Manul de Usuatio BTG TCR-25XX TCT-25X1 RET-25X2

USER MANUAL
TCR-25X1 / TCR-25X2 / TCT-25X1 / RET-25X2

Total Consistency Transmitter
BTG Instruments AB
M2072/3en
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 2011.
Original Instructions
BTG Instruments AB
P.O. Box 602
SE-661 29 Sffle
Sweden
Phone: +46 533 426 00
www.btg.com
BTG Instruments AB
Table of contents
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
Product Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1
1.2
1.3
1.4
1.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Type Plate Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CE Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.4.1
2.4.1.1
2.5
2.5.1
2.5.1.1
2.5.1.2
2.5.1.3
2.5.1.4
2.5.1.5
2.5.1.6
M2072/3en
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking, Sluice Valve Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking, Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Welding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Welding Instructions, Sluice Valve Variant. . . . . . . . . . . . . . . . . . . . . . . 15
Welding Instructions, Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . 17
Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sensor Electronics Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measuring Gap Angle Adjustment, Sluice Valve Variant . . . . . . . . . . . . 20
Mounting the Probe, Sluice Valve Variant . . . . . . . . . . . . . . . . . . . . . . . 22
Mounting the Probe, Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . . 24
Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connection of Communication Platform. . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PCD-1000 Probe Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions and Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . 26
Measuring Gap angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Welding and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Water Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Table of contents

BTG 2011
Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1
3.1.1
3.2
3.2.1
3.2.1.1
3.2.1.2
3.2.2
3.2.3
3.2.3.1
3.2.3.2
3.2.3.3
3.2.4
3.2.4.1
3.2.5
3.3
Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1
4.2
4.2.1
II
Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Regular Maintenance of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . 35
Service Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removing the Transmitter from the Pipe . . . . . . . . . . . . . . . . . . . . . . . . 36
Sluice Valve Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Weld-in Stud Variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Changing O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Changing Probe with Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Disassembling the Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembling the Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LED Intensity Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removing the Electronics Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembling the Sensor Electronics Box . . . . . . . . . . . . . . . . . . . . . . . . 44
Reinstalling the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PCD-1000 Probe Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Table of contents

BTG 2011
M2072/3en
Important Information
This user manual contains all necessary instructions for installation,
maintenance, and basic service of the transmitter.
Safety instructions and regulations for installation and service are found in the
BTG Safety Manual, M2076.
NOTE!
Always read the safety instructions before installation and service of the
transmitter!
The transmitter is operated using the CPM communication platform. For
operation instructions, see the CPM operation manual, OM2006 for TCR,
OM2009 for TCT. Commissioning instructions are found in the transmitter
specific chapter of the CPM operation manual.
M2072/3en
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502

BTG 2011
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502

BTG 2011
M2072/3en
1.1 - General
Product Introduction
1.1 General
TCR
The TCR PeakTotal is a true total consistency transmitter, it is thus virtually
insensitive to variations in filler and fines content as well as changes in fiber
properties.
TCR is available in versions with one output (TCR-25x1) and with two outputs
(TCR-25x2). The second output can for example be calibrated for ash.
Based on BTGs patented Peak method for optical analysis PeakTotal covers
total consistencies in the range of 0.5 to 10%.
The transmitter is mounted in-line close after the pump and provides real time
results. The PeakTotal is available in a retractable standard version
(TCR-250x) and a light version (TCR-251x) to use when retraction system is
not needed which combines lean design with top functionality and quick ROI.
The probe is unique low-maintenance probe, without electronic components
attached which makes the transmitter insensitive to variations in temperature
and vibration.
Fig
1 TCR-251x
Fig
2 TCR-250x
M2072/3en
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

BTG 2011
1.1 - General
TCT-2501
BTG's TCT-2501 PeakOne is an in-line transmitter for measuring total
consistency of pulp suspensions in the range 0.01-3%. It measures the large
and fine particles individually and can because of that deliver an accurate total
consistency value independently of variation in fiber, fines or ash. The pulp
brightness or color does not affect the measurement.
The transmitter is mounted in-line without any special bypass arrangement
and provides real time results. The PeakOne is available in a retractable
standard version (TCT-2501) and a light version to use when retraction system
is not needed (TCT-2511) which combines lean design with top functionality
and quick ROI. The PeakOne has a unique low-maintenance probe, without
electronic components attached which makes the transmitter insensitive to
variations in temperature and vibration.
Fig
3 TCT-2501
Fig
4 TCT-2511

BTG 2011
M2072/3en
1.1 - General
RET-2502
BTG's RET-2502 PeakTwo is an in-line transmitter for measuring ash and total
consistency of pulp suspensions in the range 0.01-3%. It can easily be
calibrated to secure stable and accurate ash consistency based on laboratory
ash determination. Ash and total consistency values are independent of
variation in pulp brightness or color.
The transmitter is mounted in-line without any special bypass arrangement
and provides real time results. The PeakTwo is available in a retractable
standard version (RET-2502) and a light version to use when retraction system
is not needed (RET-2512) which combines lean design with top functionality
and quick ROI. The PeakTwo has a unique low-maintenance probe, without
electronic components attached which makes the transmitter insensitive to
variations in temperature and vibration.
Fig
5 RET-2502
Fig
6 RET-2512
M2072/3en

BTG 2011
1.2 - Technical Data
1.2 Technical Data

General
Type
In-line smart optical total consistency transmitter for pulp suspension.
Manufacturer
BTG, Sffle, Sweden
Measuring Principle
Peak Method using 880 nm light.
For TCR performed by reflection.
For TCT/RET performed by transmission.
Quality Assurance
Quality-assured in accordance with ISO 9001. Designed in accordance with relevant CE
standards.
Product Safety
According to IEC 61010.
Fulfills all relevant electrical product safety requirements and is labelled and listed for:
European CE, Australian
, US/Canada ETL (Edison Technical Laboratories).
Function Specifications
Output Signal
Total consistency in %, mg/l, or g/l
Ash consistency in %, mg/l, or g/l (TCR-25x2 and RET-25x2 only)
User Interface
Illuminated display and keypad on the CPM
Alarm function
Provides alarm signal on low and high consistency level, unstable signal
Calibration Sets
Four separate calibration sets, individually programmable, and externally controllable using a
binary-coded switch
Communication Platform
For information about the communication platform, including input and output signals, see
separate user manual for the CPM, M2066.

BTG 2011
M2072/3en
Process Specifications
Pressure Rating
PN16 (16 bar at 20C, 230 psi at 68F)
Consistency Limits
TCR-25xx:
TCR-25x2
0.5 - 10 % pulp consistency

0 - 10 % ash consistency
TCT-25x1:
0.01 - 3.00 % total consistency
RET-25x2:
0.01 - 3.00 % total consistency

0.01 - 2.00 % ash consistency
Flow Limits
TCR:
TCT / RET:
1.3 - 5 m/s
1.5 - 5 m/s
Process Temperature Limits

Max. 120 C [248 F]
Min. 5 C [16 F]
Ambient Temperature Limits
Probe
Max. 80 C [176 F]
Electronics:
Max. 50 C [122 F]
Damping
0 - 99 s
Support System Specifications

Supply Voltage
100-240 10% V AC, 50/60 Hz, Single phase to CPM
Supplied with 24 V DC from the CPM
Power Consumption
Max 50 VA, a 2A slow blow fuse must be used
Performance Specifications
Repeatability
0.002 %Cs
M2072/3en

BTG 2011
Physical Specifications
Mounting
Min. pipe diameter:
100 mm [4"] (TCR-250x / TCT-25x1 / RET-25x2)

80 mm [3.2] (TCR-251x)
Materials
Wetted parts:
Stainless steel, EN 1.4404, equiv. to ASTM 316L
Sensor electronics box: Painted aluminum
Degree of Protection
Equivalent to IP65, NEMA 4x
Connection
Optical connection between probe and sensor electronics box, 5 m [16 ft].
Weight
Transmitter, TCR-250x:
Transmitter, TCR-251x:
3.1 kg [6.8 lb]

1.0 kg [2.2 lb]
Transmitter, TCT-2501:
Transmitter, TCT-2511:
3.4 kg [7.5 lb]

1.3 kg [2.9 lb]
Transmitter, RET-2502:
Transmitter, RET-2512:
3.4 kg [7.5 lb]

1.3 kg [2.9 lb]
Sluice valve:
4.0 kg [8.9 lb]
Sensor electronics box: 0.3 kg [0.7 lb]
LED product
Class 1
According to IEC/EN 60825-1
Wavelength: 880 nm (invisible light)

BTG 2011
M2072/3en
1.3 - Dimensions and Mounting
1.3 Dimensions and Mounting

Fig
7 Dimensions and
clearances
Transmitter, sluice valve variant
Transmitter, weld-in stud variant
Min 300
12"
100
4"
300
12"
200
8"
155
6.1"
338
13.3"
Min 100
4"
Min 100 / 4" (TCT / RET)

Min 80 / 3.2" (TCR)
108
4.3"
50
2"
250
10"
90
3.5"
46
1.8"
4.5
0.2"
23
0.9"
90
3.5"
126
5"
9
0.4"
19
0.7"
M2072/3en
114
4.6"
101.5
4"
13
0.5"
250
10"
52
2"
25
1"
Sensor electronics box

BTG 2011
1.4 - Type Plate Explanations
1.4 Type Plate Explanations

Fig
8 Type sign
BTG Instruments AB
Industrigatan 1-3
66129 Sffle
SWEDEN
TCT-2501/SS/EP/15/5
12345678
LED PRODUCT
Class 1
TYPE
4
5
NO
6
1. Manufacturer
2. Warning sign
The device is designed for industrial use. Installation, handling and
service must only be carried out by trained and authorized personnel and
according to relevant standards. Read the manual for detailed information
and pay special attention to the warning signs!
3. Transmitter Model and Variants
The transmitter model and variant is specified according to the code
system explained below:
TCT-2501/SS/EP/15/5
A
BC D
F G
Transmitter Model
TCR-25
TCT-25
Sluice valve variant
Weld-in stud variant
Output signals
One output
One output
N/A
Two outputs
N/A
Two outputs
D
SS
Wetted Part Material

Stainless Steel, EN
1.4404
E
EP
Stainless Steel, EN
1.4404
Stainless Steel, EN
1.4404
Rubber Material
EPDM
EPDM
EPDM
Measuring Gap Size
15
N/A
Gap size 1.5 mm
Gap size 1.5 mm
30
N/A
Gap size 3.0 mm
Gap size 3.0 mm
G
5
10
RET-25
Mounting variant
Fiber length
Standard length, 5 meter

BTG 2011
M2072/3en
1.4 - Type Plate Explanations
4. Manufacturing number
BTG internal product identification number.
5. LED Product Class
Only applicable for transmitter type TCR-25xx.
6. CE-marking
The Transmitter is approved according to CE directives.
M2072/3en

BTG 2011
11
1.5 - CE Declaration
1.5 CE Declaration
When using the units in other combinations 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 17050-1:2005
Manufacturers Name
Manufacturers Address
declares that the product:
Product Name
Model Number
complies with the amendments and

requirements of the:
BTG Instruments AB
P.O. Box 602 S- 661 29 SFFLE, Sweden
Total Consistency Transmitter
TCR-2501/-2511 alt. with
FCM-8000/FCI-1000/HCM-8000 modules
TCR-2502/-2512 alt. with
TCT-2501/-2511 alt. with
RET-2502/-2512 alt. with
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- 2 nd ed.
EMC
EN 61000-6-2: 99/ EN 61000-6-4: 04
PED
Pressure equipment for piping.

In accordance to Article 1,
Table 9, art.3 (3), Annex II
(Sound eng. practise)
Must not bear CE-marking
Sluice valve device acc. to ASME
CSA/CRN 0C11058.5
WEEE
RoHS
Quality System
-n.a.-, not Annex 1

compatible
ISO 9001
monitored by
Lloyds Register Quality Assurance
Sffle, September 2010
Bjrn Fahlin, DoO
12

BTG 2011
M2072/3en
2.1 - Unpacking
Installation Instructions
2.1 Unpacking
2.1.1
Fig
Unpacking, Sluice Valve Variant
9 Unpacking, sluice
valve variant
1 1 x Measuring probe
2 1 x Sensor electronics
box
3 1 x Sluice valve
4 1 x Communication
Platform, CPM
5 1 x Blind flange
(optional)
6 1 x PCD-1000 probe
cleaning system
(optional, with probe
pre-mounted)
7 1 x User Manual CD
(not shown)
8 1 x BTG Software
installation CD
(optional, not shown)
9 1 x Communication
cable (optional, not
shown)
3
4
M2072/3en
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Installation Instructions

BTG 2011
13
2.1 - Unpacking
2.1.2
Unpacking, Weld-in Stud Variant
Fig 10 Unpacking, weld-in

stud variant
1 1 x Measuring probe
2 1 x Sensor electronics
box
3 1 x Weld-in stud
4 1 x Coupling
5 1 x O-ring
6 1 x Blind flange
7 Communication
Platform, CPM
8 1 x User Manual (not
shown)
9 1 x BTG CalWin
installation CD
(optional, not shown)
10 1 x Communication
cable (optional, not
shown)
5
4
3
14

BTG 2011
M2072/3en
2.2 - Welding Instructions
2.2 Welding Instructions

2.2.1
Welding Instructions, Sluice Valve Variant
Tools required:
Block wrench, 13 mm
4 x braces (supplied by customer)
DANGER
CHECK PIPES!
Risk for corrosive,
toxic, or aggressive
liquids or gases
with high pressure or
high temperature.
D=45 mm
(1.8")
DANGER
Use protective
clothing
60 mm
(2.4")
60 mm
(2.4")
M2072/3en

BTG 2011
15
10
X=60mm
X=60mm
Y
Y=X
Y=X
11
12
NOTE!
Remove any welding and
grinding beard inside the
pipe,to reduce the risk of pulp
stuck.
13
14
16
15

BTG 2011
M2072/3en
2.2.2
Welding Instructions, Weld-in Stud Variant
Tools required:
Torque wrench, 10 mm
DANGER
CHECK PIPES!
Risk for corrosive,
liquids or gases
high temperature.
D=40 mm
(1.6")
DANGER
Use protective
clothing
60 mm
(2.4")
60 mm
(2.4")
X=60mm
NOTE!
Remove any welding and
grinding beard inside the
pipe,to reduce the risk of pulp
stuck.
Y
Y=X
M2072/3en

BTG 2011
17
10
11
10 Nm
18

BTG 2011
M2072/3en
2.3 - Mounting Instructions
2.3 Mounting Instructions

2.3.1
Sensor Electronics Box
Tools required:
Screwdriver
Mount the electronics box to a none vibrating position, such as a wall or pole,
by fastening the wall bracket to a flat surface. Use four suitable screws.
250
10"
25
1"
Fig 11 Recommended
clearances
M2072/3en

BTG 2011
19
2.3.2
Measuring Gap Angle Adjustment, Sluice

Valve Variant
Tools required:
Allen key, 4 mm, 5 mm
NOTE!
The red spot on the protractor
indicates the position of the
measuring gap.
Normal pulp:
The probe measuring gap must
have a 45 angle from the pulp
flow. If the pulp flow
corresponds to arrow A or B,
the angle must be adjusted.
Unscreened pulp:
have a 135 angle from the
pulp flow. If the pulp flow
corresponds to arrow C or D,
180
DANGER
High pressure
in the equipment
DANGER!
The transmitter must always be
removed from the pipe when
the angle is adjusted.
180
20

BTG 2011
M2072/3en
M2072/3en

BTG 2011
21
2.3.3
Mounting the Probe, Sluice Valve Variant
NOTE!
If the pipe pressure is higher than 5 bar (72 psi), we recommend that the pipe
is depressurized during mounting of the probe into the sluice valve.
Tools required:
Small brush
Block wrench, 17 mm
Socket wrench, 19 mm
Allen key, 4 mm
Consumables required:
Lubricant for O-rings (use MOLYKOTE 111 or equivalent for EPDM O-rings)
DANGER
Use protective
clothing
A
B
22

BTG 2011
M2072/3en
WARNING
Equipment
damage
WARNING!
Avoid bending the fiber cable
while mounting the back cover.
M2072/3en

BTG 2011
23
2.3.4
Mounting the Probe, Weld-in Stud Variant
Tools required:
DANGER
CHECK PIPES!
Risk for corrosive,
liquids or gases
high temperature.
WARNING
Equipment
damage
WARNING!
while mounting the transmitter.
NOTE!
The asterisk on the protractor
indicates the position of the
measuring gap.
135
Normal pulp:
flow as shown in step 4,
figure A.
Unscreened pulp:
have a 135 angle from the
pulp flow as shown in step 4,
figure B.
24
45
10 Nm

BTG 2011
M2072/3en
2.4 - Connection Instructions
2.4 Connection Instructions

2.4.1
Electrical Connections
2.4.1.1
Connection of Communication Platform
WARNING
Equipment
damage
WARNING!
The power to the
communication platform must
be turned off when connecting
the communication platform to
the sensor electronics box.
M2072/3en

BTG 2011
25
2.5 - Optional Accessories
2.5 Optional Accessories

2.5.1
PCD-1000 Probe Cleaning System
NOTE!
These instructions are only valid for installation of the PCD-1000 with
TCT-2501 or RET-2502 probe pre-mounted.
2.5.1.1
Dimensions and Installation Clearances
Fig 12 PCD-1000
Dimensions and
clearances
Min 300
12"
550
22"
140
5.5"
700
28"
133
5.3"
51
2"
Min 100
4"
26

BTG 2011
M2072/3en
2.5.1.2
Measuring Gap angle Adjustment
Tools required:
Allen key, 4 mm
Block wrench, 10mm, 16 mm
NOTE!
The screw on the protective
sleeve indicates the position of
the measuring gap.

flow. If the pulp flow
corresponds to arrow B or C,
180
180
M2072/3en

BTG 2011
27
180
28
10

BTG 2011
M2072/3en
2.5.1.3
Welding and Mounting
Tools required:
Block wrench, 13 mm, 16 mm
DANGER
CHECK PIPES!
Risk for corrosive,
liquids or gases
high temperature.
D=45 mm
(1.8")
DANGER
Use protective
clothing
60 mm
(2.4")
60 mm
(2.4")
M2072/3en

BTG 2011
29
10
X=60mm
X=60mm
Y
Y=X
Y=X
11
12
13
14
30

BTG 2011
M2072/3en
16
17
18
19
20
550
22"
15
M2072/3en

BTG 2011
31
2.5.1.4
Electrical Connections
Tools required:
Small screwdriver
PCD-1000
CPM
DO1
+COM
GND
+24V
Hazardous voltage
in the equipment
P1
HCM P2
P3
P1
DO
+ -
+
+
DANGER
100-240 V AC
PE N
S = Shield
connected to
cable gland
CPM
FCM
P1
P2
P3
P1
DO
+ -
+
+
NOTE!
For FCM connection, a jumper
must be connected between
DO1 and +COM as shown in
figure.
PCD-1000
DO1
+COM
GND
+24V
2 x 2 x 0.75 mm2
(2 x 2 x AWG18)
100-240 V AC
PE N
S = Shield
connected to
cable gland
32
1 x 2 x 0.75 mm2
(1 x 2 x AWG18)

BTG 2011
M2072/3en
2.5.1.5
Water Connections
Water inlet
3-6 bar
(45-90 psi)
Water outlet
B
D=8.5 mm
[0.33"]
2.5.1.6
D=17.2 mm
[0.68"]
Air Connections
Air Connection
Hose: 6-4
4-8 bar (58-100 psi)

or at least half the
process pressure
M2072/3en

BTG 2011
33
34

BTG 2011
M2072/3en
3.1 - Maintenance Recommendations
Service Instructions
3.1 Maintenance Recommendations
3.1.1
Regular Maintenance of the Transmitter
Maintenance needs will depend on the transmitter position, media influence,

and ambient conditions.
Regular maintenance includes:
Quarterly inspection of rubber seals in contact with media containing high

concentration of chemicals (black liquor, chlorine etc.) to prevent leakage.
Semi-annual inspection inside the cover for possible leakage.
Long-term maintenance includes:
M2072/3en
Replacement of media exposed rubber seals typically after 3-5 years

operation.
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Service Instructions

BTG 2011
35
3.2 - Service Actions
3.2 Service Actions

3.2.1
Removing the Transmitter from the Pipe
3.2.1.1
Sluice Valve Variant
NOTE!
If the pipe pressure is higher than 5 bar (72 psi), we recommend that the pipe
is depressurized before removal of the probe from the sluice valve.
Tools required:
Allen key, 4 mm
Block wrench, 17 mm
Socket wrench, 19 mm
DANGER
Use protective
clothing
36

BTG 2011
M2072/3en
WARNING
Equipment
damage
C
B
WARNING!
while removing the transmitter.
M2072/3en

BTG 2011
37
3.2.1.2
Weld-in Stud Variant
Tools required:
DANGER
CHECK PIPES!
Risk for corrosive,
liquids or gases
high temperature.
DANGER
Use protective
clothing
WARNING
Equipment
damage
WARNING!
while removing the transmitter.
10 Nm
38

BTG 2011
M2072/3en
3.2.2
Changing O-rings
Consumables required:
Lubricant for O-rings (use MOLYKOTE 111 or equivalent for EPDM O-rings)
Parts required:
Sluice valve variant:
O-ring 37.47x5.34, 27014018
O-ring 36.2x3, 27014000
Weld-in stud variant:
O-ring 39.2x3, 27003060
All O-rings that need to be changed on a regular basis are shown in fig 14
below.
Fig 13 O-rings, sluice valve
variant
1 O-ring 37.47x5.34
2 O-ring 36.2x3
Fig 14 O-ring, weld-in stud

variant
3 O-ring 39.2x3
M2072/3en

BTG 2011
39
3.2.3
Changing Probe with Electronics
NOTE!
The disassembling and assembling instructions in section 3.2.3.1 and section
3.2.3.1 are only relevant for sluice valve variant transmitters. A LED intensity
adjustment, as described in section 3.2.3.3, must however be performed for all
transmitter variants when changing the probe.
3.2.3.1
Disassembling the Probe
Tools required:
Allen key, 4 mm
NOTE!
Make a note of the angle of the probe measuring gap in relation to the flow
before disassembling the probe. The angle is indicated by the red spot at the
protractor, at the back of the probe.
WARNING
Equipment
damage
WARNING!
while disassembling the
probe.
40

BTG 2011
M2072/3en
3.2.3.2
Assembling the Probe
Tools required:
Allen key, 4 mm
NOTE!
The angle of the probe
measuring gap in relation to
the flow must be set according
to the notes made during
disassembling.
M2072/3en

BTG 2011
41
3.2.3.3
LED Intensity Adjustment
After the change is performed, a LED intensity adjustment must be carried out
before the transmitter can be put back into operation. The procedure for the
adjustment varies depending on the type of transmitter. See the CPM
operation manual for additional instructions on how to access the parameters
mentioned below.
TCR-25xx
1. Reinstall the transmitter to the pipe according to appropriate instructions in
section 2: Installation Instructions, and admit pulp to the line.
2. Connect the CPM to the transmitter and power up the transmitter.
3. On the CPM display, access the sensor configuration menu.
4. If you want to use the present calibration, perform the following:
a. Access the LED intensity parameter view.
b. Compare the displayed TCons value on the display with the actual
consistency of the pulp in the line
c. Increase the LED intensity parameter value by approximately 2
percentage units if the TCons value is too low, or decrease if the
TCons value is too high.
d. Repeat this procedure until the TCons value is equal to the actual
consistency of the pulp in the line.
5. If you want to make a new calibration, perform the following:
a. Change the value of parameter Adj. LED int. to 1.
An automatic LED intensity adjustment will be started. This will adjust
the LED intensity parameter to an appropriate value for the present
pulp conditions.
b. On the CPM display, access the calibration menu and perform a new
calibration.
TCT-25x1 / RET-25x2
1. Connect the CPM to the transmitter and power up the transmitter.
2. Place the probe in a bucket with water of drinking quality (the probe tip must
be held at least 10 cm [4] from the wall and bottom of the bucket)
3. On the CPM display, access the sensor configuration menu.
4. Change the value of parameter Adj. LED int. to 1.
An automatic LED intensity adjustment will be started. This will adjust the
LED intensity parameter to a value where the signal in clear water (CW) is
as close to 100% as possible.
5. Reinstall the transmitter to the pipe according to appropriate instructions in
section 2: Installation Instructions, and admit pulp to the line.
42

BTG 2011
M2072/3en
3.2.4
Removing the Electronics Card
NOTE!
The electronics card should only be removed for trouble shooting purposes
when referred from section 3.3: Troubleshooting.
Tools required:
Small screwdriver
Torx driver, T-10
WARNING
Equipment
damage
WARNING!
while removing the electronics
card.
M2072/3en

BTG 2011
43
3.2.4.1
Assembling the Sensor Electronics Box
Tools required:
Torx driver, T-10
WARNING
Equipment
damage
WARNING!
while mounting the electronics
card.
44

BTG 2011
M2072/3en
3.2.5
Reinstalling the Transmitter
For mounting instructions and connection instructions, see section 2:

Installation Instructions.
M2072/3en

BTG 2011
45
3.3 - Troubleshooting
3.3 Troubleshooting
Symptom
Probable Cause
1. No or incorrect output signal 1.1. Basic check
Solution
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.
1.2. Electrical error
Remove the electronics card from the sensor

electronics box according to section 3.2.4:
Removing the Electronics Card.
Check that the LED labeled +24V on the
electronics card (see fig 15) is permanently lit.
If LED +24V is off, check the wiring between
the sensor electronics box card and the
communication platform. If that does not help,
change the sensor electronics box.
1.3. Software error

Check that the LED labeled CPU1 on the
electronics card (see fig 15) is flashing
regularly. Irregular flashing from LED CPU1
indicates probable software error. Contact
BTG Service for further assistance.
1.4. Communication error

Check that the LED labeled COM on the
electronics card is flashing (see fig 15), which
indicates that the communication is working.
If LED COM is permanently lit, check that the
system cable is correctly connected to the
sensor electronics box according to section
2.4.1.1 on page 23.
If LED COM is off, check the wiring between
the sensor electronics box and the
communication platform for breaks.
If the problem still remains contact BTG
Service for further assistance.
2. Incorrect consistency
measurement
46
2.1. Calibration needed
Make a complete calibration of the transmitter.

See the CPM Operation Manual for further
instructions.
2.2. Incorrect LED intensity

configuration
Access the sensor configuration menu on the

CPM and perform an automatic LED intensity
adjustment (requires a recalibration) or adjust
the LED intensity manually.
See the CPM Operation Manual for further
instructions

BTG 2011
M2072/3en
Symptom
Probable Cause
Solution
3. Output signal varies with

change in flow
3.1. Wrong probe angle relative to

the flow.
Turn the probe so that the measuring gap is at

a 45 angle from the pulp flow.
For sluice valve variant, see section 2.3.2:
Measuring Gap Angle Adjustment, Sluice
Valve Variant.
For weld-in stud variant, see section 2.3.4:
Mounting the Probe, Weld-in Stud Variant.
4. Abnormally unsteady
output signal
3.2. The transmitter is not mounted

according to instructions. It may
be installed at a point where the
pulp suspension is layered, and
the layering may vary with the
rate of flow.
Check the installation with reference to the

recommendations in the Installation
Engineering Guide. Note the length of the
turbulence damping zone after the pump.
4.1. Selected time-constant for

damping is too short
Increase damping until signal stabilizes. See

the CPM Operation Manual for instructions.
Fig 15 Electronics card

1 LED CPU1 - Software run
indicator
2 LED COM Communication indicator
3 LED CPU2 - Not used
4 LED +24V - Power
indicator
M2072/3en

BTG 2011
47
48

BTG 2011
M2072/3en
4.1 - Spare Parts
Parts list
4.1 Spare Parts
2
7
Item
No.
Rec.
spare
parts
4
8
Qty
Part No.
Spare Part
Description
3
4
5
6
7
1
1
1
1
1
1
1
1
1
TCR-2501, Probe with electronics

TCR-2502, Probe with electronics
TCT-2501, Probe with electronics
RET-2502, Probe with electronics
TCR-2511 Probe with electronics
TCR-2512 Probe with electronics
TCT-2511 Probe with electronics
RET-2512 Probe with electronics
O-ring 39.2x3
O-ring 37.47x5.34
Sluice valve, complete
Weld-in stud, flanged type
TCR-2501 Cover, complete
TCR-2501 Cover, complete
TCT-2502 Cover, complete
RET-2502 Cover, complete
O-ring 36.2x3
Sluice kit TCT / RET
Sluice kit TCR
TCR-2511 Weld-on stud, complete
EPDM
EPDM
AISI 316
SS steel 2343
8
9
9
10
A0115105
B0011684
A0115238
B0011569
A0113563
B0011726
A0121541
B0011734
27003060
27014018
A0004796
A0043901
A0115170
B0011700
A0115220
A0115246
27014000
A0115139
B0011577
A0114728
M2072/3en
TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Parts list

BTG 2011
10
EPDM
49
4.2 - Accessories
4.2 Accessories
Item
No.
1
2
3
4
50
Rec.
spare
parts
Qty
Part No.
Spare Part
Description
1
1
1
1
A0054460
A0112953
A0111674
X20309
Blind flange complete

CPM Communication cable
CPM Communication cable
BTG Software
Sluice valve variant only

RS-485 - USB
RS-485

BTG 2011
M2072/3en
4.2 - Accessories
1 2 3 4 5 2 9
6 7 9 6 5 4 3
16
10 8
GND
DO1
11
+24V
14
PCD-1000 Probe Cleaning System
+COM
4.2.1
POWER
VALVE
VALVE
Item
No.
Rec.
spare
parts
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
*
*
*
(*)
M2072/3en
12
VALVE
13
15
Qty
Part No.
Spare Part
Description
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
27012871
27016179
27014448
27014455
27014430
27016419
27014828
27017326
26004895
A0016436
A0086082
A0085209
35008358
A0043901
A0051763
A0053124
B0100545
O-ring 44,2x3
O-ring 37,47x5,34
O-ring 59,0x1,6
O-ring 74,8x1,6
O-ring 80,0x1,6
O-ring 39,0x1,6
X-ring 69,22 x 5,34
X-ring 24,99x3,53
Guide
Cylinder end cover
Guide pin
Solenoid valve
Diaphragm valve
Weld-in stud, flanged type
Connection box, complete
Circuit card
Sealing kit
EPDM
Polyurethane
Nitril
Nitril
Nitril
Nitril
Nitril
Nitril

BTG 2011
Consist of item 1-8

and Silicone grease
48001887
51
4.2 - Accessories
52

BTG 2011
M2072/3en

Manul de Usuatio BTG TCR-25XX TCT-25X1 RET-25X2

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USER MANUAL

TCR-25X1 / TCR-25X2 / TCT-25X1 / RET-25X2

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Table of contents

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Table of contents

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.2 - Technical Data

1.2 Technical Data

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.2 - Technical Data

0.5 - 10 % pulp consistency

0.01 - 3.00 % total consistency

0.01 - 3.00 % total consistency

Process Temperature Limits

Support System Specifications

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.2 - Technical Data

100 mm [4"] (TCR-250x / TCT-25x1 / RET-25x2)

3.1 kg [6.8 lb]

3.4 kg [7.5 lb]

3.4 kg [7.5 lb]

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.3 - Dimensions and Mounting

1.3 Dimensions and Mounting

Transmitter, weld-in stud variant

Min 100 / 4" (TCT / RET)

Sensor electronics box

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.4 - Type Plate Explanations

1.4 Type Plate Explanations

Sluice valve variant

Sluice valve variant

Sluice valve variant

Weld-in stud variant

Weld-in stud variant

Weld-in stud variant

Wetted Part Material

Measuring Gap Size

Gap size 1.5 mm

Gap size 1.5 mm

Gap size 3.0 mm

Gap size 3.0 mm

Standard length, 5 meter

Standard length, 5 meter

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

1.4 - Type Plate Explanations

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

complies with the amendments and

and conforms with the following product

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

Pressure equipment for piping.

-n.a.-, not Annex 1

Sffle, September 2010

Bjrn Fahlin, DoO

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Product Introduction

Unpacking, Sluice Valve Variant

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Installation Instructions

Unpacking, Weld-in Stud Variant

Fig 10 Unpacking, weld-in

TCR-2501 / TCR-2502 / TCT-2501 / RET-2502 Installation Instructions

2.2 - Welding Instructions