LIQUID SOLIDS CONTROL

INSTRUCTION MANUAL

MODEL 1022
AUTOMATIC DIVERT SYSTEM

LIQUID SOLIDS CONTROL, INC.

P.O. Box 259, Upton, MA. USA 01568 TEL: (508) 529 - 3377
LSC MODEL 1022 INSTRUCTION MANUAL

LSC Model 1022

AUTOMATIC LIQUOR
DIVERT SYSTEM

INSTRUCTION MANUAL
May 26, 2015

LIQUID SOLIDS CONTROL, INC.

P.O. Box 259
Upton, MA 01568 U.S.A.
TEL: (508)-529-7773
FAX: (508)-529-6591
Email: [email protected]

LIQUID SOLIDS CONTROL

DIVISION OF LIQUID SOLIDS CONTROL, INC.
5723 Old West Saanich Road
Victoria, BC V9E 2H2, Canada
TEL: (250)-474-2243
FAX: (250)-474-3339
Email: [email protected]

Note: The appearance / contents of this manual were updated on June 4, 2012.
- Wiring in Figures 6A & 6B was corrected May 26, 2015

I
LSC MODEL 1022 INSTRUCTION MANUAL

TABLE OF CONTENTS
1. INTRODUCTION AND OVERVIEW ....................................................................................... 1

2. HARDWARE INFORMATION .......................................................................................4

2.1 C.P.U. BOARD ...................................................................................................................... 4
2.1.1 REPLACING THE C.P.U. BOARD ........................................................................ 5
2.2 POWER SUPPLY BOARDS: PC-3....................................................................................... 5
2.3 RELAY BOARDS: PC-2 ....................................................................................................... 5
2.4 REFRACTOMETER BOARD PC-4 (PG. 49 JUMPER CONFIGURATION) .................... 6
2.4.1 TRIM POT ADJUSTMENTS .................................................................................. 6
2.4.2 POTENTIOMETER DIALS ..................................................................................... 6
2.5 SIGNAL DISTRIBUTION BOARD (PC-5) ......................................................................... 6
2.6 PROGRAMMING DIAGNOSTIC INFORMATION MODULE ......................................... 8
2.7 THE OPERATOR’S PANEL ................................................................................................. 8
2.7.1 LED INDICATORS.................................................................................................. 8
2.7.2 RESET KEY AND EMERGENCY DIVERT PUSH BUTTON ............................. 9

3. INSTALLATION ............................................................................................................9
3.1 SENSING HEAD INSTALLATION ..................................................................................... 9
3.2 STEAM REQUIREMENTS................................................................................................... 9
3.3 ELECTRICAL INSTALLATION ......................................................................................... 9
3.4 INITIAL START-UP ............................................................................................................. 9
3.4.1 INITIAL SYSTEM SETTINGS ............................................................................. 13

4. DIVERT OPERATION ................................................................................................. 15

4.1 GENERAL DESCRIPTION ................................................................................................ 15
4.2 THE OPERATOR’S PANEL ............................................................................................... 15
4.2.1 LED INDICATORS................................................................................................ 16
4.2.2 RESET KEY AND EMERGENCY DIVERT PUSH BUTTON ........................... 16
4.3 PRISM WASH ..................................................................................................................... 16
4.3.1 STANDARD PRISM WASH ................................................................................. 16
4.3.2 SMART PRISM WASH ......................................................................................... 17

5. DIVERT MAINTENANCE............................................................................................ 17

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LSC MODEL 1022 INSTRUCTION MANUAL

6. REFRACTOMETER .................................................................................................... 38
6.1 THEORY OF OPERATION ................................................................................................ 38
6.2 INTERNAL COMPONENTS OF SENSING HEAD .......................................................... 38
6.2.1 LAMP ASSY. ......................................................................................................... 38
6.2.2 DETECTOR ASSY. ............................................................................................... 38
6.2.3 TEMPERATURE SENSOR ASSY. ....................................................................... 38
6.2.4 PRISM ASSY. ........................................................................................................ 39
6.3 REFRACTOMETER CALIBRATION ............................................................................... 39
6.3.1 CALIBRATION PROCEDURE............................................................................. 39
6.4 REFRACTOMETER MAINTENANCE ............................................................................. 41
6.4.1 PRISM REPLACEMENT ...................................................................................... 41
6.5 PRISM WASH CHECK VALVE REPLACEMENT ........................................................................ 41

7. GATE ADAPTOR ....................................................................................................... 42

7.1 GATE ADAPTOR MAINTENANCE ............................................................................................... 42
7.1.1 REMOVAL AND ANNUAL REBUILD OF GATE ADAPTORS .................................... 42
7.1.2 GATE ADAPTOR REASSEMBLY ................................................................................... 43

8. SPARE PARTS ........................................................................................................... 46

9. APPENDIX A: GLOSSARY OF TERMS ..................................................................... 47

9.1 ALARMS AND EVENT MESSAGE ............................................................................................... 47

III
LSC MODEL 1022 INTRODUCTION

1. INTRODUCTION
The LSC Automatic Black Liquor Divert System monitors the refractive index and hence the “percent
dissolved solids” of black liquor being fired in a Kraft Recovery Boiler, and signals the presence of
dangerous low-solids liquor. The object of this manual is to familiarize maintenance and the operating
personnel with the functions and technical aspects of the system.

The Automatic Black Liquor Divert System is comprised of several principal components:

 The 1022 Processor  Gate Adaptor with Limit Switches

 Dual Refractometers  Prism Wash Ball Valves with Solenoids
 Operator Interface Panel  Hard copy / printer (optional)
 The Pipe Section

A typical installation is illustrated in Figure 1 (next page).

The 1022 “Automatic Divert Processor” monitors the signals from the sensing heads. The unit can be
wired in many configurations, allowing the system to stand alone (power the divert valve) or to be
integrated with a DCS or Burner Management System through discrete contact outputs. User friendly
software with on screen prompting allows for easy access to all information on the programming and
diagnostic module in the processor enclosure.

The system will also divert for several other reasons, such as:

 AUX DIVERT  LOSS OF POWER

 MANUAL DIVERT  LOSS OF CPU CONTROL

The Model 1022 system is designed to operate by the following rule: “if for any reason, BOTH
refractometers are out of service, the System will immediately divert the liquor.”

All causes for a divert will be logged to generate a “First out” report. This information will be available
from the Maintenance Screen inside the 1022 enclosure.

Once a Divert has occurred, for any reason, there will be a two (2) minute lock out restriction prohibiting
reset of the system.

In order to “reset,” the two minute lock out time must pass and the liquor solids as indicated by at least
one of the refractometers must be higher than the “emergency trip” set point.

 NOTE: “Aux divert” input must be satisfied.

1
 Figure 1
Model 1022 Schematic

LSC MODEL 1022

2

INTRODUCTION
LSC MODEL 1022 INTRODUCTION

The Sensing Heads read the dissolved solids and signal to the Refractometer electronics. Automatic
temperature compensation of the dissolved solid reading is provided within. An automatic prism wash
cycle is provided every 20 minutes, alternating between heads. Indication of the prism wash can be
seen on the operator interface panel. It is impossible to wash both refractometers simultaneously,
either manually or automatically. The prism wash cycle also proves the sensing head is responding to
liquor changes.

The CPU is responsible for:

 Monitoring the Refractometers  Self - diagnostic

 Providing outputs to the Divert Valve  Deciding dual or single Refractometer Operation
 Burner Management System Inputs  Prism wash cycle
 Alarm status indication  Historical event memory
 Troubleshooting  Divert logic

A redundant power supply provides a secure voltage to the central processing unit, assuring maximum
up-time for the system. When in the power supply backup mode, a system malfunction alarm is given,
alerting the operator of its condition. The CPU does multiple checks of the data and programming
integrity of all information in the system.

 CPU failure in all cases will result in a failsafe situation (DIVERT).

The Pipe Section, as its name implies, becomes a part of the black liquor feed line.
Incorporated into it are:

 Two mounting plates for the gate adaptors

 Two flow deflection baffles

 Two ball valves for controlling wash steam to the sensing heads

 Check valves on the sensing heads

The gate adaptor is a thin-profile gate valve between the sensing head and pipe section so that the
sensing head can be easily isolated from the active liquor line. A limit switch on the gate adaptor
indicates to the CPU a closed position. The CPU will remove service any refractometer with a closed
gate adaptor. Closing both gate adaptors will initiate a DIVERT. Between the opening of one gate, to
the closing of the other be sure to wait 30 seconds --- failure to do so will cause a DIVERT.

3
LSC MODEL 1022 HARDWARE INFORMATION

2. HARDWARE INFORMATION
The 1022 processor is comprised of seven (7) main components PART # QTY
1) C.P.U Board ( PC-1 ) 1022401 1
2) Relay Board ( PC-2 ) 1022402 2
3) Power Supply Board ( PC-3 ) 1022403 2
4) Refractometer Board ( PC-4) 1022404 2
5) Signal Distribution Board ( PC-5) 1022405 1
6) Programming Diagnostic Information Module 1022412 1
7) Operator Interface Panel 1022408 1

2.1 C.P.U. Board

The C.P.U. is responsible for:

 Monitoring the Refractometers  Trouble shooting & Self-diagnostics

 Divert Logic  Decide dual or single refractometer operation
 Providing outputs to the divert valve  Prism wash cycle
 Burner Management system inputs  Historical event memory
 Alarm status information

The C.P.U. board is located in the center of the unit, and has five indicator lights on it. These
function lights indicate the status of the unit at all times. There are three red lights and two green lights.

From top to bottom as you look at the C.P.U.:

 Red Top Light - Indicates a power failure

 Red middle Light -Indicates a run fail error.

 Red Bottom Light - Indicates a check sum error or a EPROM malfunction

 Top Green Light - C.P.U. running

 Bottom Green Light - Power good

If for any reason the system is malfunctioning, one or both of the green indicators will be off, and one,
two, or three of the red indicators will be illuminated. The system may be reset by pushing and holding
the black switch located below the two green indicators for 10 seconds.

 NOTE: When resetting the unit the system will divert if it has not already diverted,
and the system should reset in approximately 10 seconds.

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LSC MODEL 1022 HARDWARE INFORMATION

2.1.1 Replacing the C.P.U. card

When replacing the C.P.U. board the system will divert. This is one of three cards you cannot
change while the system is operating without causing a divert. When booting up the replaced card and
the set points on the new card differ from those programmed into the previous C.P.U. card, the
configuration mismatch screen will appear, the display panel will indicate “Display Link IDLE” and the top
red light and the bottom green light will be illuminated.

There are three possibilities when at this screen:

1. DFLT 2. SITE 3. CPU

(Use default settings) (Use site settings) (Use CPU settings)

Choosing DFLT will use these settings: Choosing the SITE option Choosing the CPU option results
will result in the settings in the settings of that CPU to be
Divert set point ........................... 58% being the same as those used, whatever they are.
Low solids set point ..................... 60% used previously.
Refractometer set points
Scale factor ....................... 4mA: 55%
....................................... 20mA 75%
Divert valve travel ...................... 5 sec
Brightness set to the Medium setting

Any one of these selections will clear the CPU board malfunction, and will allow you to clear the divert
condition if all other parameters are met.

2.2 Power Supply Boards: PC-3 (Two)

These boards supply the +5 Volts and +15 Volts to the CPU simultaneously. Failure of either board will
initiate the “SysMaint” (System Maintenance) alarm. Failure of both boards will cause a divert. Either
board can be replaced without interruption of service (One at a time).

2.3 Relay Boards: PC-2 (Two)

The PC-2 Relay Boards provide alarm contacts for the various alarms, as well as the divert contact. The
divert contacts are “normally closed,” and wired in series for redundancy. Opening (or removing) either
of these contacts will cause a DIVERT. When a divert condition occurs, if there is a failure in the system,
if one of the Relay boards is removed, or if there is a power failure, at least one of the contacts will open,
causing a DIVERT. This redundancy is an important aspect of the fail safe system.

NOTE: Neither Relay Board can be removed during operation without causing a DIVERT.

5
LSC MODEL 1022 HARDWARE INFORMATION

2.4 Refractometer Board

The refractometer board sends appropriate power to the L.E.D. light source and temperature sensor.
With the aid of calibration set points, it transforms the return temperature signals into outputs
proportional to concentrations (percent Solids).
Figure 2
Adjustment
2.4.1 Trim Pot Adjustments
Controls

 TZ - Temperature Zero: Adjust to approximately zero volts

when the sensing head is at the process temperature. Refer
to the refractometer screen for the TC voltage display, under
the temperature Section. Voltage will then vary with process
temperature.
 TR - Temperature Read out: Adjust the temperature trim pot
to the process temperature in degrees C when the sensing
head is at process temperature. Outlined in more detail in
the calibration section. Refer to the refractometer screen
under the temp section.
 CZ - Coarse Zero: This is the coarse adjustment for the low
end of the scale factor.

2.4.2 Potentiometer Dials

 ZERO - This provides the fine adjustment of the low end scale factor.
 SPAN - This provides the fine adjustment of the high end scale factor.
 T.C. - (On/Off Switch) Turns automatic temperature compensation on or off.
Set to “ON” for normal operation, “OFF” for “off-line” calibration.

2.5 Signal Distribution Board: PC-5 (Refer to Figure 6A. Page 10)
This board connects all other boards in the system, and is often referred to as the “motherboard.” All
internal and external wiring and signals are connected on this board. These connections include:

 Sensing Heads A and B. hooked up to TB5 and  Gate position sense A and B TB4 and TB13
TB14 respectively. respectively.
 4-20 mA, A and B, TB3 and TB12 respectively.  Dry contact alarm outputs A-Only operation,
 AC signal to Prism wash solenoid A and B, TB1 and A Refractometer Malfunction, A Prism Wash
TB15 respectively. Fail, Low Solids Differential, Divert Fail and
System Maintenance alarms on TB11.
 AC power input TB2 refractometer A, TB10 C.P.U.
 Dry contact alarm outputs B-Only operation,
power, and TB16 refractometer B.
B Refractometer Malfunction, B-Prism Wash
 Divert signal output to divert valve: either hot 110 Fail, Solids Differential, Divert Fail and
or 220 AC, or a dry contact signal depending on System Malfunction alarms on TB11.
your application. See Figure 6b, page 11, for
proper wiring contacts on TB7  Dry contact divert valve position sense
either divert position or non-divert position
 Operator port outlet, TB9, this port is used if the on TB7, position 1,2,3, and 4.
operator panel is to be mounted remotely from the
1022 processor.  Printer interface outlet TB8

6
LSC MODEL 1022 HARDWARE INFORMATION

Jumper shown for

M-725 sensing head with the #829114
temperature sensor. (Orange and brown wires)

Jumpers shown for

M-614 sensing head with the #614300
temperature sensor. (Green with white stripe
and brown wires)

7
LSC MODEL 1022 HARDWARE INFORMATION

2.6 Programming Diagnostic Information Module

This touch pad screen control allows you to view and input the operating parameters of the system. See
screen display panels for more in-depth information about the operation of the module.

2.7 The Operator’s Panel

From the operator’s panel the Boiler Operator will know the Black Liquor solids level as well as the status
of the system.

Figure 3 The operator’s panel will indicate when a refractometer is

Operator’s Panel being washed by replacing the unit letter and colon with a
“WH” for wash and hold. A single “H” indicates the
continuing hold time.

If for any reason a refractometer is out of service, the

solids indication will read “-OUT-”. This will result in an
alarm as well as automatic switch over to the remaining
in-service refractometer.

A refractometer will be taken out of service for the following reasons:

 Gate adaptor closed for calibration or servicing of the unit
 Component failure within the refractometer  Individual refractometer power shut off
 Failing the SMART WASH criteria

If BOTH Refractometers are out of service for any reason, the System will
Immediately divert the liquor. All causes for a refractometer being taken out of service will be
logged and will be available from the Maintenance Screen inside the 1022 enclosure.

2.7.1 Led Indicators WH 75.3 % B: 75.3 %

An additional indication of a refractometer being out of service will be the Green “NORMAL OPERATION”
LED flashing at a one-second interval. If the LED goes out completely it means one of the Divert power
supplies needs servicing.
A: -OUT- B: 75.3 %
The Red “LIQUOR DIVERTED” LED is not only an indication of the Divert command, but also the divert
valve(s) status. When a divert is initiated the LED will flash at a fast rate (several times a second) until
the divert valve(s) move to the liquor diverted position. This will indicated by the “DIVERT VALVE
POSITION” LEDs. The Red LED indicates that the liquor is diverted and the Green LED indicates that the
divert valve(s) is (are) in the firing liquor position. When a reset is initiated, the “LIQUOR DIVERTED”
LED will flash slowly (once per second) until the divert valve(s) return to the firing liquor position.

8
LSC MODEL 1022 INSTALLATION

2.7.2 Reset key and Emergency Divert Push Button Reset - WAIT 119 Sec

The “EMERGENCY PUSH” manual divert button is available to the boiler operator at all times. Once the
button has been pushed, there is a 10 second grace period that will allow an immediate reset in case of
an accidental divert. After that there will be a 2 minute lock-out of a reset. Trying to use the “RESET
KEY” before the 2 minutes has elapsed will result in a message being displayed indicating the remaining
time, as illustrated above.

After the two minute lock out time has expired, and the percent solids indicated by at least one of the
refractometers is higher than the “emergency trip” set point, then a reset is permitted.

3. INSTALLATION
3.1 Sensing Head Installation
A typical sensing head installation is illustrated in Figure 5 on the next page.

3.2 Steam Requirements

To achieve an effective prism wash, in most black liquor applications, the steam requirements are:

* 80 to 85 psi of saturated steam over and above the process line pressure.
* Tubing arrangement as shown in Figure 4 below.

This tubing arrangement allows two to three seconds of steam/condensate mixture to precede the full
steam pressure.

3.3 Electrical Installation

The basic system wiring is illustrated in Figure 6 (Pages 10 & 11). All wiring must be performed by a
qualified industrial electrician, per local electrical codes.
Figure 4
3.4 Initial Startup
Before powering up the system check once more to
Prism Wash Tubing Installation
see that all the external wiring to the unit is connected
as shown in Figure 6. The programming and
diagnostic module should now be illuminated. If not,
adjust the intensity of the screen with the dial on the
bottom right hand corner of the module. The main
menu should now be visible on the screen. Proceed to
set the alarm position, time and operating conditions
for the mill requirement.

9
 LSC P/N 190302 (Air to open / Spring to close)

LSC MODEL 1022

LSC P/N 190305 (Air to open / Air to close)
Figure 5 Complete Prism Wash Ball Valve with If necessary, the ¼” Ball
Installation using Gate Adaptors Actuator and solenoid. Valve can be ordered by
itself LSC P/N 190310

Industrial Flanges are Optional LSC P/N 829424

Limit Switch

LSC P/N 829246

LSC Gate Adaptor
Isolation Valve
LSC P/N 190261
Male Connector
10

Dual pipe section w/ direct

INSTALLATION
Weld-in connections LSC P/N 190202
Flexible Prism
This pipe section is using LSC P/N 614315 LSC P/N 190260 Wash Hose
LSC P/N 190302 PW Valve In-line Sensing Head with Female Connector
(Air to Open / Spring to close.) Side Entry Prism wash
 LSC MODEL 1022
Figure 6A
Model 1022 Wiring Diagram
(Motherboard)
11

INSTALLATION
 Figure 6B
Model 1022 Wiring Diagram (Detail views)

LSC MODEL 1022

12

INSTALLATION
LSC MODEL 1022 INSTALLATION

The 1022 has a battery backup and will retain all preset values in the event of a power failure. In order
to set the appropriate set points, leave the main menu by selecting “MENU”, then “SET”. Notice the
screen has changed to the “SET PARAMETERS” menu. This menu will be the starting point for the
following settings. To return to this menu after each setting, press “EXIT” the appropriate number of
times. See the illustrations in Section 5, Divert Maintenance, for a full description of each screen.

In each menu that requires settings, the screen will display: ++, >, --, and <.

 (++) Increases the digit at the cursor

 (>) Moves the cursor to the right one digit
 (--) Decreases the digit at the cursor
 (<) Moves the cursor to the left one digit.

3.4.1 Initial System Settings

A. Setting the Time and Date

Press “TIME”, then adjust the appropriate time and date. Time is displayed in a 24 hour format, and must
be adjusted for the bi-annual time change if recognized. The CPU has a built in calendar that is pre-
programmed for leap years, so that once the date is set it should not have to be adjusted again.

B. Setting the Divert/alarm Set Points:

 For DIVERT/ALARM SET POINTS: Press “SETP”  For DIVERT POINT: press “TRIP”

Adjust to mill specifications, as determined by mill management.

This is the point at which the 1022 will initiate a divert command.

NOTE: This set point cannot be adjusted below 58%, as specified by B.L.R.B.A.C. guidelines. If
the percent solids drops to or below this setting, the unit will initiate a DIVERT signal.
This signal is sent through a dry contact configuration or by removal of a 110/220 VAC
output. These signals can be used to directly control equipment or provided to other
management, control or safety systems for their divert decision making purposes.

C. Low % Alarm: Press “LOW %”

Adjust to mill specifications, as determined by mill management. The Low Solids alarm is intended to
alert the boiler operator to the fact that the liquor solids content is approaching dangerously low values.

D. DIFF. Alarm:
This is a non-adjustable alarm pre-determined at 2% by B.L.R.B.A.C. 2% is the maximum difference in
refractometer readings before the “%Diff” alarm is initiated (“set”). The solids differential alarm is
intended to alert the boiler operator that the instrument requires technical attention.

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LSC MODEL 1022 INSTALLATION

E. Refractometer Scale Factor: Press “SF”

This is the setting of the 4-20 mA output which corresponds to the high & low % solids ranges.
Prior to settings of the “Scale Factor” the appropriate gate adaptor must be closed and this is
indicated by “CLOSED” beside A or B refractometers. The CPU will only allow you to proceed to
the next step under this condition. Closure of both gate adaptors will initiate a divert.

1. Press “A” or “B”

2. Press 4 m A

3. Set the low end of the scale as per the scale factor. (I.e. 55%)

4. Exit back one menu to set the high end of the scale factor

5. Press 20 mA

6. Set the high end of the scale as per the scale factor. (I.e. 75%)

7. Exit back two menus, open the gate, wait 45 seconds and close the other gate. Follow the above
procedure again.

F. Miscellaneous Parameters: Press “MISC”

Operator interface panel brightness:

There are three possible settings for the brightness of the operator interface panel. Press
“BRIT” to set at the desired light intensity.

Divert Valve Travel - Press “TRAV”:

This value is to be set at the period of time it takes for the divert to cycle. If the valve fails to
complete its cycle in this allotted time a divert failure alarm will be initiated.

14
LSC MODEL 1022 DIVERT OPERATION

4. DIVERT OPERATION
4.1 General Description

The Model 1022 Automatic Divert System will provide a significant advancement in reliable
divert system operation.

This system is designed to operate as “normal” with both refractometers in service. With both in
service, Both must indicate low solids to initiate automatic liquor diversion. If one refractometer
is “out of service,” the other “in service” refractometer alone indicating low solids will initiate
automatic liquor diversion.

The Model 1022 system is designed to divert according to the following conditions: “if for any
reason BOTH refractometers are out of service, the System will immediately divert the liquor.”

The system will divert for several other reasons, such as:

 AUX DIVERT  LOSS OF POWER

 MANUAL DIVERT  LOSS OF CPU CONTROL

All cases for divert will be logged to generate a “First out” report. This information will available
from the Maintenance Screen inside the 1022 enclosure.

Once a divert has occurred, for any reason, there will be a two (2) minute lock out restriction
prohibiting reset of the system.

In order to “reset,” the two minute lock out time must pass and the liquor solids as indicated by
at least one of the refractometers must be higher than the “emergency trip” set point.
 NOTE: “Aux divert” input must be satisfied.

4.2 The Operator’s Panel

From the operator’s panel the Boiler Operator will know the Black Liquor solids level as well as
the status of the system.
The operator’s panel will indicate when a
Figure 3 refractometer is being washed by replacing the unit
Operator’s Panel letter and colon with a “WH” for wash and hold. A
single “H” indicates the continuing hold time.

WH 75.3 % B: 75.3 %
If for any reason a refractometer is out of service,
the solids indication will read “-OUT-”. This will result
in an alarm as well as automatic switch over to the
remaining in-service refractometer.
A: -OUT- B: 75.3 %

15
LSC MODEL 1022 DIVERT OPERATION

A refractometer will be taken out of service for the following reasons:

 Gate adaptor closed for calibration/servicing of the unit.

 Failing the SMART WASH criteria.
 Component failure within the refractometer.
 Individual refractometer power shut off.

NOTE: If BOTH Refractometers are out of service for any reason, the System will
Immediately divert the liquor. All causes for a refractometer being taken out of
service will be logged and will be available from the Maintenance Screen inside the
1022 enclosure.

4.2.1 Led Indicators

An additional indication of a refractometer being out of service will be the Green “NORMAL
OPERATION” LED flashing at a one-second interval. If the LED goes out completely it means
one of the Divert power supplies needs servicing.

The Red “LIQUOR DIVERTED” LED is not only an indication of the Divert command, but also the
divert valve(s) status. When a divert is initiated the LED will flash at a fast rate (several times a
second) until the divert valve(s) move to the liquor diverted position. This will indicated by the
“DIVERT VALVE POSITION” LEDs. The Red LED indicates that the liquor is diverted and the
Green LED indicates that the divert valve(s) is (are) in the firing liquor position. When a reset is
initiated, the “LIQUOR DIVERTED” LED will flash slowly (once per second) until the divert
valve(s) return to the firing liquor position.

4.2.2 Reset key and Emergency Divert Push Button Reset - WAIT 119 Sec
The “EMERGENCY PUSH” manual divert button is available to the boiler operator at all times.
Once the button has been pushed, there is a 10 second grace period that will allow an
immediate reset in case of an accidental divert. After that there will be a 2 minute lock-out of a
reset. Trying to use the “RESET KEY” before the 2 minutes has elapsed will result in a message
being displayed indicating the remaining time, as illustrated above.

NOTE: “Aux Divert” input must be satisfied

4.3 Prism Wash

Version 1.2 firmware for the Model 1022 incorporates enhanced Prism Wash control features.
For those customers that find a fixed duration of wash is preferable, we now support that
feature. Also prism wash interval time can be adjusted even with “Smart Wash” enabled.

Smart wash functions as before, however it does use the “Interval Parameter” setting. If the
1022 detects a failed prism was it will retry at half the Interval Time no matter what mode the
prism wash system is in.

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LSC MODEL 1022 DIVERT OPERATION

4.3.1 Standard Prism Wash

Access to these parameters is done through the maintenance menu. Press the “MENU” button. This
brings you to the “SET PARAMETERS” button and the “MISC PARAMETERS” button. From the
MISCELLANEOUS PARAMETERS screen the “WASH PARAMETERS” appears as a new option.

The “PRISM WASH PARAMETERS” screen allows the setting of the wash parameters.

INTERVAL: The interval can be set from a minimum of 300 seconds to a maximum of 900 seconds
between the wash of one refractometer and the wash of the second refractometer. The interval setting
will be used by Smart Wash when enabled. Typical setting is 600 sec.

DURATION: The duration can be set between 5 seconds to a maximum of 60 seconds. The 1022
considers a wash successful if at any time during the wash the refractometers output falls to zero volts.

SMART WASH: This setting is used to toggle smart wash on or off.

4.3.2 Smart Prism Wash

The 1022 CPU controls the refractometer prism wash timing and monitors the response. The timing for
normal washing consists of a wash every twenty minutes. The CPU staggers the wash so that a wash is
initiated every ten minutes alternating between refractometers. It is impossible to wash both
refractometers simultaneously, either manually or automatically. The wash system is called “SMART
WASH” because it is controlled by the CPU, which is programmed to make decisions based on the wash
performance. The CPU starts a wash with a maximum time limit of 30 seconds. However, as soon as the
refractometer satisfies the wash criteria, the wash will halt and the 40 second signal hold will start.

If for any reason the refractometer fails the first wash, a second wash attempt will result in the
refractometer being taken “out of service” and full control will be passed to the remaining “in service”
refractometer.

The SMART WASH system also eliminates excessive and abusive prism washing during an empty pipeline

5. DIVERT MAINTENANCE

All information needed to maintain the 1022 Divert System is shown on the diagnostic screens accessible
through the computer control panel. These screens are illustrated and explained on the following pages.

17
 LSC MODEL 1022
TIME UNTIL NEXT PRISM WASH, SECONDS INDICATOR FOR NEXT PRISM WASH EVENT

“A” REFRACTOMETER
ACTIVE SOLIDS VALUE

INITIATE “A”
REFRACTOMETER
“B” REFRACTOMETER
PRISM WASH
ACTIVE SOLIDS VALUE

INITIATE “B”
REFRACTOMETER
PRISM WASH
CURRENT TIME & DATE
18

EVENT HISTORY

LAST WASH DURATION

SECONDS “NG” IF FAILED

DIVERT MAINTENANCE
C.P.U. STATUS

ALARMS ABBREVIATIONS; ACCESS TO MAINTENANCE MENU

SEE ALARM SCREEN
DESCRIPTION, PAGE 35

MAIN DISPLAY
 LSC MODEL 1022
CHOOSE PRINT MENU, TO PRINT
HISTORY, REPORT OR LOG
(IF PRINTER IS SUPPLIED)
MENU OF SCREENS FOR
ENTERING OPERATIONAL
CONSTANTS: DIVERT & ALARM
THRESHOLD VALUES, DATE &
TIME, DIVERT VALVE ALARM
TIMING, ECT.

PROVIDES LIVE SIGNALS FROM

BOTH REFRACTOMETERS AND THE
C.P.U. POWER SUPPLY VOLTAGES
19

DISPLAYS LIST OF POSSIBLE ALARMS

AND SHOWS ACTIVE ALARMS. ALARM
ABBREVIATIONS ARE SHOWN AT THE
BOTTOM OF THE MAIN MENU.

DISPLAY AND HELP MENU

FOR A CHRONOLOGICAL
RECORD OF SYSTEM

DIVERT MAINTENANCE
EVENTS.

EXIT TO MAIN MENU

MAINTENANCE MENU
 LSC MODEL 1022
CANCEL ANY ON
GOING PRINTING.

DUMP THE COMPLETE HISTORY

TO THE PRINTER. FOR A
SELECTIVE HISTORY REPORT
SEE “HISTORY HELP SCREEN”

PRINT OUT THE SYSTEM SET

POINTS AND STATUS REPORT
20

PRINT EVENTS AS THEY OCCUR

BACK ONE SCREEN

DIVERT MAINTENANCE
PRINT SCREEN
 LSC MODEL 1022
ACCESS SETTING OF THE THRESHOLD
VALUES FOR THE DIVERT AND LOW
SOLIDS ALARM. TO DISPLAY THE %
SOLIDS DIFFERENCE REQUIRED FOR
THE SOLID DIFFERENTIAL ALARM.

ACCESS SETTING OF DATE & TIME FOR

MAIN DISPLAY AND HISTORY

ACCESSES THE INITIAL STEP IN SETTING THE

REFRACTOMETER % SOLIDS RANGE LIMITS.
21

ACCESS THE SETTING OF THE OPERATOR

PANEL DISPLAY BRIGHTNESS, AND TRAVEL
TIME FOR DIVERT VALVE FAILURE.

BACK ONE SCREEN

DIVERT MAINTENANCE
MISCELLANEOUS PARAMETERS
 LSC MODEL 1022
DIVERT POINT SET POINT
ACCESS FOR SETTING
DIVERT SET POINT.

ACCESS FOR SETTING

LOW SOLIDS
LOW SOLIDS ALARM
ALARM SET POINT
SET POINT.
22

BACK ONE SCREEN

DIFFERENTIAL ALARM
WILL ALARM AT 2%
SOLIDS DIFFERENTIAL

DIVERT MAINTENANCE
DIVERT & ALARM SET POINTS (%)
 LSC MODEL 1022
INCREMENT DIGIT HIGHER
THRESHOLD
DIVERT VALVE

MOVE CURSOR RIGHT

CURSOR
DECREMENT DIGIT LOWER
ACTIVE CHANNEL “A”
CURRENT SOLIDS
MOVE CURSOR LEFT
23

ACTIVE CHANNEL “B”

CURRENT SOLIDS

NOTE: THRESHOLD UPDATE

DIVERT MAINTENANCE
IN EFFECT UPON EXIT.
BACK ONE SCREEN

SETTING DIVERT
 LSC MODEL 1022
INCREMENT DIGIT HIGHER
THRESHOLD
DIVERT VALVE
MOVE CURSOR RIGHT

CURSOR DECREMENT DIGIT LOWER

ACTIVE CHANNEL “A”

CURRENT SOLIDS
MOVE CURSOR LEFT
24

ACTIVE CHANNEL “B”

CURRENT SOLIDS

DIVERT MAINTENANCE
NOTE: THRESHOLD UPDATE
IN EFFECT UPON EXIT.
BACK ONE SCREEN

LOW % ALARM
 LSC MODEL 1022
INCREMENT DIGIT HIGHER

DATE:
MONTH/DAY/YEAR
MOVE CURSOR RIGHT

TIME:
HOUR:MINUTE:SECOND DECREMENT DIGIT LOWER
25

MOVE CURSOR LEFT

CURSOR: MOVES TO
RIGHT AND LINE DOWN,
WHEN STARTING FROM
UPPER LEFT.

DIVERT MAINTENANCE
SECONDS OF TIME BEGIN
ADVANCING UPON EXIT.
BACK ONE SCREEN

TIME / DATE ENTRY

 LSC MODEL 1022
ACCESS MENU FOR SETTING RANGE
LIMITS FOR “A” OR “B” CHANNEL
26

BACK ONE SCREEN

DIVERT MAINTENANCE
NOTE: IMPORTANT:
BEFORE EITHER CHANNEL’S RANGE LIMITS CAN BE CLOSE ONLY ONE GATE AT A TIME
SET, ITS CORRESPONDING GATE MUST BE CLOSED

REFRACTOMETER SCALE FACTOR “SF”

 LSC MODEL 1022
UPPER RANGE LIMIT
SETTING % SOLIDS
ACCESS FOR SETTING
UPPER RANGE LIMIT
OF PERCENT SOLIDS
27

ACCESS FOR SETTING

LOWER RANGE LIMIT
OF PERCENT SOLIDS
LOWER RANGE LIMIT
SETTING % SOLIDS

DIVERT MAINTENANCE
BACK ONE SCREEN

SOLIDS RDG: FOR REFRACTOMETER “A” OR “B”

 LSC MODEL 1022
INCREMENT DIGIT HIGHER

LOWER RANGE LIMIT

READING % SOLIDS
MOVE CURSOR RIGHT
28

CURSOR DECREMENT DIGIT LOWER

MOVE CURSOR LEFT

ACTIVE CHANNEL “A”
PERCENT SOLIDS

DIVERT MAINTENANCE
LOWER RANGE LIMIT
SETTING UPDATE IN
EFFECT UPON EXIT.
BACK ONE SCREEN

REFRACTOMETER “A” OR “B” SOLIDS RDG 4 mA

 LSC MODEL 1022
INCREMENT DIGIT HIGHER

HIGH RANGE LIMIT

READING % SOLIDS
MOVE CURSOR RIGHT
29

CURSOR DECREMENT DIGIT LOWER

MOVE CURSOR LEFT

ACTIVE CHANNEL “A”
PERCENT SOLIDS

DIVERT MAINTENANCE
HIGH RANGE LIMIT
SETTING UPDATE IN
EFFECT UPON EXIT.
BACK ONE SCREEN

REFRACTOMETER “A” OR “B” SOLIDS RDG 20 mA

 LSC MODEL 1022
ACCESS PRISM WASH
INTERVAL MENU

ACCESS PRISM WASH

30

DURATION MENU

TOGGLE SMART
WASH ON / OFF

DIVERT MAINTENANCE
BACK ONE SCREEN

PRISM WASH PARAMETERS

 LSC MODEL 1022
INCREMENT DIGIT HIGHER
ADJUSTABLE 300-900
SECONDS BETWEEN
A & B PRISM WASH
MOVE CURSOR RIGHT

CURSOR
DECREMENT DIGIT LOWER
31

MOVE CURSOR LEFT

DIVERT MAINTENANCE
BACK ONE SCREEN

PRISM WASH INTERVAL

 LSC MODEL 1022
ADJUSTABLE 5 - 60 SECONDS.
0 SECONDS EQUALS SMART WASH.

INCREMENT DIGIT HIGHER

MOVE CURSOR RIGHT

DECREMENT DIGIT LOWER

32

MOVE CURSOR LEFT

DIVERT MAINTENANCE
BACK ONE SCREEN

PRISM WASH DURATION

 LSC MODEL 1022
ACCESS A DISPLAY OF
REFRACTOMETER “A” SIGNALS

ACCESS A DISPLAY OF
REFRACTOMETER “B” SIGNALS
33

ACCESS A DISPLAY OF POWER

SUPPLY BOARD OUTPUTS AND
SUPPLIED VOLTAGE AT THE C.P.U.

DIVERT MAINTENANCE
BACK ONE SCREEN

MODULE OPERATION
 LSC MODEL 1022
“A” REFRACTOMETER ANALOG OUTPUT.
ZERO TO 10 VDC, CORRESPONDING TO
THE PERCENT SOLIDS RANGE. CALIBRATE
WITH REFERENCE TO THIS SIGNAL.

ACTIVE PERCENT
SOLIDS READING (NOT
DURING PRISM WASH)
GATE ADAPTOR STATUS
“OPEN” OR “CLOSED”

SENSING HEAD LAMP

VOLTAGE 4 – 10 VOLTS ANALOG VOLTAGE
ACCEPTABLE COUNTER: PART OF
34

“TEMP” READING

SENSING HEAD TEMP-

ERATURE. ADJUST TO
KNOWN HEAD TEMP TEMPERATURE
WITH “TR” ON REFRAC- COMPENSATION
TOMETER BOARD VOLTAGE. SET TO ZERO
WITH HEADS AT LINE
TEMPERATURE USING
“TZ” ON REFRAC-

DIVERT MAINTENANCE
TOMETER BOARD

ACTIVE VALUES OF +15 AND -15 VDC BACK ONE SCREEN

SUPPLIES ON REFRACTOMETER
BOARD “A” (IF MORE THAN 1.5 VDC
FROM NOMINAL, REPLACE
REFRACTOMETER BOARD

REFRACTOMETER “A” OR “B” DIAGNOSTIC SCREEN

 LSC MODEL 1022
POWER SUPPLY #1
(LEFT SIDE OF C.P.U.)
+5 VDC FROM PS#1

POSITION ON MOTHER
BOARD FOR PS#1 +15 VDC FROM PS#1

POWER SUPPLY #2 +5 VDC FROM PS#2

(RIGHT SIDE OF C.P.U.)
35

POSITION ON MOTHER +15 VDC FROM PS#2

BOARD FOR PS#2

+5 VDC LOCATED AT
THE C.P.U

DIVERT MAINTENANCE
BACK ONE SCREEN

C.P.U. / RELAY POWER

 LSC MODEL 1022
NOTE:
ALARM STATUS BAR ILLUMINATES ABBREVIATIONS FOR
ALARM INDICATED BELOW, REFERENCED BY NUMBER.

“A” REFRACTOMETER
1 ONLY OPERATION

“A” REFRACTOMETER
2 MALFUNCTION “B” REFRACTOMETER
7 ONLY OPERATION

“A” REFRACTOMETER “B” REFRACTOMETER

3 PRISM WASH FAIL 8 MALFUNCTION

LOW SOLIDS WARNING “B” REFRACTOMETER

4 ‘A’, ‘B’ OR BOTH
9 PRISM WASH FAIL
36

LSC DIVERT SIGNALING “A” & “B” REFRACTOMETERS

5 IN EFFECT 10 DIFFER BY MORE THAN 2% BLS

SYSTEM MAINTENANCE DIVERT VALVE POSITION NOT

6 REQUIRED: ONE C.P.U.
11 TALLYING WITH DIVERT SIGNAL
POWER SUPPLY FAILED

DIVERT MAINTENANCE
BACK ONE SCREEN
C.P.U. DIVERT OUTPUT C.P.U. DIVERT OUTPUT
TO RELAY BOARD (A) J5 TO RELAY BOARD (B) J10

ALARM STATUS
 LSC MODEL 1022
ACCESS “HELP” SCREEN FOR
GUIDE TO SELECTION
ALARM DESCRIPTOR CONTROLS ON THIS SCREEN

ALARM CAUSE

DATE OF EVENT ALARM STATE,

INITIATED “SET”

TIME OF EVENT
“A” REFRACTOMETER
PERCENT SOLIDS
ALARM STATE,
37

“B” REFRACTOMETER REMEDIED “CLR”

PERCENT SOLIDS

DIVERT MAINTENANCE
NUMBER OF EVENTS THAT BACK ONE SCREEN
ARE NOT ON-SCREEN
WHICH ARE MORE RECENT

HISTORY
 LSC MODEL 1022
SELECTIVE HISTORY PRINT:
PRINT EVENTS DISPLAYED
ON HISTORY SCREEN AND
MORE RECENT EVENTS.

PREVIOUS PAGE:
DISPLAY EVENTS THREE
ENTRIES PREVIOUS TO THOSE
CURRENTLY BEING DISPLAYED.

NEXT PAGE:
DISPLAY EVENTS THREE
ENTRIES LATER THAN THOSE
CURRENTLY BEING DISPLAYED.
38

SCROLL EVENTS
ONE ENTRY EARLIER

SCROLL EVENTS
ONE ENTRY LATER

DIVERT MAINTENANCE
BACK ONE SCREEN

NOTE:
SELECTIONS DO NOT REGISTER WHEN THE SCREEN IS IN THE “HELP” MODE. THE SCREEN
IS A GUIDE TO THE SELECTION CONTROLS WHEN THE HISTORY SCREEN IS BEING VIEWED.

HISTORY HELP SCREEN

LSC MODEL 1022 REFRACTOMETER

6. REFRACTOMETER
6.1 Theory of Operation

The sensing head detects changes in the refractive index of the process fluid. The sensing window is
actually the flat base of a sapphire hemisphere (prism) which sets up a sapphire/ liquor interface. The
internal components are located in fixed self-aligning positions to achieve an optimum critical angle. The
“critical angle” is the angle at which refraction stops and reflection starts, and is directly related to the
refractive index of the process fluid.

6.2 Internal Components of Sensing Head

Various components of the sensing head are shown in Figure 7 (next page).

6.2.1 Lamp Assembly

 Infrared LED: a diode in a Resin case with epoxy.

 Collimating lens: creates a uniform beam, mounted in the end of a collar into which fits the LED.
The LED is secured with a set screw.

 Focusing lens/source mounting block: the lens creates the converging beam, and is epoxied into
the mounting block. The block anchors the collimating assembly with a retaining screw.

6.2.2 Detector Assembly

 Detector: dual silicon solar cell; measure and reference.

 Terminal strip: the junction point for internal wiring.

 Detector mounting block with detector locator

6.2.3 Temperature Sensor Assembly

 Temperature sensing diode sealed in aluminum casing with epoxy.

 Heat sink compound: ensures efficient heat transfer between the diode and the sensing head base block.

 Insulating retaining collar and retaining screw.

6.2.4 Prism Assembly

 Prism gasket: made from Teflon, must be baked to seal.

 Prism: high quality industrial sapphire hemisphere.  Prism hold down assembly

39
LSC MODEL 1022 REFRACTOMETER

6.3 Refractometer Calibration

The refractometer measures refractive index and is not affected by the make-up or materials contained in
the liquid. On that basis, synthetic samples can be prepared to simulate actual process samples when
actual process line conditions and liquids are not practical.

Two samples are needed, one for the low and one for the high end of anticipated refractive index. Avoid
highly volatile materials or mixtures that are not miscible. Be sure that samples are allowed to equilibrate
at ambient temperature. Samples at ambient temperature should simulate the refractive index of the
process material at its nominal operating temperature.

6.3.1 Calibration Procedure

Note: Before Proceeding:
1) Close ONLY ONE GATE ADAPTOR AT A TIME so that one refractometer remains active.
2) Shut off the steam supply ONLY to the refractometer being calibrated.

Calibration is performed using the adjustment controls illustrated below.

1) Remove the sensing head from the gate adaptor and rinse off the gate and sensing head with hot
water in order to remove the black liquor without thermally shocking the prism.
2) Allow approximately 20 - 30 minutes for the sensing head to reach room temperature.
3) Place the sensing head on its cover and remove the wash nozzle by removing the two straight slot
screws located on the prism wash nozzle.
4) From the main screen in the 1022 box, press the “MENU” button, then press the “VIEW MODULE
OPERATION” button. From there press the corresponding “REFRACTOMETER” button (A or B). From
this screen all refractometer parameters are viewed.
5) Apply several drops of low refractive index sample onto the prism of the sensing head. Cover the
prism to prevent from stray light sources.
6) Turn the zero dial to 500 and flip the temperature compensation switch to
“OFF”.
7) Adjust the course zero trim potentiometer (labeled “CZ”) to achieve 0 volts as displayed on the
screen.
8) Clean the sensing head window well and apply the high end sample. Cover the prism to prevent
interference from stray light sources. The output will go up to a high value.
9) With the span control knob, set the output to read 10.0 VDC. Re-check both low and high end
samples making sure indications are exact and correct, and that the output indication is below scale
when the sensing window is clean and dry.
10) Flip the TC switch to ON.
11) Replace the wash nozzle.
12) Reinstall the Sensing Head on the Gate Adaptor.
13) Open the gate and turn on the steam supply.
14) After the head has reached the process temperature, approximately 30
minutes, set the temperature read out and the temperature compensation
for the Sensing Head calibrated. (A or B)
15) Set the temperature read out to the process temperature by adjusting “TR”.
16) Adjust the temperature compensation voltage to 0 by adjusting “TZ”.
17) Press the exit button twice to return to the main operating screen.
18) Any fine zero adjustments can now be made using the ZERO counting dial to
correlate to off line testing.

40
LSC MODEL 1022 REFRACTOMETER

Figure 7
Sensing Head Assembly
LSC # 829114 LSC #725302
Or # 614300
LSC #725309
SEE VIEW B

LSC #725307

LSC #725308

LSC #614009-2205
PRISM WASH NOZZLE
(OPTIONAL)

LSC #829050

LSC #829052

BRN
BRN BRN
GRN GRN
YEL WHT LSC #829051
BLU BLU
LSC #610100
BLK BLK
RED RED LSC #829098

VIEW B

41
LSC MODEL 1022 REFRACTOMETER

6.4 Refractometer Maintenance

6.4.1 Prism Replacement

Replacement of the prism or prism gasket is required when the prism becomes etched, foggy or
damaged visibly. See Figure 7 View A (page 40) for an exploded view of the prism assembly.

1) Remove all internal components

2) Assemble all parts as shown in Figure 7, View A
3) Torque the hold down screw to 25 inch-lbs.
4) Bake assembly at 400 degrees Fahrenheit for 4 hrs.
5) Upon completion of baking remove and tighten the hold-down screw to 35 inch-lbs.
6) Allow the assembly to cool.
7) With a sharp knife point, remove any gasket material extruded over the prism window on
the underside of the baseplate.
8) Tighten the hold down screw lock- nut.
9) Replace remaining parts. Install cover along with O-ring.

6.5 Prism Wash Check Valve Replacement

One of the most common causes of prism wash failure is the seizure of the check valve at the steam line
inlet to the sensing head. The usual remedy is replacement of the check valve by the following
procedure:

1) Close Gate Adaptor

2) Shut-off steam to sensing head and or
3) Shut off air to solenoid which activates steam ball valve.
4) Remove the steam line and the check valve.
5) Apply Teflon tape or a suitable thread sealing compound to the threads of the new check valve.
6) Install the new check valve, matching the valve’s flow direction to that of the prism wash system.
7) Return all line and valves to their operational positions.

NOTE: Closing the gate will automatically place the 1022 in single head operation. The CPU
acknowledges the closure of the gate adaptor and the unit will not send a signal to the prism
wash solenoid. However, please follow the above procedure for safety precautions.

42
LSC MODEL 1022 GATE ADAPTOR

7. GATE ADAPTOR

The LSC gate adaptor provides a means for simple and quick removal of a LSC In-line Refractometer
Sensing head from an active process pipeline. The Gate adaptor employs a completely captivated slide
plate, mechanically sure, operated by an eccentric cam. Operation of the Gate adaptor is accomplished by
turning a 25mm hex cam just under ½ turn. Double Teflon seals are provided against both sides of the
slide plate. The Gate adaptor provides for an external lock “fully open” or “fully closed” with positive
visual and physical indication of “fully open” or “fully closed”

The components of the Gate Adaptor assembly are illustrated in Figure 8 (page 42).

7.1 Gate Adaptor Maintenance

Before maintenance can be done the sensing head must first be safely removed;

1) Turn off the steam and air supply to the Prism Wash Valve.
2) Rotate the 25mm hex cam counter clockwise to align the closed indication with the cam reference
point. Insert the LSC lock (PN # 670350) through the ¼ hole located next to the open indication.
(See illustration) If our lock is not available a 2” x .250” dia. pin may be used.
NOTE: The lock will go through only when the gate slide is 100% fully closed, or 100% fully open.
3) Break the steam line connection between the prism wash valve and the Sensing Head check valve,
and remove (free) one end of the line. Note: Be very cautious of steam pressure that may be
trapped within this short piece of line.
4) Note: When closing the Gate Adaptor, some Black Liquor will be trapped (or captivated) between the
Sensing Head and the closed Gate slide plate. This area is a 3/8 inch X 2 inch dia.
5) Loosen the four (4) mounting bolts (1/4 x 20) sequentially, and in small increments. Never remove
one of the bolts completely at one time. Loosen the four bolts in a manner that you understand and
except some small amount of black liquor to "ooze" out from between the Sensing Head and Gate
Adaptor. Always be fully prepared, and be protected! (hands arms and face!)

7.1.1 Removal and Annual Rebuild of Gate Adaptors

1) Once the sensing head has been removed and all liquids drained from the process line, gate adaptor
removal can begin.
2) Remove the four threaded inserts from the sensing head mounting holes, allowing access to four of
the gate adaptor mounting bolts.
3) Unscrew the six mounting bolts that hold the gate onto the pipe section. Note that the four corner
bolts are captive and must be unscrewed in successive increments to avoid jamming.
4) Dismantle the gate adaptor by removing twenty-two socket head cap screws.
5) Remove O-rings and clean all liquor from O-ring grooves.
6) Inspect all parts for visual damage and replace or repair as necessary.

43
LSC MODEL 1022 GATE ADAPTOR

7.1.2 Gate Reassembly

1) Apply a thin layer of High-Temperature Teflon Grease, LSC part no. 829487 to all four internal sliding
surfaces and O-ring grooves. (See Figure 8.) This lubricant protects the O-rings and moving parts
during operation. Use of other lubricants could lead to leaking and eventual seizing.

2) For ease of assembly, set bottom plate on a set of riser blocks at least 1/2” thick.

3) Place the four, 5/8” captive gate mounting bolts, with their high collar lock washers, into the counter-
bored holes in the bottom plate.

4) Press the O-rings (LSC #640065 & 640023) into the appropriate grooves of the top and bottom
plates and smooth any excess lubricant.

5) Position the slide gate on the bottom plate aligning the oval hole over the C-shaped cutout in the
bottom plate.

6) Place the greased cam actuator assembly onto the slide gate with the small bearing in the oval hole.

7) Position the side rails on the bottom plate.

8) Situate the top plate onto the previously arranged assembly, guiding the cam actuator to seat it in
the opening of the top plate.

9) Position the end plates and install the twenty-two socket head cap screws (complete with lock
washers and anti-seize compound).

10) Tighten the bolts in progressive succession, starting in the center and alternately progressing to the
ends.

11) Slowly cycle the actuator (using a 1” box wrench) to seat the O-rings and evenly distribute the excess
grease.

12) Before mounting the Gate Adaptor to the pipe, make sure the pipe mounting plate surface and O-ring
groove are clean.

13) Install a new Teflon O-ring (LSC part no. 640040 into the pipe mounting plate O-ring groove.

14) Position the gate adaptor on the pipe and fasten with the four captive bolts (be sure to use an anti-
seize compound on the threads), then install the remaining two 7/16” bolts with lock washers.

15) Screw the threaded inserts into the four captive bolt holes.

16) Make sure each insert is screwed below the top plate surface, bottomed and tight!

17) Seat a new Teflon O-ring (P/N 640040) into the groove on the gate and re-attach the sensing head,
steam fittings, and gate adaptor limit switch (if removed).

18) The gate should be cycled open.

19) Re-establish the steam and air supply to the prism wash system.

NOTE: Due to close tolerances in all locations where socket head cap screws are used
a high collar lock washer must be used.

44
LSC MODEL 1022 GATE ADAPTOR

NOTE:
1. GATE ADAPTOR SHOWN IN CLOSED
POSITION WITH LOCK.
2. ASSEMBLE LOCK (LSC #670350) THRU
HOLE IN GATE ADAPTOR TO LOCK IN
OPEN OR CLOSED POSITION
3. LOCK HOLE (WITHOUT LOCK
ASSEMBLED) TO BE USED AS A VISUAL
INDICATOR TO DETERMINE POSITIVE
FULLY OPEN OR POSITIVE FULLY
CLOSED POSITION OF VALVE

45
LSC MODEL 1022 SPARE PARTS KITS

8. SPARE PARTS

614903 : IN-LINE SENSING HEAD SPARE PARTS KIT

QTY DESCRIPTION PART #

4 SCREW, PH #2-56 X 3/8 LONG 102006

4 LOCK WASHER, # 2 102820
3 SCREW, SH/CS #6-32 X 3/8 LONG 106206
2 LOCK WASHER, # 6 HC 106830
7 SCREW, SH/CS 1/4-20 X 7/8 LONG 125214
7 LOCK WASHER, 1/4 HC 125830
1 PRISM SAPPHIRE 610100
1 TEMPERATURE SENSOR ASSEMBLY 614300
1 O-RING, 3-5/8 OD X 3-3/8 ID 640040
1 O-RING, 4-7/16 OD X 4-1/4 ID 640066
1 GASKET T – BOX 725010
1 DETECTOR HOLDER ASSEMBLY 725307
1 LIGHT SOURCE ASSEMBLY 725308
1 GASKET PRISM SEAL 829098

829254 : GATE ADAPTOR SPARE PARTS KIT

QTY DESCRIPTION PART #

1 CAM ASSEMBLY 829245
4 THREADED INSERTS 829233
2 O-RING (SMALL) TEFLON ENCAPSULATED 640023
2 O-RING (LARGE) TEFLON ENCAPSULATED 640065
2 O-RING (WHITE) 640040
1 STICK FREE LUBE 829487

46
LSC MODEL 1022 SPARE PARTS KITS

1022915 : 1022 GENERAL SPARE PARTS KIT

QTY DESCRIPTION PART #

1 1022 PC – 1, CPU BOARD 1022401

1 1022 PC – 2, RELAY CIRCUIT BOARD 1022402
1 1022 PC – 3, POWER SUPPLY CIRCUIT BOARD 1022403
1 1022 PC – 4, REFRACTOMETER CIRCUIT BOARD 1022404
1 MAINTENANCE PANEL 1022412

1022920 : EXTENDED SPARE PARTS KIT

QTY DESCRIPTION PART #

1 1022 PC – 5, MOTHER BOARD 1022405

1 OPERATOR PANEL ASSEMBLY 1022408ND

9. APPENDIX A: Alarms and Event Messages

SET An alarm has been activated

CLR An alarm has been cleared

AOP “A” refractometer only operation

BOP “B” refractometer only operation

LO% Low solids alarm

DIF Differential solids (2%) alarm

D-V Divert valve limit switch input a failure means the divert valve
has not followed the Divert signal within the predetermined
amount of time.

Wfail The corresponding refractometer has failed the “Smart Wash”

MALFUNC The corresponding refractometer is malfunctioning. REF:

“History” screen for reason.

GatCL The corresponding Gate Adaptor has been closed.

47