PSI 300 Particle Size Analyzer Operating Manual: Code 10000004257e Revision A Page 1

Code 10000004257e Revision A Page 1 (37)
PSI 300
Particle Size Analyzer
Operating Manual
Operating Manual
Contents
1. OPERATING THE ANALYZER .....................................................................................................................3

1.1 Operating principles ...........................................................................................................................3
Control switches and indicators .....................................................................................................3
Local display ..................................................................................................................................3
Using the touch screen ..................................................................................................................4
1.2 Starting and stopping the analyzer.....................................................................................................5
Before starting the analyzer ...........................................................................................................5
Starting the analyzer ......................................................................................................................5
Stopping the analyzer ....................................................................................................................6
1.3 Operational states ..............................................................................................................................7
1.4 Using the maintenance switches........................................................................................................8
1.5 Using the zero check button...............................................................................................................9
1.6 Using the calibration button................................................................................................................9
1.7 Using the local display........................................................................................................................9
Main and Last assay values displays...........................................................................................10
Trend and Histogram displays .....................................................................................................12
1.8 Status displays .................................................................................................................................13
Setting sample lines to bypass/normal ........................................................................................14
Sample line status display............................................................................................................15
Alarm display and acknowledging alarms....................................................................................15
Zero level history display..............................................................................................................16
1.9 Options displays ...............................................................................................................................17
Assay variable settings ................................................................................................................18
Display settings ............................................................................................................................19
Measurement Sequence setup ....................................................................................................20
Analyzer System parameters .......................................................................................................20
Sample Measurement setup ........................................................................................................22
Primary Sampler Control setup ....................................................................................................23
Advanced Options setup ..............................................................................................................23
Instruments display ......................................................................................................................24
2. CONTROLLED PRIMARY SAMPLING .......................................................................................................26
3. COLLECTING CALIBRATION SAMPLES ..................................................................................................27

Collecting calibration samples......................................................................................................27
Calibration results ........................................................................................................................29
Calibration parameters.................................................................................................................30
4. DAILY MAINTENANCE ...............................................................................................................................31
5. ALARM AND STATUS MESSAGES ...........................................................................................................32

5.1 Analyzer status.................................................................................................................................32
5.2 Alarm messages...............................................................................................................................34
6. DEFAULT PARAMETERS...........................................................................................................................35
Assays..........................................................................................................................................35
Display settings ............................................................................................................................35
Analyzer system...........................................................................................................................36
Sample measurement ..................................................................................................................36
Sampler control ............................................................................................................................37
Optional devices...........................................................................................................................37
DCS Parameters ..........................................................................................................................37
Operating Manual
1. OPERATING THE ANALYZER
1.1 Operating principles
Control switches and indicators

The Main power switch locates on the right hand of the Valve Box Set, under
the Probe Control Set. Other control switches, buttons and indicators are
located on front panel of the Probe Control Set.
Figure 1. The control switches and indicators on the PCS.
They are,
PSI 300 Standby switch; when switched to STANDBY the analyzer stops
the measurement operation, flushes the flow tank and goes to a safe
standby state, and when switched to NORMAL the analyzer starts the
measurement sequence.
Calibration sample button, to cut a calibration sample out of the next
sample line to be analyzed
Zero Check button to request a zero check. Zero check maintains
accuracy of the PSI 300 particle size measurement.
Alarm status lamp to indicate that there is an active alarm in the system.
In addition the analyzer system can have a remote Maintenance switch in the
pneumatic control valve boxes of the primary samplers.
Local display
The local touch screen display functions as a user interface for various tasks
within the analyzer system.
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Figure 2. The local display on the PCS.
The local display in the Probe Control Set shows:

Operational state
Assay and diagnostic data
Alarms
Assay trends, and current particle size distribution graphs
Special commands for standby
Current functional parameters and variable settings
Using the touch screen

The local display is equipped with a touch screen as a user command input
device. Pressing the display’s surface on a desired point acts similarly as
clicking on it with a left mouse button. Screen changing, pop-up opening, and
button and selection commands on the local display are performed simply by
pressing shortly the appropriate component shown on display.
For most parameter inputs pressing the component opens a keypad dialog
window that will work in the same way as the keyboard.
Figure 3. The keypad dialog.

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1.2 Starting and stopping the analyzer
Before starting the analyzer

Check the Base Frame Assembly and secondary sampler. Make sure that:
The secondary sampler tank, the primary sample inlet, the sample return
pipe and the sample cutters are free of foreign material (dried slurry, scale,
plastic, wood chips, rocks etc.).
– Flush with water if necessary. The sample cutter pipes can be flushed
with a water spray from below.
The calibration and composite sample buckets are in place and clean if
they are needed.
The instrument air filter and water separator, located in the Valve Box Set,
under the VBS, are clean.
Starting the analyzer
a When starting the analyzer, make sure that there are no other personnel
working on any part of the analyzer.
If PSI 300 includes density meter, refer to density meter operating manual.
Density meter requires field configuration on first startup after
installation.
To start the analyzer:

1. Turn the Standby switch located on the front panel of the Probe Control
Set to the NORMAL position.
2. Open the water supply valve.
3. Open the instrument air valve.
Note: if you are starting the analyzer for the first time, or there has been a
change in the instrument air supply, check that the pressure is set at 4 bar
(?) in the pneumatics unit in the Valve Box Set.
4. Check that there is no water or air leakage.
5. Start the primary sample flows if the primary samplers are not controlled by
the analyzer.
6. Turn the power switch to position 1 (ON).
If you are starting the analyzer for the first time or need to change the
parameters, turn the Standby switch to STANDBY. See chapter 1.9
Options displays how to change analyzer parameters.
7. Motor of the measurement probe is started.

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8. The PSI 300 software is loaded, this will take for a while.
9. The main operating window is shown on the local display of PSI 300.
10. The analyzer starts with the Initialization sequence. Check that pneumatic
valves are working as show on the Status display, see detailed information
later on this section. For detailed information of display messages or
troubleshooting, see section 8 in this manual, or refer to the PSI 300
Maintenance Manual.
11. The next phase is the Zero Check sequence. If the zero check is not
acceptable an alarm is set and the reason of the alarm needs to be
corrected.
12. Finally the Auto Measurement is started.
The start up procedure is now complete and the analyzer has started measuring
the sample.
Stopping the analyzer

Stopping for a short period of time (< 1 week)
If the analyzer needs to be stopped for less than a week, it is recommended

that you stop only the sample measurement and leave the analyzer to Standby.
By following these instructions you can avoid blockages in the pipelines when
restarting the analyzer.
To stop the sample measurement:

13. Turn the standby switch of the Probe Control Set to STANDBY. The
measurement of the current sample or the other currently running
sequences are completed. Flow tank and measurement probe are
automatically drained and flushed with water. The system stops and
flushes those sample lines that are in automatic control mode.
14. The analyzer is brought to the Standby state. All automatic functions
remain stopped until the Standby switch is turned back to NORMAL
position.
15. If the primary samplers are not controlled automatically by the analyzer
(option), stop the primary sample flows manually. Ensure that the sample
delivery/return lines are flushed with water to ensure an easy restart.
16. Make sure that the sample cutters in the Base Frame Assembly (BFA) are
clean. Flush with water if needed.
17. Make sure Quick drain valve is open.
Now it is easy to restart the sample measurements again.
To restart the analyzer:
18. Start the primary sample flow, if not controlled automatically (option).
19. Turn the Standby switch to NORMAL. The analyzer will start the sample
measurement automatically after Initialization and Zero Check
Measurement.
Stopping for a long period of time (> 1 week)
In case the analyzer needs to be stopped for longer than a week, it is

recommended that you shut the power down of the entire analyzer.
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To stop the entire analyzer:

20. Follow the instructions 1 to 5 given above.
21. Turn the main power switch to position 0 (OFF). Motor of the measurement
probe is stopped.
22. Shut off the water and instrument air supplies.
23. Release the water pressure from the piping. Because of an air purge, the
instrument air pressure is slowly released by turning the air supply valve
off.
Now the analyzer has been shut down properly and it is easy to restart.
1.3 Operational states

PSI 300 is designed to run automatically with minimal operator actions. The
analyzer continuously diagnoses its operation in different process conditions
and disturbances and acts according to them. The system performs consecutive
functional sequences after starting the analyzer and during the normal
operation. The main states of the analyzer are presented in Figure 4. The
current states are shown as messages on the Main and Status displays.
Initialization
Zero Check
Auto Measurement
Zero Check
Standby or
Flushing
Figure 4. The operational states of the analyzer.
The analyzer starts through the Initialization state. Next follows the Zero
check with additional primary sampler (when in automatic control) flushes. In
zero check, 40-120 measurements are performed during water flush. When the
standard deviation of the measurements falls below the limit (default 5 um), the
calculated mean value of this 40 measurements is set as a new zero level. If the
mean value exceeds the alarm limits, zero check alarm is activated and the
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value is not accepted. Fraction calculation is then normalized with the new
granted zero level to eliminate the wear of the measurement elements.
After this system passes to the Auto Measurement. The analyzer starts to take
secondary sample cuts and making particle size assays according to the
defined sample sequence. Sample measurements consists of 120 individual
measurements which are collected into the measuring file. After the
measurement assays are calculated based on these measurements updated on
the local display and outputs. Also the calibration sampling (if was active) is
completed. Next the next line in sequence will be selected for measurement.
If there are no operator or remote requests or alarm conditions the analyzer

keeps on running in the Auto Measurement state until a time based Zero Check
Measurement occurs. After the new zero level update the Auto Measurement
goes on. The system monitors the operation with pressure, air and level
switches as well as by diagnosing the measurement results. If an abnormal
condition is detected, such as water, instrument air or sample delivery break, an
appropriate alarm or warning is set. For more information about alarm and
warning messages see section 5.
An alarm condition, the standby switch or a remote standby command from the
automation system brings the analyzer to the Standby state. Flow tank and
measurement probe are drained and flushed and the primary samples (when in
automatic control) are flushed and stopped. The Tank’s drain valve is left open.
When all these operations are completed the Going Standby message turns to
Standby message. When the system is on Standby the user can start Zero
Check by pressing Zero Check button or flush the tank by pressing Flush
button on the Status display.
After the standby switch is set to NORMAL or all current alarms are
acknowledged, the analyzer continues from Standby to Initialization state.
1.4 Using the maintenance switches

The analyzer standby switch is on the Probe Control Set (PCS). In addition, the
system has separate standby switch for the primary samplers if they are
automatically controlled.
At any point of time, switching the standby switch on the Probe Control Set
(PCS) to STANDBY causes the analyzer to go to the Standby state. The flow
tank’s drain valve is left open and all water valves are closed. Any automatically
controlled primary samplers are flushed and closed. Now the analyzer is safe
for maintenance operations.
The flow tank and measurement probe can by flushed in Standby state by
pressing Flush button on the Status display, to make an additional manual
flush.
a When using the manual valve commands, make sure that there are no
other personnel working on these parts of the analyzer.
When the Standby switch for a primary sampler is switched to STANDBY all
pneumatic controls stop operation immediately. The water and sample line
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valves close and NLA’s cleaning knife is drawn into the cutter. The primary
sampler is safe for maintenance operations. Note that the pipelines may contain
pressurized water and process sample.
The analyzer keeps running normally, except that the primary sample line is set
to BYPASS.
When using the primary sampler’s standby switch it is recommended to

first turn the Probe Control Set’s (PCS) standby switch to STANDBY, or
the corresponding sample line to BYPASS using the Status display. If the
primary sampler is in remote control, it should be stopped through the
automation system. This ensures that the primary sampler and the sample
pipeline are flushed properly before the flow is stopped.
1.5 Using the zero check button

The system makes a zero check measurement at every system startup and
after standby switch is turned to OFF. System makes a zero check
automatically also if certain time interval, that is set in the Analyzer System
display, is expired.
Zero check can also be activated manually during Auto measurement by

pressing the Zero Check button on front panel of the Probe Control Set. Zero
Check request (yellow text) appears on the Main and Status displays. Before
Zero Check measurement is started, system waits that ongoing sequence is
completed.
Zero Check can also be activated by pressing Zero Check button when the
system is in Standby state. In Standby state, it is also possible to activate a
manual tank flushing by pressing a Flush button on the Status display.
1.6 Using the calibration button

Calibration sampling is activated by pressing the calibration button on front
panel of the Probe Control Set. Calibration sample is taken from the next line
which is measured next. Calibration sample request with the sample line
number (yellow text) appears on the Main and Status displays. When
calibration sampling starts green light is switch on in the calibration button.
More about Calibration sampling is told in chapter 3, Collecting calibration

samples.
1.7 Using the local display

The local display consists of four screens, which can be opened any time by
pressing the touch buttons on the bottom of the display. These navigation
buttons are shown constantly on any screen.
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Figure 5. The navigation buttons in the local display.
To the right of the navigation buttons there is an additional button to be used

when you wipe the display clean. This button opens a blank screen and
disables other navigation buttons. After the cleaning of the display is done,
return to the normal screens by pressing the same button again.
There are several sub-screens and pop-ups under the four main screens. The
structure is as follows,
Main
– Last assay values
Trend
– Three 2 hours trend displays
– Three 8 hours trend displays
– Current particle size distribution histogram graph and filtered particle
size distribution histogram graph (for each sample line) .
Status
– Alarms
– Sample line status
– Zero level history and 70 weeks zero level history.
– Calibration results
Options
– Assay options
– Display settings options
– Analyzer system options
– Sample measurement options
– Primary sampler cleaning options
– Advanced options
– Instruments
– DCS parameters
– System test
Navigation bar clock time is displayed in 24 hour format and day format
depends on panel regional settings (default: US).
Main and Last assay values displays

The Main display indicates the operational state of the analyzer. The alarm,
warning, and information messages are displayed on this screen. At the most
six assay values are shown to give quick information of the state of the
measured process. The Main display contains no operational command
buttons.
Last assay values display shows current values of the maximum 40 assays.
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Figure 6. The Main display.
The Main display consists of a number of text fields, including:

‘Assays’ field, for max. six current assay values, with titles and units.
‘Analyzer State’ for
– operational state of the analyzer (Standby, Zero Check, Auto
Measurement)
– functional messages on the processes that are currently active (like
Cleaning Primary Sampler, Taking Calibration Sample, Taking
Composite Sample)
– ALARM messages and detailed information of alarms and warnings.
– The status of operator control switches and buttons: Standby Request
ON, Calibration Sample Request ON and Zero Check Request ON.
‘Assay Status’ for the present and next sample measurements – the time to
the next assay update, and the time when the next sample line in the
sequence will be started.
‘Time to the next composite sample’
‘Calibration Sample’: After the sample has been requested the calibration
ID is shown until the calibration sample is ready and the next measurement
starts.
For more information of the status, alarm, and warning messages, see section
5.
Last assay values display shows current values of the maximum 40 assays.
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Figure 7. The Last Assay Values display.
Trend and Histogram displays

The Trend display shows at most four assay value trends plotted either with 2 or
8 hours timescale. (There are three 2 and 8 hour trend displays. These trends
do not depend on sample line).
Figure 8. The Trend display.
The Trend display consists of:

trend graph area.
variable title legend.
buttons to change between three trend displays.
buttons to change between 2 h and 8 h trends.
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arrow buttons to rescale the y-axis or reset the scale back to original
settings.
link button to the Distribution display..
The distribution displays show the current (last measured) particle size
distribution. (There is one display for each sample line). The filtered distribution
display show the current filtered particle size distribution.
Figure 9. The Distribution display.
The Histogram display consists of:

histogram graph area
frequency distribution (%) plotted with blue bars.
link buttons to Trend displays, (two other sample lines; the selected sample
line is shown in yellow).
link button to filtered distribution display.
1.8 Status displays

The Status display indicates the detailed operational state of the analyzer. All
active alarm, warning, and information messages are displayed on this screen.
An animated system diagram shows the current operation of the controls and
the state of the inputs.
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Figure 10. The Status display.
The Status display consists of:

Animated analyzer system diagram
– buttons for putting the sample lines to bypass or on; indication colors:
yellow=on, gray=bypassed
– valve operation; colors: green=open, gray=closed.
– level sensor status; colors: green=on, gray=off
– pressure sensor status; colors: green=pressure ok, red=pressure
insufficient.
– yellow box presents measurement head; inside box green color is
blinking when sample is measured.
– If PSI 300 includes density measurement, there is an icon between the
particle measurement head and tank representing density meter.
Operational state of the analyzer, alarm, warning and information
messages. They are same as on the Main display.
Assay Status for the present and next sample measurements – the time to
the next assay update, and the time when the next sample line in the
sequence will be started.
link buttons for the Alarm, Sample Line Status and Zero Level History
displays.
Press button Flush; manual flushing in standby –state
Press button Reset Alarms; alarm reseting -> PSI 300 tries to start
measuring again
Press button to copy calibration log to external USB removable disk.
Link button for Calibration results display.
Setting sample lines to bypass/normal

The sample line buttons on top of the animated system diagram toggle the
sample lines between normal and bypass states. Yellow color indicates that the
sample line is on whereas gray indicates bypassed condition.
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When a sample line is switched to bypass it will not be measured, that is, it is
skipped in the sample sequence.
If the sample line is in AUTOMATIC mode switching the line to bypass will
request a primary sampler cleaning and the sample flow is stopped. When the
bypassed sample line is switched back on, the primary sampler is flushed and
the flow is started again.
Sample line status display
Figure 11. The Sample Line Status display.
Alarm display and acknowledging alarms

The alarm display shows the alarm and warning message lists.
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Figure 12. The Alarm display.
The Alarm display consists of:

lists of recent alarms and warnings, with columns for date, time and
description of the alarm or warning
link button to the Status display.
In an alarm situation, the system brings the analyzer to Going Standby –state
and drains and flushes the flow tank. The alarm lamp flashes on the front panel
of the Probe Control Set, and the alarm messages are displayed on the Main,
Status and Alarms displays. The measurement does not continue until the
reason for the alarm is removed.
To acknowledge the alarm:

1. Go to the Status display.
2. Press the Reset Alarms button.
3. System tries to restart the measurement.
System tries to restart the measurement also automatically in 10 minutes time

intervals. If the alarm is removed, analyzer continues from the Standby state to
the Initialization sequence.
If the instrument air / water pressure is low the analyzer does not continue
functioning until sufficient air / water pressure is reached.
Zero level history display

The Zero level history display shows mean value (um, blue dots) as well as
density (kg/m3, red dots) of last 70 zero checks. A new value is always added
on the right border of the chain and old values are moved to the left. The oldest
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value is removed from the left border of the chain so that together 70 values are
shown.
There is also an average weekly zero check history display. The display
includes history from last 70 weeks. This display can be accessed from Zero
level history display.
Notice: Density measurement is not yet available in PSI 300.
Figure 13. The Zero level history display.
Zero level history display consists of:

Graph area
Link button to Status screen
Link button to weekly average value history screen.
1.9 Options displays

The PSI 300 analyzer has a number of parameters to adjust the functioning of
the sampling and measurement process, to define assay variables and the user
interface. This section presents a summary the parameters.
To enter to the parameter displays press the Options button. This opens first the
Password pop-up window. Enter the three digits password number and press
ok. The password is not requested if it is disabled on the Advanced Options
display.
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Figure 14. The Password pop-up window.
Note: Make sure that you remember the password after changing it on the
parameters display.
Each options display has three buttons on the right hand side,
– saves the parameter values so that they are kept after a
shutdown.
– retrieves the last saved settings.
– retrieves the factory default parameter values.
The save and load operations concern all parameters at the same time. After
any parameter change a save is required for the changes to remain in effect in
an analyzer restart.
Assay variable settings

The first Options display contains parameter values for up to 40 assay
variables.
Figure 15. The Assay Configuration display.
The Assay Configuration display contains:

drop down menu or selection buttons each assay variable, from 1 to 40
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selection button for assay type

– Not in Use (Default)
– Particle size
– Particle size from distribution
– Flowrate
– Density
– Solids %
– pH
assay label button
Parameter buttons for assay types:
– Calibration inputs for particle size
– Low and high limit for particle size from distribution
– Multiplier and offset for Density
– Solids density for Solids %
– Multiplier and offset for Ph
sample line selection, validity time and filtering constant buttons for the
selected assay
Sample line label buttons.
Display settings
The Display Settings display contains the setup of the numerical assay values
shown on the Main display and the variable selection and settings for the Trend
display.
Figure 16. The main display settings pop-up window.
The Display Settings include:

selection buttons and drop-down menus for six assays to be shown on the
Main display, and their unit texts. The ‘µm’ buttons allow the micrometer
symbol to be written into the end of the title or unit text fields of the display.
Selection buttons and drop-down menus for four assays to be plotted on
the Trend 1 display, and their unit texts.
By clicking the black arrow on the Trend 1 Display Settings -row there
opens another display with similar structure for Trend 2 and Trend 3.
(There is together three trend displays).
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Measurement Sequence setup

The sequence order in which the three sample lines are analyzed is defined in
the display. The sequence length can be up to 12, and when the end is reached
the sequence starts again from the beginning.
Figure 17. The Measurement Sequence display.
The display includes,

sample line selection buttons for each sequence position
selection for sequence length
Analyzer System parameters

The system parameter display contains general parameter values for the
sample handling. They are,
Calibration Sampling
Cuts – no. of cuts for a single calibration sample
Cut Duration – cut duration in calibration sample cutting
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Cylinder Delay – cylinder delay in calibration sample cutting
Composite Sampling
Cuts – no. of cuts for a single composite sample
Interval – time interval between composite sample cuts (zero means that
no composite sample is performed)
Zero Check
Interval – time interval between zero checks (zero means that automatic
zero check is not performed)
Zero Level High Limit – high limit for mean value of measurements during
zero check (default 1100 um).
Zero Level Low Limit – low limit for mean value of measurements during
zero check (default 100 um).
St. Dev. Limit in Zero Check – high limit for standard deviation of
measurements during zero check (default 5 um).
Tank Cleaning
Slurry Draining Time – slurry draining time of the flow stabilization tank
before flushing
Extra Flushing Time Before ZC – extra water flushing time of the flow
stabilization tank before zero check measurement starts
Flushing Time Between Samples – water flushing time of the flow
stabilization tank between measurements of sample lines
Water Draining Time – water draining time of the flow stabilization tank
after flushing
Sample Prepare Time – delay ensures a stable and representative process
sample flow for fraction measurements
Flushing Interval (Single Line Mode) – when only one inlet is activated, flow
stabilization tank is flushed at regular intervals, not after every fraction
measurement
Figure 18. The Analyzer System setup display.

Operating Manual
Sample Measurement setup

The secondary sampler of the PSI 300 is controlled by means of a level switch
and the application program. The purpose of the secondary sampler is to
provide a representative sample for the measurement and maintain a constant
slurry flow to the measurement probe.
Based on the level switch signal, the slurry is dosed to the flow tank. The slurry
feeding adapts automatically to the availability of the sample flow from the
primary sampler. Sample dosing is based on short pulses in order to keep the
level at the level switch. System increases or decreases the rate of short pulses
automatically based on the primary sample flow rate. After measurement used
pulse duration is saved on the Pulse Duration parameter value.
The level switch can be simulated with simulation parameter. When the
simulation is active, PSI 300 ignores level switch operation and continues
measurement. This is useful if PSI 300 is needed to run without slurry flow.
Sample measurement parameters, Multiplexed/Single Line Mode:
Startup delay – time that tank is filled after level switch is already on
(overfilling in the first pulse)
Pulse duration – filling pulse duration, default 200 ms, changes
automatically according to the primary sample flow rate
Time Btw Pulses SP – set point for the time between pulses
Pulse Delay – minimum time between pulses, waits the level switch
Max Tank Fill Time – maximum tank filling time
Simulation fill time – time for tank filling before going to simulation mode
(must be less than max tank fill time).
Simulation active – When active, PSI 300 goes to simulation mode after
simulation fill time.
Probe Flow – sample flow through the measurement probe
Figure 19. Sample measurement options display.

Operating Manual
Primary Sampler Control setup

The Primary Sampler Control setup defines the operation mode for each
sample line. The mode can be
Disabled – no controls
Automatic – PSI 300 will control the sample lines autonomously
The setup display contains also the time parameters of the automatic
sequences. For the sampler control function, see section 2.
Figure 20. Primary Sampler Control setup.
Advanced Options setup

There are a number of parameters that should be left at their default values
unless there is a special reason that requires changing their value. They are,
Advanced System Settings

Options Password – when enabled, the 3-digit passcode is requested to
open the Options displays. The value of the passcode can be changed
here..
In addition, the Advanced Options display contains the link buttons,

Instruments – Maintenance display for particle size probe, density meter
and Ph-meter.
DCS parameters – Window for setting up parameters for Profibus, Modbus,
OPC and analog signal communications.
System Test - make a manual I/O test (functions only when the system is
on maintenance)
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Exit - stop the controller software application (functions only when the
system is on maintenance)
Figure 21. The Advanced Settings display.
Instruments display
Instruments display can be used on PSI 300 installation or maintenance. It
includes raw input signal from measurement probe. the display includes two
kinds of values: values that are valid when probe motor is on and values that
are valid when the maintenance measurement is active.
The instruments display contains,
Following values are valid only if the probe motor is off,

Input signal 0-32767 – Non-scaled input value from measurement probe.
Total value – Scaled input value from measurement probe (measurement
value + zero check).
Zero level – Zero level value from last zero check.
Following values are shown only when the maintenance measurement is on,
Last value – measurement value without zero level.
Last value (tot.) – Measurement value with zero level.
The display contains buttons,

Maintenance measurement – This button activates measurement loop
while PSI 300 is on standby mode.
Flush – This button opens all water valves.
Advanced – Return button to advanced display
Raw measurements – Measurement loop collects data to measurement
buffer what can be seen on raw measurements display.
Optional devices – Instruments display for density meter and Ph-meter.
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Figure 22. Instruments

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2. CONTROLLED PRIMARY SAMPLING

PSI 300 has facilities to control the primary samplers. The controls include all or
some of the following outputs;
a shutoff valve for the sample line
water valves for both upstream (from the sample valve towards the
process) and downstream (from the sample valve towards the analyzer)
flushing of the sample line
a pneumatic cylinder actuator to move a mechanical knife to remove trash
from the sample cutter
In addition, an input can be connected from a manual standby switch that

disables all control signals to the sampler.
When the analyzer goes to Standby all automatically controlled sample lines
setup to AUTOMATIC CONTROL are stopped, and when the system completes
Initialization they are started again. The same applies to any individual sample
line that is switched to BYPASS or ON by the user or through the plant
automation system.
On stopping any of the sample lines, the automatic sampler control makes the
following operations:
upstream flush
sample valve close
upstream flush
downstream flush
On starting a sample line, the sequence is

upstream flush
downstream flush
sampler cleaning knife movements
sample valve open
upstream flush
wait delay to stabilize sample flow
A periodic primary sampler flush can be set up for each sample line. The flush
sequence is a combination of the stop and start sequences.
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3. COLLECTING CALIBRATION SAMPLES
Collecting calibration samples

Calibration process requires physical calibration samples to be collected and
analyzed in the laboratory.
Calibration samples are cut in a similar way to the measured samples, using the
cutters on the opposite side of the secondary sampler. The number of the cuts
can be adjusted by the parameters at Analyzer System display to get a suitable
sample size. Other parameters related to calibration sampling on the Analyzer
System display are cut duration and cylinder delay which adjust movement and
speed of the cylinder.
Calibration sampling is activated by pressing the calibration button on front

panel of the Probe Control Set. Calibration sample is taken from the next line
which is measured next. Calibration sample request with the sample line
number (yellow text) appears on the Main and Status displays. When
calibration sampling starts, green light is switch on in the calibration button.
Calibration request is denied during composite sampling. Wait until

composite sampling finishes and press calibration button again.
Calibration sample is taken concurrently with the normal sample line

measurement. Secondary sampler takes first a sample cut to the flow tank and
then a sample cut to the calibration sample bucket on the opposite side. This
continues until the prospective number of calibration cuts is taken. After that
sampler continues taking cuts to the flow tank until 120 particle size
measurements are performed and collected to the measurement file. When
calibration sample cuts are taken alternately with the normal sample cuts
representativeness of the calibration sample is very high.
When collecting the calibration samples, it is essential that the samples are not
mixed with each other. It is also important that the samples are not
contaminated in any way. The whole sample collection and handling procedure
and the sample marking method should be clear to all users to avoid mistakes.
Sample buckets
The sample buckets should have watertight lids to avoid contamination or

partial loss of the sample during transportation. The sample bucket volume
should be 2 to 3 liters (1/2 to 3/4 gal) and it should be shaped for easy flushing
of the solids.
Operating Manual
Figure 23. Placing the sample bucket under the daily /calibration sampler.
When collecting the calibration samples, make sure that the process conditions
are suitable, that there are no alarms or warnings indicated and the sampling
equipment functions normally. Check also that the samples flow normally, the
sample bucket is clean and marked with the sample line name, and that you
have a pen available for writing the sample ID tags on the buckets.
It is important that both the analyzer and the related sampling equipment
functions normally during the sample collection.
To collect calibration samples:

1. Flush the calibration sampler cutter with water. Make sure especially that
the sample cutter is clean.
2. Place the sample bucket under the outlet of the calibration sampler.
3. Wait until the sample line number you want to take a sample from is
indicated as ‘Next Sample’ on the Main or Status display.
4. Press the Calibration Sample button on the Probe Control Set (PCS).
5. Make sure that the Calibration Sample Request is displayed on the Main
display.
6. The calibration sampling starts for the indicated sample line when the
sample measurement is started.
7. Follow up the sample measurement and the calibration sample cutting. The
volume of the sample is adjusted with the Calibration sample cuts
parameter value at Analyzer System display.
8. When the measurement ends, remove the sample bucket from the sample
outlet. Check that the volume of the sample is sufficient and close the
sample bucket with a lid. If the volume does not seem normal, there may
have been a problem with the sample flow. Check the validity of the
sample.
Operating Manual
9. See the sample identification stamp on the Main or Status display. Write
the ID stamp on the side of the bucket.
10. Flush the calibration sampler and sample cutters with water.
11. See calibration results from calibration results display in status display.
Calibration results
When the calibration sampling finishes, PSI will update calibration results in
calibration results display:
Figure 24. Calibration results
Calibration results display consists of:

Calibration ID
Date and time
Line
Average
Standard deviation
1/Average
Distribution values from –50 µm to +1000 µm
Button for copying calibration log to external USB removable disk.
The panel includes external compact flash storage. A calibration log is saved to
flash storage. The calibration log includes maximum 199 calibration samples.
After 199 calibration sample, the log is emptied and Calibration ID starts from 1.
The calibration log can be copied to external USB removable disk from buttons
in calibration results display and status display.
The calibration log can also be accessed from web server if the PSI 300 is
connected to plant network.
Operating Manual
The web server can be accessed through Internet explorer by typing the PSI
300 IP address to browser address bar. This shows a web interface for PSI 300.
Calibration log can be found from “Custom documents -> Calibration”.
When PSI 300 calibration has already been done, these assay values can be
used for verification of the PSI 300 analysis results against the laboratory
analysis.
Calibration parameters
Calibration coefficients (A0, A1, A2 and A3) are obtained from the regression
analysis done with the calibration data. They are set separately for each particle
size by four calibration parameter buttons on the Assay Configuration display.
Figure 25. Setting the calibration coefficients.

Operating Manual
4. DAILY MAINTENANCE
The PSI 300 analyzer is designed to operate independently and requires little
daily maintenance. However, you should conduct general check-ups regularly.
Table 1. Maintenance of the PSI 300 analyzer.
Operation Interval
Operation of the secondary Daily
sampler and the primary sample
flow
Condition of the calibration and Every time the sample buckets are
composite sample cutter collected for laboratory analysis
Check Local Display’s cleaning Weekly
requirement
Experience will indicate how often check-ups are needed.
If the analyzer does not control the primary sampler automatically, make
sure that the primary sampler is checked and cleaned regularly to
maintain the best possible performance.
Operating Manual
5. ALARM AND STATUS MESSAGES
5.1 Analyzer status

The analyzer status messages indicate the operational state of the analyzer and
are shown in the Main and Status displays. They do not require any operator
actions.
Operating Manual
Table 2. The status messages related to the operational state.
Status indication Color Description
Zero Check Green Zero Check measurement maintains accuracy of the PSI 300.
It follows 1) after turning power on, 2) after turning standby switch OFF, 3) after
Zero Check button is pressed, 4) after certain time interval that is set in
Analyzer System display.
Auto Measurement Green Measures the process samples in the sequence order. Updates the assay
variables after every measurement.
Going Standby Green The analyzer is going to Standby. Flow tank is drained and flushed before
analyzer is in Standby state.
Also when an alarm occurs, tank is drained and flushed and is going to
Standby. Analyzer tries restart after 10 minutes time interval or when Reset
alarms button at Status display is pressed.
Standby Green Before Standby tank is drained and flushed at Going Standby state.
When system is in Standby state, the drain valve is open and other valves are
closed.
Standby – Zero Check Green Manual Zero Check in Standby state. Zero Check is activated by pressing Zero
Check button.
Single Line Green PSI 300 operates in single sample line mode (two other sample lines are
bypassed)
Flushing *) Green Tank is flushed, water valves and quick drain valve are open.
Measuring *) Green Measuring sample flow (or water in Zero Check).
Tank Draining *) Green Tank is drained, slurry draining before flushing or water draining after flushing.
Quick drain valve is open.
Zero Check Request Yellow Zero Check button is pressed. The analyzer is waiting for the end of
measurement cycle to start Zero Check.
New Zero Check Measurement *) Green Zero Check measurement failed. After three trials an alarm is activated.
Zero Check OK! Green Zero Check measurement succeeded.
Calibration Sample Request for Line Yellow The calibration sample button is pressed. The analyzer is waiting for next
# measurement cycle to start the sampling.
Taking Calibration Sample for Line # Green The analyzer is taking calibration sample cuts.
CALIB ID # Green Calibration sample ID.
Standby Request Yellow The Standby switch is turned to ON. The analyzer is going to Standby.
Mech. Cleaning Primary Sample Line Yellow / Primary sampler’s mechanical cleaning (knife cuts). Mechanical cleaning is
# blinking done before measurement for the sample line that that will be measured next.
Full Cleaning Primary Sample Line # Yellow / The primary sampler full cleaning is running. Full cleaning is done with Zero
blinking Check. Can also to be activated time based.
Primary Sampler in Maintenance # Yellow The primary sampler is safe for maintenance operations. The analyzer
continues running and is waiting for the primary sample.
* The message is shown only on the Status display.

Operating Manual
5.2 Alarm messages

The analyzer alarm message indicates the alarm condition of the analyzer and
detailed description of the alarm on the Main and Status displays. The active
alarms are also listed on the Alarm display’s alarm list. Alarm messages are
displayed with red color.
Table 3. The alarm messages of the analyzer.
Alarm message Description Required action

ALARM Indicates that alarm has occurred, blinking. Find out the reason and acknowledge the
alarm after maintenance operation.
Zero Level Over High Mean value of measurements in Zero Check over Check flushing water availability and
Limit high limit (default 1100 um). pressure
Check that measuring elements are clean
Check that slurry draining time (parameter at
Analyzer System display) before flush is
sufficient
Zero Level Below Low Mean value of measurements in Zero Check Probe measurement elements are worn out
Limit below low limit (default 100 um). Check and replace measurement elements
St. Dev. In ZC Too High Standard deviation of measurements in Zero Measurement probe or flushing water is not
Check over high limit (default 5 um). clean
Check measurement probe
Check air and water pressure
Alarm No Signal No measuring signal from measurement probe. Check signal converter
Check associated wiring
Check measurement probe differential
transformer core
Alarm Motor Stopped Measurement probe motor is stopped. Check the motor fuse
Check motor wiring
Check measurement probe differential
transformer core
Alarm No Flow Line 1/2/3 No slurry from primary sampler or Check primary sample availability
Air pressure low or inlet cylinder broken or Check compressed air pressure
Tank level switch broken Check level switch operation
Alarm Water Pressure Water pressure is low. Check water pressure
Alarm Air Pressure Air pressure is low. Check air pressure
Alarm Blockage Flow nozzle at tank bottom is blocked or Check flow nozzle and quick drain
Quick drain duct is blocked or Check tank level switch
Tank level switch is broken Clean flow nozzle and quick drain duct
Operating Manual
6. DEFAULT PARAMETERS
These are factory default parameters for PSI 300 analyzer. Parameters are
classified according to Options display in PSI 300 user interface.
Assays
Parameter Value Unit Other
Line 1 label Line 1 -
Validity time 20 min
Filtering const. 1 -
Assay type Not in use - For assays 1-40
Assay label empty - For assays 1-40
Display settings
Main display: visible No - Display objects 1-6
Main display: Units none - Display objects 1-6
Trend 1 label Trend 1 -
Trend Y-Axis high 100.0 - For trends 1-3
Trend Y-Axis low 0.0 - For trends 1-3
Trend visibility No - For trends 1-3, objects

1-4
Trend units None - For trends 1-3, objects
1-4
Operating Manual
Analyzer system
Calibration cuts 15 - For lines 1-3
Calibration cuts 700 ms

duration
Calibration cylinder 0 ms
delay
Composite cuts 1 - For lines 1-3
Composite interval 0 min For lines 1-3
Zero check interval 480 min
Zero level high limit 1100 um
Zero level low limit 100 um
St. Dev. Limit in Zero 5 um

check
Slurry draining time 10 sec
Extra flushing before 5 sec

Zero Check
Flushing time between 10 sec
samples
Water Draining time 10 sec
Sample prepare time 10 sec
Single mode flushing 120 sec

interval
Sample measurement
Startup delay 500 ms For lines 1-3
Pulse duration 200 ms For lines 1-3
Time between samples 3000 ms For lines 1-3

SP
Pulse delay 0 ms
Max. Tank fill time 10000 ms
Simulation fill time 5000 ms
Simulation active OFF
Probe flow 14.0 l/min

Operating Manual
Sampler control
Primary sampler 0 min For lines 1-3
cleaning interval
Primary sampler control Auto - For lines 1-3
mode
Flush upstream 2.0 sec For lines 1-3
duration
duration
Flush downstream 2.0 sec For lines 1-3
duration
Knife cuts 3 repeats For lines 1-3

duration
duration
duration
Flow delay to analyzer 8.0 sec For lines 1-3
Optional devices
Ph measurement off - -
Density measurement off - -
DCS Parameters

Profibus off - -
Profibus controls from off - -

DCS
Modbus off - -
4-20 mA outputs off - -
4-20 mA outputs low 0 - -

limit
4-20 mA outputs high 100 - -
limit
4-20 mA outputs 2.0 - -
assays
TELEFAX MESSAGE DATE: Page 1
READER COMMENTS
The design team of Outotec is committed to ensure the quality and usefulness of this manual
and the PSI 300 Particle Size analyzer system. Your comments, recommendations and
suggestions will help make our continuous effort more effective.
Please take few moments to write your comments either directly on the form provided or on a
photocopy of it.
Your assistance is greatly appreciated.

Thank you for choosing the PSI 300 Particle Size analyzer system.
Outotec, Analyzers
Fax to: FAX: INT + 358 205 292998
or mail to: P.O. Box 84, FI-02201 Espoo, Finland
or e-mail to: analyzers@outotec.com
Attn: Manager, Analyzer Sales Support
From:
Analyzer Serial Number:
Manual: PSI 300

Particle Size Analyzer
Operating Manual
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1. OPERATING THE ANALYZER .....................................................................................................................3

2. CONTROLLED PRIMARY SAMPLING .......................................................................................................26

3. COLLECTING CALIBRATION SAMPLES ..................................................................................................27

4. DAILY MAINTENANCE ...............................................................................................................................31

5. ALARM AND STATUS MESSAGES ...........................................................................................................32

1. OPERATING THE ANALYZER

1.1 Operating principles

Control switches and indicators

Figure 1. The control switches and indicators on the PCS.

Figure 2. The local display on the PCS.

The local display in the Probe Control Set shows:

Using the touch screen

Figure 3. The keypad dialog.

1.2 Starting and stopping the analyzer

Before starting the analyzer

Starting the analyzer

To start the analyzer:

7. Motor of the measurement probe is started.

Stopping the analyzer

If the analyzer needs to be stopped for less than a week, it is recommended

To stop the sample measurement:

Stopping for a long period of time (> 1 week)

In case the analyzer needs to be stopped for longer than a week, it is

To stop the entire analyzer:

1.3 Operational states

Figure 4. The operational states of the analyzer.

If there are no operator or remote requests or alarm conditions the analyzer

1.4 Using the maintenance switches

When using the primary sampler’s standby switch it is recommended to

1.5 Using the zero check button

Zero check can also be activated manually during Auto measurement by

1.6 Using the calibration button

More about Calibration sampling is told in chapter 3, Collecting calibration

1.7 Using the local display

Figure 5. The navigation buttons in the local display.

To the right of the navigation buttons there is an additional button to be used

Main and Last assay values displays

Figure 6. The Main display.

The Main display consists of a number of text fields, including:

Figure 7. The Last Assay Values display.

Trend and Histogram displays

Figure 8. The Trend display.

The Trend display consists of:

Figure 9. The Distribution display.

The Histogram display consists of:

1.8 Status displays

Figure 10. The Status display.

The Status display consists of:

Setting sample lines to bypass/normal

Sample line status display

Figure 11. The Sample Line Status display.

Alarm display and acknowledging alarms

Figure 12. The Alarm display.

The Alarm display consists of:

To acknowledge the alarm:

System tries to restart the measurement also automatically in 10 minutes time

Zero level history display

Notice: Density measurement is not yet available in PSI 300.

Figure 13. The Zero level history display.

Zero level history display consists of:

1.9 Options displays

Figure 14. The Password pop-up window.