USER MANUAL

Pulptec™ MEK-2500
Rotating Consistency Transmitter

© BTG Instruments AB M2068/1en

 Disclaimer

The contents of this document are subject to revision without notice due to continued progress in methodology,
design, and manufacturing. BTG shall have no liability for any error or damages of any kind resulting from the use of
this document. © BTG 2008.

BTG Instruments AB
P.O. Box 602
SE-661 29 Säffle
Sweden
Phone: +46 533 426 00
www.btg.com

© BTG Instruments AB
Table of contents

1 Product Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Type Sign Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 Safety Regulations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.2 Safety Regulations for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 CE Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Measuring Vessel/Weld-in Stud Installation . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Measuring Vessel, PN10, Weld-end . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.2 Measuring Vessel, PN10, Flanged-end . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.3 Measuring Vessel, PN25, Weld-end . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.4 Measuring Vessel, PN25, Flanged-end . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.5 Weld-in Stud, PN16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.6 Weld-in Stud, PN25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Mounting of Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.1 Weld-in Stud Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.2 Inspection Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.1 Flushing Water Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.2 External Flow Regulator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.3.1 Connection of Communication Platform. . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.3.2 Connection of Electrical Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
M2068/1en MEK-2500 Table of contents I
© BTG 2008
5 Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.1 Regular Maintenance of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Service Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.1 Calibration Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 MEK-2500 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Sensing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

II MEK-2500 Table of contents M2068/1en

© BTG 2008
 1.1 - General

1 Product Introduction

1.1 General
The MEK-2500 is a versatile consistency transmitter that can be optimized for
many different applications using different components. The transmitter is
suitable for applications throughout the entire process: from the blow line after
the digester, in screening and washing stages, and in the bleach plant through
to the machine chest before the paper machine.
The rotating shear force measuring method means the transmitter is virtually
insensitive to the normal variations such as in fiber composition, freeness,
fillers, black liquor content, flow velocity, air content, and pressure.
The MEK-2500 is an intelligent, microprocessor-based transmitter which is
fully operated using the CPM-1300 communication platform.
Communications with a Distributed Control System are made by means of a
superimposed signal according to a standard HART® protocol.

Fig 1 MEK-2500

M2068/1en MEK-2500 Product Introduction 1

© BTG 2008
 1.2 - Technical Data

1.2 Technical Data

General
Type
MEK-2500 in-line rotating consistency transmitter for pulp suspensions.
Manufacturer
BTG, Säffle, Sweden.
Measuring Principle
Shear force measuring using force balance transducer.
Quality Assurance
Quality-assured in accordance with ISO 9001. Designed in accordance with relevant CE
standards.

Function Specifications
General
Pressure Rating
PN16 / PN25 (16/25 bar at 20°C, 230/360 psi at 68°F) depending on selected transmitter
components
Communication Platform
See separate manual for the CPM-1300 Communication Platform.
User Interface
Illuminated display and keypad on the CPM-1300 Communication Platform.
HART Communication, CPM-1300
Analog Output Signal, CPM-1300
4-20 mA. Galvanically isolated. Current limited to min. 3.9 and max. 20.5 mA.
Loop load signal: Voltage supply/load 24 V DC
Digital Output Signal, CPM-1300
Superimposed signal over 4-20 mA current loop according to , HART® protocol.
Alarm Signal, CPM-1300
Optocoupler output.
Provides alarm signal on drive belt runtime and unstable signal.
Calibration sets, CPM-1300
Four separate calibration sets, individually programmable, and externally connectable using a
binary-coded switch.
2 x optically isolated contact inputs.
Communications, CPM-1300
Keypad and display on the Communication Platform.
Universal HART terminal or PC based AMS software via HART® communication

2 MEK-2500 Product Introduction M2068/1en

© BTG 2008
 1.2 - Technical Data

Process Specifications
Consistency Limits
1 - 16% consistency, depending on type of pulp and sensing element.
Flow Limits
0.5-5 m/s (1.6-16.1 fps)
Process Temperature Limits
Max. 120°C (248°F)
Min. 15°C (60°F)
Ambient Temperature Limits
Max. 60°C (140°F)
Damping
Programmable between 0 and 99 s.

Support System Specifications

Flushing Water
The flushing water must be of standard quality, with no impurities larger than 200 μm.
Recommended flow is 0.5-1.5 l/min (0.13-0.4 gal/min.) Min. 0.5 bar/7.25 psi.
Power Consumption
Max. 200 mA (2 A at start)
Supply Voltage
Built-in multi-voltage power supply. See separate manual for the CPM-1300 Communication
Platform.

Performance Specifications
Repeatability
Better than ± 0.3% of full scale deflection under stable operating conditions.
Time Response
Time constant without electrical damping: < 0.5 s

Physical Specifications
Pipe Size
250 mm (10"): to measuring vessel
300 mm (12"): to weld-in stud
The transmitter can be mounted in a horizontal, vertical or inclined pipe.
Materials
Housing:
Aluminum casting, painted with epoxy/polyurethane.
Wetted parts:
-Stainless steel, equiv. to EN 1.4404/ASTM 316L (Standard)
-Nickel alloy, Hastelloy C-276, Avesta 254 SMO
Electric motor
-Squirrel caged 3-phase motor with special fastening, 0.3 kW, 4-pole, insulation class F,
standard wide-voltage motor.
Degree of Protection
Transmitter: IP 65
Electric motor: IP54
Weight
Transmitter: 36 kg (80 lb)

M2068/1en MEK-2500 Product Introduction 3

© BTG 2008
 1.3 - Dimensions and Mounting

1.3 Dimensions and Mounting

Fig 2 Dimensions and
recommended
clearances

min. 125
5.0"

10.6"
270
min. 500
20"

342 122 Ø270

13.5" 4.8" 10.6"

4 MEK-2500 Product Introduction M2068/1en

© BTG 2008
 1.4 - Type Sign Explanations

1.4 Type Sign Explanations

Fig 3 Type sign
1 2 3 4

TYPE NO
MEK-2500 SSW
WET PARTS MADE OF SENSING ELEMENT
5 EN 1.4404
SPECIFICATION PRESSURE
6 FPM PN16
N1619
7 BTG Instruments AB, Industrigatan 1-3, 661 29 Säffle, SWEDEN

8 9 10 11

1. Transmitter model
2. Mechanical seal code
3. Manufacturing number
BTG internal product identification number.
4. Sensing element
Sensing element part number.
5. Wetted parts made of
EN 1.4404, 254 SMO, or Hastelloy C
6. Rubber quality in wetted parts
FPM (Standard) = Fluorocarbon rubber for pH 1-12.
EPDM = Ethylene Propylene rubber for pH 8-14.
7. Manufacturer
8. Pressure rating
PN16 or PN25
9. CE-marking
The MEK-2500 is approved according to CE directives.
10. C-TIC marking
The MEK-2500 electronics box is approved according to Australian
C-TIC N1619 directives.
11. Warning sign
The device is designed for industrial use. Installation, handling and ser-
vice must only be carried out by trained and authorized personnel and ac-
cording to relevant standards. Read the manual for detailed information
and pay special attention to the warning signs!

M2068/1en MEK-2500 Product Introduction 5

© BTG 2008
 1.4 - Type Sign Explanations

6 MEK-2500 Product Introduction M2068/1en

© BTG 2008
 2.1 - General

2 Safety Instructions

2.1 General
These safety regulations are based on a risk analysis carried out in
accordance with the requirements of relevant CE directives in order to comply
with European standards for CE marking.
In practice, a consistency transmitter is not hazardous in operational mode.
Read these safety regulations before installing the transmitter. Be careful to
follow the safety routines when installing the transmitter, when removing the
unit for service, and when carrying out service. Use warning signs for safety
information!
Mounting parts, such as measuring vessels and weld-in studs, are dealt with in
accordance with the pressure vessel standards of specific countries.
Always take precautions when handling equipment in pressurized pipes.
All installation, operation, service, and other handling must be carried out by
trained and authorized personnel and according to valid standards.

NOTE!
Follow this manual during installation, operation, and service.

For personal and functional safety: Use only parts that have been
manufactured or approved by BTG.

2.2 Conventions
The following conventions are used in this manual:
• DANGER!
A DANGER! admonition is used when there is a hazard with a risk for
injury or possible death to a person.
• WARNING!
A WARNING! admonition is used when there is a risk for damage to
program, device, machine, sampler and so on.
• CAUTION!
A CAUTION! admonition is used when there is a risk for system failure,
service interruption, disturbances to plant operation, a measuring
application and so on.
The admonitions above are hierarchic. A DANGER! admonition includes the
possibility of both a WARNING! and a CAUTION! admonition.

M2068/1en MEK-2500 Safety Instructions 7

© BTG 2008
 2.3 - Safety Regulations

2.3 Safety Regulations

DANGER
2.3.1 Safety Regulations for Installation
CHECK PIPES!
Risk for corrosive, All welding or bolting must take place in accordance with current standards
toxic, or aggressive
liquids or gases and regulations.
with high pressure or
high temperature.
All handling of electrical units must take place in accordance with current
standards and regulations.
DANGER Use approved lifting gear during installation to prevent injury. Ensure that the
Hazardous voltage measuring vessel/weld-in stud and transmitter is anchored solidly during
in the equipment
installation.

DANGER

Crushing

2.3.2 Safety Regulations for Service

DANGER
Hazardous voltage All handling of electrical units must take place in accordance with current
in the equipment
standards and regulations.
If the motor is switched on so that the transmitter rotates, there is risk of injury
by crushing or cutting if the covers have been removed. This applies to the
DANGER cover over the motor’s drive belt wheel, the cover over the measuring part and
the inspection cover. Also take care when working close to the propeller and
Crushing the sensor if these are exposed.
Take every professional precaution before servicing. Do not wear gloves or
rings which may get caught!

DANGER Before removing the transmitter from the measuring chamber or opening the
inspection cover, check carefully that the line is empty. Hot or corrosive
Cutting liquid flowing out under pressure may cause serious chemical burn
injuries!
Take care when opening the cover of the communication platform with built-in
power supply unit. This contains live parts which may cause electric
DANGER shocks. Live parts are protected against normal contact provided that the
CHECK PIPES! connections are made correctly.
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or
When the transmitter is exposed to dangerous basic or acidic corrosive media,
high temperature. it should be removed from the pipeline regularly for inspection. Replace any
damaged seals. If pressurized parts on the transmitter or weld-in stud have
corroded, check that the material is correct for the application. Leakages may
cause personal injury or damage to equipment due to corrosion or
burning!

8 MEK-2500 Safety Instructions M2068/1en

© BTG 2008
 2.4 - CE Declaration

2.4 CE Declaration
When using the units in combinations other than those tested for, BTG can not
guarantee CE directive conformity.
The units in combination with customer-installed external devices may conform
with EMC and safety requirements when properly installed and CE-marked
equipment is used.
The system operator is responsible for CE directive conformity.
Conformity must be verified by inspection.

CE Declaration of Conformity

According to EN 45014

Manufacturer’s Name BTG Instruments AB

Manufacturer’s Address P.O. Box 602 S- 661 29 SÄFFLE, Sweden
declares that the product:
Product Name Consistency Transmitter
Model Numbers MEK-2400/2500
complies with the amendments and Machinery Directive 2006/42/EC
requirements of the: Low Voltage Directive 2006/95/EC
EMC Directive 2004/108/EC
PED Directive 97/23/EC
RoHS 2002/95/EC
WEEE 2002/96/EC

and conforms with the following product

standards and PED conformity assessment
procedure
Safety EN ISO 12100-1

LVD EN 61010-1

EMC EN 61000-6-2: 99
EN 61000-6-4: 04

PED Pressure accessory for piping

in accordance to:
Guideline related to Article 1, 2.1.4
Accepted by WPG on:
1998-11-26
Accepted by Working Group "pressure" on:
1999-01-28
Must not bear CE-marking
CRN 0H08616.2 acc. to ASME VIII div.1
WEEE -n.a.-, not Annex 1
RoHS/ ACPEIP -n.a.-

Quality System ISO 9001

monitored by
Lloyd’s Register Quality Assurance
Säffle, January 2008

Anders Hjort, MD

M2068/1en MEK-2500 Safety Instructions 9

© BTG 2008
 2.4 - CE Declaration

10 MEK-2500 Safety Instructions M2068/1en

© BTG 2008
 3.1 - Unpacking

3 Installation Instructions

3.1 Unpacking

1. 1 x Smart Rotating Consistency Transmitter, MEK-2500

2. 1 x Mounting kit (not shown)
3. 1 x User manual (not shown)

M2068/1en MEK-2500 Installation Instructions 11

© BTG 2008
 3.2 - Measuring Vessel/Weld-in Stud Installation

3.2 Measuring Vessel/Weld-in Stud Installation

3.2.1 Measuring Vessel, PN10, Weld-end

1 2 3
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or 1150 mm
high temperature. (45.3")

DANGER
Use protective
clothing

4 5

B
1150
45.3"

475 675
18.7" 26.6"

A. Measuring vessel with weld-ends, left-hand design (standard).

B. Measuring vessel with weld-ends, right-hand design (on request).

12 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.2 - Measuring Vessel/Weld-in Stud Installation

3.2.2 Measuring Vessel, PN10, Flanged-end

1 2
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
1150 mm
with high pressure or
high temperature. (45.3")

DANGER
Use protective
clothing

B
1150
45.3"

475 675
18.7" 26.6"

A. Flanged measuring vessel, left-hand design.

B. Flanged measuring vessel, right-hand design.

M2068/1en MEK-2500 Installation Instructions 13

© BTG 2008
 3.2 - Measuring Vessel/Weld-in Stud Installation

3.2.3 Measuring Vessel, PN25, Weld-end

1 2 3
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or 530 mm
high temperature. (45.3")

DANGER
Use protective
clothing

4 5

3.2.4 Measuring Vessel, PN25, Flanged-end

1 2
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or 600 mm
high temperature. (23.6")

DANGER
Use protective
clothing

14 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.2 - Measuring Vessel/Weld-in Stud Installation

3.2.5 Weld-in Stud, PN16

1 2 3
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or D= 309 mm
high temperature.
(12.2")

NOTE!
The M-measurement is measured from the inside of the pipe (step 5 in figure
below). It is determined in advance and may be either 70 or 150 mm
(consistency, < 4% = 150, > 4% = 70).
In installations where M=70 mm and the pulp is unscreened, deflectors must
be installed in the pipe according to section 3.3.1 on page 17, before
proceeding with step 4.

4 5 6
DANGER
Use protective M
clothing

7 8 9

10 X 11

X=Y=M

M2068/1en MEK-2500 Installation Instructions 15

© BTG 2008
 3.2 - Measuring Vessel/Weld-in Stud Installation

3.2.6 Weld-in Stud, PN25

1 2 D1 3
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or D1=200-250 mm Þ D2=146.3 mm
high temperature.
D2 D1³300 mm Þ D2=220mm

NOTE!
The M-measurement is measured from the inside of the pipe (step 4 in figure
below). It is determined in advance and may be either 70 or 150 mm
(consistency, < 4% = 150, > 4% = 70).
In installations where M=70 mm and the pulp is unscreened, deflectors must
be installed in the pipe according to section 3.3.1 on page 17, before
proceeding with step 4.

4
DANGER
M
Use protective
clothing

M=70mm

5 6
A 45°

A 1mm
(0.04")

1.5 mm
(0.06")

7 8
X

X=Y=M

16 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.3 - Mounting of Optional Accessories

3.3 Mounting of Optional Accessories

3.3.1 Weld-in Stud Deflector

DANGER 1 2 3
32 mm
Use protective
clothing
A (1.3")

92 mm
(3.6")

60 mm
(2.4")
30 mm
(1.2")

4 5 B 6

B=32 mm (1.3")

M2068/1en MEK-2500 Installation Instructions 17

© BTG 2008
 3.3 - Mounting of Optional Accessories

3.3.2 Inspection Cover

1 2
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases D= 157 mm
with high pressure or (6.2")
high temperature.

DANGER
Use protective
clothing

3 4 5

10 mm
min 6 mm (0.4")
(0.24")

6 7

18 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.4 - Mounting Instructions

3.4 Mounting Instructions

Tools required:

Block wrench

1 2

15x

M2068/1en MEK-2500 Installation Instructions 19

© BTG 2008
 3.5 - Connection Instructions

3.5 Connection Instructions

3.5.1 Flushing Water Connection

NOTE!
The flushing water must be of standard quality, with no impurities larger than
200 μm. Recommended flow is 0.5-1.5 l/min (0.13-0.4 gal/min.) Min. 0.5 bar/
7.25 psi. It is recommended to use an external flow regulator for the seal water,
see section 3.5.2: External Flow Regulator Connection.

1
A

High (> 120°C) Water flow 0.95 l/min

media temp
A
Water coupling
with internal
flow regulator Normal (< 120°C)
media temp Water flow 0.5 l/min

A
G 1/4"

D $12 mm B

0.9-9 bar
D (13-130 psi)

20 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.5 - Connection Instructions

3.5.2 External Flow Regulator Connection

NOTE!
The flushing water must be of standard quality, with no impurities larger than
200 μm. Recommended flow is 0.5-1.5 l/min (0.13-0.4 gal/min.) Min. 0.5 bar/
7.25 psi. It is recommended to use a flow regulator for the seal water, see
figure below.

BTG seal water control unit

1.75 0.5 0.25

Flow Unit

1.75 0.5 0.25

Flow Unit

D $12 mm

0.9-9 bar
(13-130 psi)

D To Seal
(0.5 - 0.95 L/min)

G 1/4"

0.9-9 bar
(13-130 psi)

M2068/1en MEK-2500 Installation Instructions 21

© BTG 2008
 3.5 - Connection Instructions

3.5.3 Electrical Connections

3.5.3.1 Connection of Communication Platform

22 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 3.5 - Connection Instructions

3.5.3.2 Connection of Electrical Motor

DANGER 1 2
Hazardous voltage Motor
in the equipment rotation
direction

Motor supply cable:

4x1.5 mm2 (4x AWG14)
(Shield is not required)

3
Suggested connection of
the transmitter motor

1 Transmitter
2 From the pump control
circuit
3 Contact for motor
protection and control
device for manual run in
junction box
4 Auto/Manual switch
5 Safety switch

M2068/1en MEK-2500 Installation Instructions 23

© BTG 2008
 3.5 - Connection Instructions

24 MEK-2500 Installation Instructions M2068/1en

© BTG 2008
 -

4 Operating instructions

For operating instructions, see the CPM-1300 operation manual.

Commissioning instructions are found in the MEK-2500 specific chapter of the
CPM-1300 operation manual.

M2068/1en MEK-2500 Operating instructions 25

© BTG 2008
 -

26 MEK-2500 Operating instructions M2068/1en

© BTG 2008
 5.1 - Maintenance Recommendations

5 Service Instructions

5.1 Maintenance Recommendations

5.1.1 Regular Maintenance of the Transmitter

Maintenance needs will depend on the transmitter position, media influence,
and ambient conditions.
Regular maintenance includes:
• Weekly inspection of flushing water and possible leakage.
• Semi-annual inspection of transmission belt condition.
• Semi-annual inspection of wetted rubber details and metal parts for
damage, if exposed to aggressive chemicals.
Long-term maintenance includes:
• Replacement in transmission of pulley and belt recommended after 10
years operation.
• Replacement of motor ball bearings recommended after 10 years of
operation.
• Cleaning/lubrication or replacement of rotating ball bearings of drive unit
and measuring unit (two for the drive shaft, one for the moment shaft)
recommended after 10 years of operation.
• Replacement of mechanical seal typically after 5 years operation,
depending on operating conditions.

M2068/1en MEK-2500 Service Instructions 27

© BTG 2008
 5.2 - Service Actions

5.2 Service Actions

For Service Kits shown in Parts List, see separate manuals.

28 MEK-2500 Service Instructions M2068/1en

© BTG 2008
 5.3 - Trouble Shooting

5.3 Trouble Shooting

Symptom Probable Cause Solution

1. No or erroneous signal 1.1. Basic check Make sure that the process is working as
usual and pulp is flowing in the pipe.

Make sure that power is supplied to the

communication platform and the motor.

1.2. The motor is not running Remove the cover on the power input at the
motor and check the voltage. If power are
correctly supplied, the motor is faulty and must
be changed.

1.3. Other electrical error Remove the back cover of the transmitter to
expose the brake wheel and the optical card,
and also remove the sensor card cover.
Perform the checks below to attempt to
identify and correct the error.

Check that the yellow LED4 on the sensor

card is lit and that the illumination changes
while braking the transmitter by hand.
If this is not the case, check the wiring
between the sensor card and optical card. If
that does not help, change the optical card.

If the problem still remains contact BTG

Service for further assistance.

Measure between test point TP2 (+5V) and

TP0 (GND) on the sensor card. The voltage
should be 5 ± 0.5 VDC.
If this is not the case, change the optical card.

2. Output signal varies with 2.1. The transmitter is not mounted Check the installation with reference to the
changes in flow according to instructions. It may Installation Engineering Guide. Note the
be installed at a point where the length of the turbulence damping zone after
pulp suspension is layered, and the pump and check that the length of the
the layering may vary with the connection piece is suitable for the
rate of flow. consistency.

2.2. Torque shaft not properly The transmitter needs to be taken out of the
located, changes position with line and tested in a pressurized, water-filled
pressure fluctuations caused by test vessel. Contact BTG Service for further
changes in flow. assistance.

2.3. Position of torque wheel may Contact BTG Service for assistance.
change somewhat when
pressure changes.

3. The transmitter is 3.1. Wrong sensing element used Change the sensing element to a larger
insensitive to consistency model.
variations If the problem still remains contact BTG
Service for further assistance.

4. The feedback signal is too 4.1. Wrong sensing element used Change the sensing element to a smaller
high (higher than the max model.
FB value), which causes the
output signal to saturate

M2068/1en MEK-2500 Service Instructions 29

© BTG 2008
 5.3 - Trouble Shooting

Symptom Probable Cause Solution

5. The output signal is 5.1. The time constant is too short Increase damping until signal stabilizes.
unstable
5.2. Heavy vibrations in the pulp line Take steps as soon as possible to cure
is causing signal drift. The end vibration in the line.
position stops are abnormally
worn.

6. The output signal is 6.1. The setpoint value is incorrect. Contact BTG Service for assistance.
unstable after change of
optical card or sensor card

7. Unstable signal level 7.1. The elastic seal between the Contact BTG Service for assistance.
drive torque shafts has been
ruined.

7.2. Torque shaft bearings Contact BTG Service for assistance.

damaged by mechanical force
or corrosion.

8. Mechanical seal: Cracked 8.1. Misalignment between fixed Change the mechanical seal.
metal bellows seat and rotating part. Contact BTG Service if this symptom returns
in the immediate future.

9. Mechanical seal: Deep 9.1. The seal may have run dry, and Change the mechanical seal.
grooves worn in the seat particles may have been
rings trapped between the seat
surfaces as a result of careless
assembly or excess internal
pressure. Grooves can also be
caused by long-term normal
operational wear.

10. Mechanical seal: Irregular 10.1. The seat is not aligned Change the mechanical seal.
wear marks on seat rings

11. Mechanical seal leaks 11.1. Sealing surfaces damaged due Change the mechanical seal.
to dry running.

11.2. Flushing water supply blocked Install a water filter.

by badly contaminated water. NOTE! Must be cleaned regularly.

30 MEK-2500 Service Instructions M2068/1en

© BTG 2008
 5.3 - Trouble Shooting

5.3.1 Calibration Trouble Shooting

Typical errors in single point calibration

Symptom Probable Cause Solution

1. Calibration lacks precision 1.1. Sample 1 (Feedback in water) Activate sample 1 and perform a new lab
is not activated. The calibration calibration. For instructions, see the CPM-
line is drawn between 0% FB 1300 Operation Manual.
and the single sample.

2. The measurement has a 2.1. The process consistency If consistency can vary, it is recommended
poor correlation to lab deviates too much from the that additional samples, that cover the entire
samples value of the singel sample, calibration range, are added, and a new lab
which reduces the accuracy. calibration are performed. For instructions,
see the CPM-1300 Operation Manual.

Typical errors in multi point calibration

Symptom Probable Cause Solution

1. Calibration lacks precision 1.1. Bad sampling equipment. Check the sampling equipment and quality of
due too low correlation sampling methods. This is the most common
factor (wide scatter of reason for lack of precision in a calibration
calibration points round
calibration line) 1.2. A few bad samples reduces the Identify calibration samples that deviate too
precision of the calibration. much from the lab values, and deactivate
them. Perform a new calibration and make
sure that the correlation factor exceeds 0.7

1.3. The setpoint value of the Empty the line and check the that Feedback in
feedback systemly controller is air value is within 10-20% (with sensor,
incorrectly adjusted. propeller and mechanical seal mounted). If
not, the setpoint value must be adjusted.
Contact BTG service assistance.

2. Calibration lacks precision 2.1. To few samples used in the Take additional calibration samples, and
outside normal working calibration, or a the samples make sure they cover as much as possible of
range covers a to narrow consistency the measuring range.
span.

M2068/1en MEK-2500 Service Instructions 31

© BTG 2008
 5.3 - Trouble Shooting

32 MEK-2500 Service Instructions M2068/1en

© BTG 2008
 6.1 - MEK-2500 Service Kits

6 Parts List

6.1 MEK-2500 Service Kits

Rec.
Item
spare Qty Part No. Service kits Description
No.
parts
1 * 1 B0020107 Mechanical Seal Kit John Crane, CAP20/FKM
* 1 B0020115 Mechanical Seal Kit John Crane, CAP20/EPDM
* 1 B0020123 Mechanical Seal Kit Eagle, CAP20/FKM
* 1 B0020131 Mechanical Seal Kit Roplan, 316L/FPM, SS
* 1 B0020149 Mechanical Seal Kit Roplan, 316L/FPM, Hastelloy
* 1 B0020156 Mechanical Seal Kit Roplan, 316L/FPM, SMO 254
* 1 B0020164 Mechanical Seal Kit Roplan, 316L/EPDM
2 1 B0020081 Drive Belt Kit Viton
1 B0020099 Drive Belt Kit EPDM
3 * 1 B0020172 Temporary Drive Belt Kit
4 1 B0020180 Mounting Kit Nitril
1 B0020206 Mounting Kit Viton,
1 B0020222 Mounting Kit EPDM
1 B0020198 Mounting Kit, High Pressure Nitril
1 B0020214 Mounting Kit, High Pressure Viton
1 B0020230 Mounting Kit, High Pressure EPDM
5 1 B0020248 Sensing Element Bolt Kit SS
1 B0020255 Sensing Element Bolt Kit Hastelloy & SMO 254
6 1 B0020263 Electric Motor Kit 346 V
1 B0020271 Electric Motor Kit 380-415 V
1 B0020289 Electric Motor Kit 500-550 V
1 B0020297 Electric Motor Kit 660-725 V
1 B0020305 Electric Motor Kit 380-415 V, CSA
1 B0020313 Electric Motor Kit 500-550 V, CSA
7 1 B0020321 Drive Belt Wheel Kit
8 1 B0020339 Drive Belt Cover Kit
9 1 B0020974 Sensor Card Kit
10 1 B0020354 Optical Card Kit
11 1 35011089 Seal water contorl unit See section 3.5.2 on page 21

M2068/1en MEK-2500 Parts List 33

© BTG 2008
 6.2 - Sensing Elements

6.2 Sensing Elements

Basic Characteristic
Type Part No shape/diam. Material

A 73198806 EN 1.4404
73194444 SS 2343 + Rubber
73198871 Hastelloy C

" m
A0004879 254 SMO

8.3 10 m
2
B 73198814 EN 1.4404
13194451 SS 2343 + Rubber
13274808 m METCO 130
73198889 5m Hastelloy C
18 .3 "
A0004887 7 254 SMO

C 73198822 EN 1.4404
13194469 SS 2343 + Rubber
73198897 Hastelloy C
A0004895 254 SMO
120
4.7"
G 74359761 EN 1.4404
74359845 Hastelloy C
A0006338 254 SMO
150
6"

H 74359779 EN 1.4404
74359852 Hastelloy C
A0006346 125
254 SMO
5”
I 74359787 EN 1.4404
74359860 Hastelloy C
A0006353 100 254 SMO
4"
J 74359795 EN 1.4404
74359878 Hastelloy C
A0006361 254 SMO
80
3.5"

34 MEK-2500 Parts List M2068/1en

© BTG 2008