat sink and the regulator, and the insulation bushing between the screw and the regulator (fig 7-18) 8. Check insulation between the regulator body and the display unit body with an ohmmeter (must be over 1 M) 9. Install 4 mounting nuts. 10.Re-install the removed power supply unit and connect the cables March 2005 W41040300 V2.2 Page 49 of 66

Figure 7-18. Regulator isolation (bottom view of the connection board)

7.17 Replacing LC Display Board

1. Disconnect all the wires, open the 7 mounting nuts of the board and remove the board, see fig 7-17 2. Mount the new board and connect the cables

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Appendix 1: Installation drawing standard installation cone

This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party or be used for any unauthorized purpose. (c) Kajaani Process Measurements Ltd. 2002 4 Vers. 3 Description 2 1 Date Prepd

Cut the installation cone to fit with existing process tube. If not cut already in factory.

2 1

2:15

1. Cut the installation cone to fit with existing process tube. If not cut already in factory. 2. Cut hole to the process tube. Hole must be same size that reducer inside diameter 3. Edges of the hole must be ground smooth. 4. Set the installation cone in its place and weld it to the process tube. 60 mm 2.5mm 2.36" 0.1"

4mm 2.5mm 0.2" 0.1" B

Tt asiakirjaa ei saa ilman meidn lupaamme jljent. Sit ei myskn saa esitt toiselle tai muutoin asiattomasti kytt. (c) Kajaanin Prosessimittaukset Oy. 2002

Illustration of sensor element position. a4

90 +0.5 -0.5

B-B CROSS-SECTIONAL VIEW of KC/5 installation. Material KAJAANI PROCESS MEASUREMENTS Ltd Treatment Title KC/5 Installation Cone Welding Instructions Tolerance Scale 1:4 Prepd 17.05.2004JHe Drawing No. E41040264 V1.0

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Appendix 2: BTG weld-in stud adapter and flange dimensions

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Appendix 3: Assembly drawings and parts lists Appendix 3.1.: Standard Installation Cone, PN10 Gate Valve
6

17

12

10 8

3 11 7 14 13 1

9 15

18

4 5

16

16 2

Item Part No. 1 2000046 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2000096 2000097 2450004 2450005 2600008 2700011 2700012

Vers.

Description Hex Screw Screw, Socket Head Cap Hex nut Double-nipple Ball valve, Reduced bore Knife Gate Valve O-ring O-ring Installation Cone Mounting Flange, SS Insertion Housing, SS Flange Bolt Lock Ring Brake Sleeve Flange Guide Ring Housing Guide Ring Guide Bolt Flange Gasket

Value Device Code M8-70 DIN 931 A4 M8x45 DIN 412 A4 M16 DIN 934 A4 R 1/4 Aisi316 DIN 2990 R 1/4 Aisi 316 (onninen 2017k) Fabri C67S316EBU ANSI 125/150-3" Aisi 316 69.85x3.53 FPM 80x5 FPM

Qty Unit 2 pcs 7 4 1 1 1 3 1 1 1 1 4 1 1 1 2 4 2 pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

E41040185 V1.0 H31040129 V1.0 H31040130 V1.0 H41040128 V1.0 H41040131 V1.0 H41040132 V1.0 H41040134 V1.0 H41040135 V1.0 H41040140 V1.0 H41040160 V1.0

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Appendix 3.2.: Standard Installation Cone, PN16 Gate Valve

18

12

10 8

3 11 7 14 13 1

9 15

17

4 5

16

16 2

Item Part No. 1 2000046 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2000096 2000097 2450004 2450005 2600011 2700011 2700012

Vers. Hex Screw

Description Screw, Socket Head Cap Hex nut Double-nipple Ball valve, Reduced bore Knife Gate Valve, handw. operated SS O-ring O-ring Installation Cone Mounting Flange, SS Insertion Housing, SS Flange Bolt Lock Ring Brake Sleeve Flange Guide Ring Housing Guide Ring Flange Gasket Guide Bolt

Value Device Code M8-70 DIN 931 A4 M8x45 DIN 412 A4 M16 DIN 934 A4 R 1/4 Aisi316 DIN 2990 R 1/4 Aisi 316 (onninen 2017k) metal seat, wafer PN16 DN 80 69.85x3.53 FPM 80x5 FPM

Qty Unit 2 pcs 7 4 1 1 1 3 1 1 1 1 4 1 1 1 2 2 4 pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

E41040228 V1.0 H31040129 V1.0 H31040130 V1.0 H41040128 V1.0 H41040131 V1.0 H41040132 V1.0 H41040134 V1.0 H41040135 V1.0 H41040160 V1.0 H41040140 V1.0

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Appendix 3.3.: BTG Adapter, PN10 Gate Valve

6

18 13 10 3 11 7 15 14 1 X 12 12 16 19 4 5 17

2 17

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 X

Part No. 2000046 2000096 2000097 2450004 2450005 2600008 2700011 2700012 H31040233 H31040129 H31040130 H31040223 H41040128 H41040131 H41040132 H41040134 H41040135 H41040140 H41040160 2000123

Vers.

V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0

Description Hex Screw Screw, Socket Head Cap Hex nut Double-nipple Ball valve, Reduced bore Knife Gate Valve O-ring O-ring Installation Flange, BTG, SS Mounting Flange, SS Insertion Housing, SS Flange Gasket, BTG Flange Bolt Lock Ring Brake Sleeve Flange Guide Ring Housing Guide Ring Guide Bolt Flange Gasket Screw, Hex cap

Value Device Code Qty Unit Notes M8-70 DIN 931 A4 2 pcs M8x45 DIN 412 A4 7 pcs M16 DIN 934 A4 4 pcs R 1/4 Aisi316 DIN 2990 1 pcs R 1/4 Aisi 316 (onninen 2017k) 1 pcs Fabri C67S316EBU ANSI 125/150-3" Aisi 316 1 pcs 69.85x3.53 FPM 3 pcs 80x5 FPM 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 4 pcs 1 pcs 1 pcs 1 pcs 2 pcs 4 pcs 2 pcs M8x25 DIN 933 A4 16 pcs Not included in assy

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Appendix 3.4.: BTG Adapter, PN16 Gate Valve

6

18 13 10 3 11 7 15 14 1 X 12 12 16 19 4 5 17

2 17

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 X

Part No. 2000046 2000096 2000097 2450004 2450005 2600011 2700011 2700012 H31040127 H31040129 H31040130 H31040223 H41040128 H41040131 H41040132 H41040134 H41040135 H41040140 H41040160 2000123

Vers.

V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0

Description Hex Screw Screw, Socket Head Cap Hex nut Double-nipple Ball valve, Reduced bore Knife Gate Valve, handw. operated SS O-ring O-ring Installation Flange, BTG, SS Mounting Flange, SS Insertion Housing, SS Flange Gasket, BTG Flange Bolt Lock Ring Brake Sleeve Flange Guide Ring Housing Guide Ring Guide Bolt Flange Gasket Screw, Hex cap

Value Device Code M8-70 DIN 931 A4 M8x45 DIN 412 A4 M16 DIN 934 A4 R 1/4 Aisi316 DIN 2990 R 1/4 Aisi 316 (onninen 2017k) metal seat, wafer PN16 DN 80 69.85x3.53 FPM 80x5 FPM

M8x25 DIN 933 A4

Qty Unit Notes 2 pcs 7 pcs 4 pcs 1 pcs 1 pcs 1 pcs 3 pcs 1 pcs 1 pcs 1 pcs 1 pcs 1 pcs 4 pcs 1 pcs 1 pcs 1 pcs 2 pcs 4 pcs 2 pcs 16 pcs Not included in assy

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Appendix 3.5.: Standard Installation Cone, PN25

Item 1 2 3 4 5 6 7 8 9 10 11

Part No. 2000088 2000097 2000149 2700011 E31040234 E41040236 H41040235 H41040239 H41040240 H41040279 H41040285

Vers. Hex Screw Hex nut

Description

Value Device Code M16-80 DIN 931 A4 M16 DIN 934 A4 M5x25 DIN 7991 A4 69.85x3.53 FPM

Qty 8 8 4 3 1 1 1 1 1 2 4

Unit pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

Screw, Slotted Head Cap O-ring V1.3 V1.0 V1.0 V1.0 V1.0 V1.0 V1.0 Insertion Housing PN25, STD, SS Installation Cone PN25, STD, SS Flange Gasket PN25, STD, SS Housing Guide Ring Front Insertion Guide Ring Rear Fastening Support Block PN25 Fastening Bolt

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Appendix 3.6.: BTG Adapter, PN25

Item 1 2 3 4 5 6 7 8 9

Part No. 2000001 2000149 2700011 E31040247 H31040286 H41040239 H41040240 H41040279 H41040285

Vers.

V1.0 V1.0 V1.0 V1.0 V1.0 V1.0

Description Hex Screw Screw, Slotted Head O-ring Insertion Housing PN25, STD, SS Flange Gasket, BTG, PN25 Housing Guide Ring Front Insertion Guide Ring Rear Fastening Support Block PN25 Fastening Bolt

Value Device Code M10-50 DIN 933 A4 M5x25 DIN 7991 A4 69.85x3.53 FPM

Qty Unit 16 pcs 4 pcs 3 pcs 1 pcs 1 pcs 1 pcs 1 pcs 2 pcs 4 pcs

Notes Not included in assy

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Appendix 3.7.: Sensor Front Assembly, PN16 SS

Sensor Front Assembly, PN16 SS
1 7 16 14 5 3 6 13 2 15 7

1 12 10 9 11

17

1 6

14

1 3

15

12

10

9 1 1

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No. 2000036 2000106 2000114 2000129 2650004 2650005 2650006 2650007 2700010 2700013 E31040153 H41040118 H41040119 H41040158 H41040182 H41040188 H41040244

Description Screw,Slotted cheese head Set Screw Lock Ring Screw, Slotted cheese head Bellows Seal Stationary Ring Bellows Seal Stationary Ring O-ring O-ring Main Assembly Seat Adapter Sealing Cover Protection Rubber Snap Ring Shield Cover Shield Locking Ring

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Appendix 3.8.: Moment shaft and motor assembly

Moment shaft and motor assembly
19 8 9 1 3 2 5 1 1 1 10 18 4

16 17 12

14

1 5 6

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2000093 2000109 2000111 2000112 2100004 2100005 2600007 2650008 2750001 2750002 2750005 2800001 E31040148 E41040145 E41040146 E41040152 H41040038 H41040108 H41040154

Part No.

Description Lock Ring Scerw, Socket Head Cap Screw,Slotted cheese head Scerw, Socket Head Cap Wave Spring Extension Spring 2.0xDu12x46 Cone Clamp Radial Shaft Seal Needle Roller Bearing Thrust Ball Bearing Groove Ball Bearing Rotor Bearing Assembly Drive Disk Assy Moment Disk Assy Body Assembly Lock Cone Moment Shaft Seal Washer

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Appendix 3.9.: ISO-torq Adapter installation

A. Removing the ISO-torq Insertion Spiral Assembly
1. Extract ISO-torq 1000 sensor (4) from the process and close the gate valve (3). 2. Remove the sensor from spiral (5). 3. While gate valve (3) is closed open the bolts (6) holding the spiral in the mounting flange (2) and remove insertion spiral (5). 4. Remove the ISO-torq seal sleeve (1). For more detailed information consult the ISO-torq manual

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B. Installing KC/5 IsoTorq Adapter

Adapter comes preassembled as shown below

1. Insert new flange quide ring (white Teflon ring, H41040288V1.0) into the Iso-torq mounting flange (2).

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2. Bolt the adapter onto the ISO-torq mounting flange. Note direction Insertion Jack mounting holes are horizontal

3. Make sure that Locking Ring is positioned on top of seal sleeve so that the slit in Locking Ring is in 7 oclock position and the tightening bolt in 5 oclock position to have access to the tightening bolt.

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Appendix 4: KC/5 Spare parts Kit ( Recommended Spare Parts)

KC/5 Spare Part Kits Description x x x xx xx xx xx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx Elastic shield Rod Seal Needle Roller Bearing Front seal, Bellows Seal T502, SiC/EPDM Front seal, Stationary Seat C606/25, SiC/EPDM Rear seal, Bellows Seal T502, SiC/FPM Rear seal, Stationary Seat T6/25, SiC/FPMSiC/FPM Optics Board Sensor Board Connection Board AC/DC Power Supply O-ring, Seal sleeve, 69.85x3.53FPM O-ring, Mounting flange, 80x5 FPM Torque brake

Order Code H41040158V1.0 2650016 2750001 2650017 2650005 2650018 2650007 A41040062V1.0 A41040070V1.0 A41040202V2.0 3100003 2700011 2700012 A41040222V1.0 A41040302V1.1 A41040312V1.0 A41040313V1.0

Assebly drawing number App 3.7. part 14 App 3.8. part 8 App 3.8. part 9 App 3.7. part 5 App 3.7. part 6 App 3.7. part 7 App 3.7. part 8

App 3.1. part 7 App 3.1. part 8

x xx

KC/5 Elastic Shield Replacement Kit KC/5 Mechanical Seal Replacement Kit xxx KC/5 Complete Spare part kit

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Appendix 5: Model selection table

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Appendix 6: Technical specifications

SENSOR TYPE OUTPUT SIGNAL BINARY INPUTS Rotating Consistency Transmitter Analog output 4 - 20 mA + HART, (active or passive, selectable) 24 VDC (supplied from DCS), three for built-in calibration curves, one for process stop, one for sample button Alarm output; max 30 VDC, 2A; Opening or closing dry contact Single phase, 84-264 VAC, 47-63 Hz, 2.5 Amp. 10 AT fuse required. Max. 150 W 150 W integrated Direct Drive Servo Motor 1.5 % to 16 % consistency, full range with same sensing element Better than 0.003 % Cs Standard: 16 bar (232 psi). High pressure model 25 bar (362 psi). Gate valve standard 10 bar (150 psi), 16 bar (232 psi) optional

BINARY OUTPUT POWER REQUIREMENTS POWER CONSUMPTION MOTOR MEASURING RANGE SENSITIVITY PRESSURE RATING

PROCESS TEMPERATURE 0 - 100 C (32 - 212 F), 120 C (248 F) with cooling water AMBIENT TEMPERATURE FLOW VELOCITY SEAL COOLING Sensor 0 - 60 C (32 - 140 F), Display unit 0 - 50 C (32 - 122 F) 0 - 5 m/s (0 - 16.4 feet/s) Self-contained seal fluid system; or seal water, R1/8 internal thread (compatible with NPT R1/8) Sensor IP67 (better than NEMA 4X), Display IP65 (NEMA 4X) enclosure. 10 m (30) interconnect cable from Sensor to Display Unit, 20m and 30m optional 75 mm (3") opening with drip-proof gate mechanism; 316L standard. Installation cone fits all pipe diameters of 150 mm (6") and larger, 316L standard, Duplex stainless steel and titanium optional. Wetted parts AISI 316L or Titanium. Sensor unit: 520 x 140 x 180 mm (20.5 x 5.5 x 7), 14.8 kg (32 lbs) Installation assembly: 430 x 560 x 200 mm (17 x 22 x 8), 19 kg (42 lbs) Display Unit: 200 x 300 x 150 mm (7.9 x 11.8 x 5.9), 6 kg (13 lbs) W41040300 V2.2 Page 66 of 66

HOUSING CABLING

GATE VALVE INSTALLATION CONE

SENSOR MATERIAL DIMENSIONS (L*H*W) AND WEIGHTS

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