Measure

what is measurable
and make measurable
that which is not.
Galileo Galilei (1564-1642)

Instruction Manual and Safety Information

Fermentation Monitor 5100

Inline Refractometer with Pico 3000 or mPDS 5

(Original Instruction)
Disclaimer
This document may contain errors and omissions. If you discover any such errors or if you would like to see
more information in this document, please contact us at our address below. Anton Paar assumes no liability
for any errors or omissions in this document.

Changes, copyright, trademarks etc.

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as such. They are the property of their respective owner.

Further information
Published and printed by Anton Paar GmbH, Austria
Copyright © 2020 Anton Paar GmbH, Graz, Austria
Address of the instrument producer: Anton Paar GmbH
Anton-Paar-Str. 20
A-8054 Graz / Austria – Europe
Tel: +43 (0) 316 257-0
Fax: +43 (0) 316 257-257
E-Mail: info@anton-paar.com
Web: www.anton-paar.com

Date: January 2020

Document number: D32IB003EN-C

Instruction Manual and Safety Information

Fermentation Monitor 5100

Inline Refractometer with Pico 3000 or mPDS 5

(Original Instruction)
 Contents

Contents
1 Safety Instructions.................................................................................................................................. 5
1.1 General Safety Instructions............................................................................................................... 5
1.2 Special Safety Instructions................................................................................................................ 6
1.3 Conventions for Safety Messages .................................................................................................... 6
2 Fermentation Monitor 5100 - An Overview ........................................................................................... 7
2.1 Components of the Fermentation Monitor 5100 ............................................................................... 7
2.2 Dimensions ....................................................................................................................................... 8
3 Checking the Supplied Parts ................................................................................................................. 9
4 Putting the Fermentation Monitor 5100 into Operation..................................................................... 10
4.1 Installation Requirements ............................................................................................................... 11
4.2 Mounting the Fermentation Monitor 5100 ....................................................................................... 11
4.3 Electrical Wiring .............................................................................................................................. 13
4.3.1 Interface Overview.................................................................................................................. 13
4.3.2 Wiring the Sensor and mPDS 5 or Pico 3000 RC .................................................................. 13
4.3.2.1 Wiring with mPDS 5........................................................................................................ 15
4.3.2.2 Wiring with Pico RC ........................................................................................................ 18
4.3.3 Power Supply.......................................................................................................................... 18
4.3.4 Cable Glands and Connectors................................................................................................ 19
4.3.4.1 Shielding ......................................................................................................................... 19
4.3.5 Anton Paar CANopen ............................................................................................................. 19
5 Start-up and Use of Fermentation Monitor 5100 ................................................................................ 20
5.1 General Application Description - Benefits ..................................................................................... 20
5.2 Application Description: Fermentation Monitor 5100 with mPDS 5 ................................................ 21
5.3 Application Description: Fermentation Monitor 5100 with Pico 3000.............................................. 22
5.4 Comparison to Reference Methods ................................................................................................ 23
6 Troubleshooting.................................................................................................................................... 23
7 Upkeep and Cleaning ........................................................................................................................... 24
7.1 Cleaning in Place (CIP) / Steaming in Place................................................................................... 24
7.2 Wetted Parts ................................................................................................................................... 24
7.3 Storing and Transporting the Instrument ........................................................................................ 24
7.4 Packing the Instrument for Returns ................................................................................................ 24
8 Maintenance Work and Repair............................................................................................................. 25
8.1 Maintenance Performed by and Authorized Anton Paar Service Engineer .................................... 25
8.2 Repair Performed by and Authorized Anton Paar Representative ................................................. 25
Appendix A: Technical Specifications................................................................................................... 26
Appendix B: Welding Instructions for Housing Connection T and the Prism Wash System Tank . 28
Appendix C: Fermentation Monitor 5100 / mPDS 5 SOP - Automatic Mode for 4 Sensors .............. 29
Appendix D: Document Numbers........................................................................................................... 33

4
 1 Safety Instructions

1 Safety Instructions
• Read the documentation and related documents • In case of damage or malfunction, do not con-
(Pico 3000 and mPDS 5 manuals) before using tinue operating Fermentation Monitor 5100. Do
the Fermentation Monitor 5100. not operate the instrument under conditions
which could result in damage to goods and/or
• Follow all hints and instructions contained in the
injuries and loss of life.
documentation to ensure the correct use and
safe functioning of the Fermentation Monitor • Check the Fermentation Monitor 5100 for chem-
5100. ical resistance to the samples and cleaning
agents.
• The documentation is a part of the product.
Keep this document for the complete working
Maintenance and service
life of the product and make sure it is easily
accessible to all people involved with the prod- • The results delivered by the Fermentation Moni-
uct. If you receive any additions or revisions to tor 5100 not only depend on the correct func-
the documentation from Anton Paar GmbH, tioning of the instrument, but also on various
these must be treated as part of the documenta- other factors. We therefore recommend you
tion. have the results checked (e.g. plausibility
tested) by skilled personnel before consequen-
tial actions are taken based on the results.
1.1 General Safety Instructions • Service and repair procedures may only be car-
ried out by authorized personnel or by Anton
Liability Paar GmbH.
• This document does not claim to address all
safety issues associated with the use of the Disposal
instrument and samples. It is your responsibility • Concerning the disposal of the Fermentation
to establish health and safety practices and Monitor 5100, observe the legal requirements in
determine the applicability of regulatory limita- your country.
tions.
• Anton Paar GmbH only warrants the proper Returns
functioning of the Fermentation Monitor 5100 if • For repairs send the cleaned Fermentation Mon-
no adjustments have been made to the mechan- itor 5100 to your Anton Paar representative.
ics, electronics, and firmware. Only return the instrument together with the
• Only use the Fermentation Monitor 5100 for the filled out RMA (Return Material Authorization)
purpose described in the documentation. Anton and the form "Safety Declaration for Instrument
Paar GmbH is not liable for damages caused by Repairs". Please download the Safety Declara-
incorrect use of the Fermentation Monitor 5100. tion form from our website www.anton-
paar.com.
Installation and use • Do not return instruments which are contami-
• The Fermentation Monitor 5100 is not an explo- nated by radioactive materials, infectious agents
sion-proof instrument and therefore must not be or other harmful substances that cause health
operated in areas with risk of explosion. hazards.

• The installation procedure should only be car- Precautions for highly inflammable samples
ried out by authorized personnel who are famil- and cleaning agents
iar with the installation instructions.
• Observe and adhere to your national safety reg-
• Do not use any accessories or spare parts other ulations for handling the measured samples
than those supplied or approved by Anton Paar (e.g. use of safety goggles, gloves, respiratory
GmbH (see Chapter 3). protection etc.).
• Make sure all operators are trained to use the • Do not spill sample/cleaning agents or leave
instrument safely and correctly before starting their containers uncovered. Immediately remove
any applicable operations. spilled sample/cleaning agents.

D32IB003EN-C 5
1 Safety Instructions

• Make sure that the setup location is sufficiently

ventilated. The environment of Fermentation
Monitor 5100 must be kept free of inflammable WARNING
gases and vapors.
Description of risk.
• Supply a fire extinguisher. Warning indicates a hazardous situation which, if
not avoided, could result in death or serious
injury.
1.2 Special Safety Instructions
• Service and repair procedures may only be car- CAUTION
ried out by authorized personnel or by Anton
Paar GmbH. Description of risk.
Caution indicates a hazardous situation which, if
• Do not open the housing of the Fermentation
not avoided, could result in minor or moderate
Monitor 5100. There are no user-serviceable
injury.
parts inside.
• Check the technical data in appendix A for
ambient condition. NOTICE
Description of risk.
Notice indicates a situation which, if not avoided,
1.3 Conventions for Safety Messages could result in damage to property.

The following conventions for safety messages are TIP: Tip gives extra information about the situation
used in this document: at hand.

DANGER
Description of risk.
Danger indicates a hazardous situation which, if
not avoided, will result in death or serious injury.

6 D32IB003EN-C
 2 Fermentation Monitor 5100 - An Overview

2 Fermentation Monitor 5100 - An Overview

The Fermentation Monitor 5100 consists of an Table 1: Configurations
L-Rix 5100 VARIVENT® N which has to be com-
bined with an evaluation unit with a special applica- Fermentation
tion program. Monitor 5100
+ mPDS 5
Available configurations:
• Fermentation Monitor 5100 with mPDS 5 (sev-
eral plug-in boards and optional Davis 5). 1 to 4
Fermentation Monitors can be connected to one
mPDS 5.
• Fermentation Monitor 5100 with Pico 3000 (sev-
eral interfaces available) and optional Pico 3000
HMI 2.1 Components of the
Fermentation Monitor 5100

Fig. 1: Fermentation Monitor 5100 (sensor)

Table 1: Configurations

Fermentation
Monitor 5100
+ Pico 3000
1 2 3 4 5 6 4 1

1 Cable glands (or connectors)

2 Electronics module (with optional Pico 3000)
3 Sensor module
4 Prism
Fermentation 5 Hinged clamp VARIVENT® N 1.4401
Monitor 5100 6 Tuchenhagen VARIVENT® N, DN 65
+ Pico 3000 Fig. 2: Components Fermentation Monitor 5100 (sensor)
+ HMI
The central optical element is the prism situated in
the sensor module.
The Fermentation Monitor 5100 is only available
with a Tuchenhagen VARIVENT® Type N - flange
(Fig. 2).

D32IB003EN-C 7
2 Fermentation Monitor 5100 - An Overview

2.2 Dimensions
L-Rix Sensor VARIVENT® N

Fig. 3: Front view

Fig. 4: Lateral view

TIP: For more details please see the instruction
manual for L-Rix.

8 D32IB003EN-C
 3 Checking the Supplied Parts

3 Checking the Supplied Parts

The Fermentation Monitor 5100 was tested and 2. Check the delivery for completeness by compar-
packed carefully before shipment. However, dam- ing the supplied parts to those noted in table 2.
age may occur during transport.
3. If a part is missing, contact your Anton Paar rep-
1. Keep the packaging material (box, foam piece, resentative.
transport protection) for possible returns and
4. If a part is damaged, contact the transport com-
further questions from the transport and insur-
pany and your Anton Paar representative.
ance company.
Table 2: Supplied Parts

Symbol Pcs. Article Description Mat. No.

1 Fermentation Monitor 5100 220647

consists of:
- 1pcs. L-Rix 5100 Sensor VARIVENT N
- 1 pcs. Sensor protection cap
- 1 pcs. VARIVENT clamp
- 1 pcs. Calibration data sheet

1 Documentation
German or English

3 Cable gland 90711

TIP: For details on required mPDS 5 and Pico 3000 please refer to the respective instruction manuals.

Symbol Pcs. Article Description Mat. No.

Options according to individual order

1 Power supply DC 24 V, 2.5 A 96693

1 Housing connection flange Tuchenhagen Type U 21331

10 bar

1 Housing connection flange Tuchenhagen Type T 86888

10 bar

D32IB003EN-C 9
4 Putting the Fermentation Monitor 5100 into Operation

Symbol Pcs. Article Description Mat. No.

Prism wash system tank consists of 226436

• Housing connection flange Tuchenhagen Type T
(Mat. No. 86888)

and an
• integrated cleaning nozzle
- Cleaning medium pressure: 3 to 10 bar
- Connection cleaning medium G3/8" IT
- For hose with 13 mm inner diameter
- Ball valve PN 40, DN 10, G3/8"

1 Blanking plate Tuchenhagen VARIVENT® 14578

1 Hinged clamp VARIVENT N 1.4401 for VARIVENT® 7403

Access Unit

1 Nut for hinged clamp m6/15 a2 for for VARIVENT® 7451

Access Unit

4 Putting the Fermentation Monitor 5100

into Operation
NOTICE
WARNING • Read this manual carefully before installing
• Installation, putting into operation, mainte- the Fermentation Monitor 5100. Incorrect
nance and service work should only be car- operation can result in damage to the sensor.
ried out by trained and authorized personnel. • Work on the instrument with care!
• Observe the permissible operating and ambi-
ent conditions for the
Fermentation Monitor 5100 (see appendix A
Specifications).
• Do not exceed the defined maximum pres-
sure, maximum sample temperature and
maximum CIP/SIP temperature for Fermenta-
tion Monitor 5100.

10 D32IB003EN-C
 4 Putting the Fermentation Monitor 5100 into Operation

4.1 Installation Requirements

NOTICE
CIP/SIP temperature > 145 °C (293 °F) can
damage the detectors!
CIP/SIP duration > 30 minutes can damage the
detectors!

Line pressure absolute 100 mbar to

16 bar
(10 bar @ > 120 °C
[248 °F])

Process temperature - 20 °C to 105 °C

(- 4 °F to 212 °F)

Max. temperature up to 145°C

(CIP/SIP) (293 °F)

Max. duration of SIP at 30 min

145 °C
Fig. 5: Welding the connection flange to the fermentation
Power supply DC 24 V tank - recommended position
Ambient temperature -20°C to 60°C
(- 4 °F to 140 °F)
CAUTION

4.2 Mounting the Use the blanking plate for the Housing Connec-
tion Flange Tuchenhagen during welding to pre-
Fermentation Monitor 5100 vent warping which would prevent insertion of
the L-Rix.
1. Weld the Housing Connection Flange Tuchen-
hagen Type U (Mat. no. 21331) approx. 1/3 of Instead of the Housing connection flange Tuchen-
the cone height above the cone top as shown in hagen Type U (Mat. no. 21331), it is possible to
weld the Housing connection flange Tuchenhagen
Type T (Mat. no. 86888) or the Prism wash system
tank (226436) into the tank. The prism wash sys-
tem tank comes with ball valve and nozzle for hose
connection (3-10 bar, hose with 13 mm inner diam-
eter).

D32IB003EN-C 11
4 Putting the Fermentation Monitor 5100 into Operation

Fig. 6: Details of the installation spot using Tuchenhagen

Type T (21331) Fig. 7: Details of the installation spot using the Prism
wash system tank
2. Insert the L-Rix and clamp with the hinged
clamp.
3. Connect with power supply and PLC.

12 D32IB003EN-C
 4 Putting the Fermentation Monitor 5100 into Operation

4.3.1 Interface Overview

DC 24 V Power supply

CAN Anton Paar CANopen for communi-

H/L/GND cation between sensor and mPDS 5
or Pico 3000 RC

NOTICE
The CAN address must be set if several sensors
are connected to one mPDS 5.

Fig. 8: Installation example with Pico 3000 and HMI

4.3 Electrical Wiring

1
WARNING 1 CAN address selector (default=0)
2 Terminal block for power supply and CAN connection
The instructions given in this chapter must be
followed precisely. Installation and service work Fig. 9: Fermentation Monitor 5100 Sensor interfaces wir-
are only allowed to be performed by trained and ing
authorized personnel..
4.3.2 Wiring the Sensor and mPDS 5 or
Recommendations: Pico 3000 RC
• Only use shielded cables with double insulation. All sensors communicate with the mPDS 5 or Pico
Ground the shield of the CAN cable on both 3000 RC via a CANopen bus network. The mPDS 5
sides (mPDS 5/Pico 3000 RC and sensor side) or Pico 3000 RC is the CAN-master, all sensors are
and make sure that there is no potential differ- slaves.
ence between the sensor and the evaluation
unit.
• Check the polarity when lengthening the cable.
• Use a screwdriver (0.4 x 2.5 mm) to install the
cables in the plugs.

Fig. 10: Detailed view of the terminals of the sensor

D32IB003EN-C 13
4 Putting the Fermentation Monitor 5100 into Operation

All sensors have 2 CAN-interfaces. One is used for

the connection to the Pico RC or to the mPDS 5 and Wire color
the other one is used for the terminating resistor or CAN H Yellow (#1)
an additional sensor in the CAN-network. It does not
matter which one is used as CAN IN and CAN OUT. CAN L Green (#2)
A CAN-network wiring of more than one sensor can CAN GND Brown (#3)
be done simply without cable stubs.
Not used White (#4)
The CAN-bus needs a 120 Ω terminating resistor at
one CAN-interface. To build up a network with more CAN-cable assignment for CAN-cable with power
sensors, the terminating resistor at CAN OUT must supply:
be removed so that the next sensor can be connect-
ed at CAN OUT. If several sensors of the same type Wire color
are connected to one mPDS 5, unique CAN ad- CAN H Yellow (#1)
dresses must be selected.
CAN L Green (#2)
CAN-cable assignment for CAN-cable (mat.no.
94268) if a separate power cable is used: CAN GND Brown (#3)

+24 V White (#4)

TIP Wiring of the sensor with integrated Pico 3000

is described in the Pico 3000 reference guide.

14 D32IB003EN-C
 4 Putting the Fermentation Monitor 5100 into Operation

4.3.2.1 Wiring with mPDS 5

Termination „ON“
mPDS 5

CAN

CAN Connector,

brown GND
yellow 1C+
Mat.No. 184983

120 Ohm
Sensor 1
GND
H

GND L H
L

CAN IN CAN OUT

CAN address: 0
Sensorboard

Power Power
IN OUT
GND
+24V
Fuse

*
... Shield connected
... Circuit board - internal wiring
... Terminal
Power supply ... Fuse the power supply cable according to the used cables and
DC 24 V * national standards. For the dimension of the fuse consider the
minimal wire cross-section in the power loop.
There is NO fuse for the power line on the circuit board!

Fig. 11: Wiring mPDS 5 and a sensor with separate CANopen and power supply cables

D32IB003EN-C 15
4 Putting the Fermentation Monitor 5100 into Operation

Termination „ON“

CAN Connector, mPDS 5

Mat.No. 184983
+24V: 2V+
GND: GND
Fuse

*
brown: GND
yellow: 1C+
green: -1C-

Power supply
white: 1V+

DC 24 V

*
120 Ohm ... Shield connected
GND
+24V

H
L

GND ... Circuit board - internal wiring

GND L H
Power Power CAN IN CAN OUT
... Terminal
IN OUT
... Fuse the power supply cable according to the used cables and
* national standards. For the dimension of the fuse consider the
minimal wire cross-section in the power loop.
CAN address: 0 There is NO fuse for the power line on the circuit board!
Sensorboard

Fig. 12: Wiring mPDS 5 and a sensor with a combined CANopen and power supply cable

16 D32IB003EN-C
 4 Putting the Fermentation Monitor 5100 into Operation

Termination „ON“

mPDS 5

CAN

CAN Connector,
yellow 1C+

brown GND

Mat.No. 184983

120 Ohm
Sensor 1 Sensor 2
GND

GND

GND

GND
H

H
L

H
L
CAN IN CAN OUT CAN IN CAN OUT

CAN address: 0 CAN address: 1 for the same sensor type

Sensorboard Sensorboard

Power Power Power Power

IN OUT IN
GND
OUT
+24V
GND
GND

+24V
+24V

*
Fuse

*
... Shield connected
... Circuit board - internal wiring
... Terminal
Power supply ... Fuse the power supply cable according to the used cables and
DC 24 V * national standards. For the dimension of the fuse consider the
minimal wire cross-section in the power loop.
There is NO fuse for the power line on the circuit board!

Fig. 13: Wiring mPDS 5 with two sensors with separate CANopen and power supply cables

D32IB003EN-C 17
4 Putting the Fermentation Monitor 5100 into Operation

4.3.2.2 Wiring with Pico RC

Pico 3000 RC

Power Power
IN OUT CAN IN CAN OUT

H
GND

GND

GND

GND
L
+24V

+24V
Power supply
*
Fuse +24V
GND
DC 24 V
*

brown
yellow
green
white
120 Ohm

GND
+24V

H
L
GND
GND L H
Power Power CAN IN CAN OUT
... Shield connected IN OUT

... Circuit board - internal wiring

... Terminal
... Fuse the power supply cable according to the used cables and
* national standards. For the dimension of the fuse consider the
CAN address: 0

minimal wire cross-section in the power loop.

There is NO fuse for the power line on the circuit board!
Sensor 1

Fig. 14: Wiring with Pico 3000 RC

4.3.3 Power Supply Recommended cable for the power supply:

TIP: The Fermentation Monitor 5100 shall be sup- Power supply

plied with SELV DC 24 V as shown in Fig. 11.
Conductor cross max. 1.5 mm²
section
WARNING
The connection cables must comply Suggested cable LiYCY
with local regulations and must be type Shielded 2 pole cable, dou-
adapted to the local ambient condi- ble insulation
tions. It is necessary to take special Ground the shield at power
account of the mechanical load. adapter side and sensor
end.

NOTICE Wire cross section min. 0.34 mm², max. 1.5

If the power supply is interrupted ,the calculated mm² without wire end fer-
values in the mPDS 5 are no longer valid. The rule;
Pico 3000 can deal with short power failures but max.0.75 mm² with wire
depending on the PLC program there may occur end ferrule
issues after restart. Install a UPS to eliminate the Diameter of 4.5 to 10 mm to ensure
impact of short power failures. cables optimal sealing against the
cable gland

18 D32IB003EN-C
 4 Putting the Fermentation Monitor 5100 into Operation

4.3.4.1 Shielding
CANopen
For a professional shielding at the cable glands con-
Cable type CANopen/DeviceNet cable nect the cable shield at the L-Rix as shown below:
120 shielded twisted
pair
Wire cross sec- min 0.25 mm², max. 1.5
tion mm² without wire end fer-
rule; max. 0.75 mm² with
wire end ferrule

Diameter of 4.5 to 10 mm to ensure

cables optimal sealing against the Fig. 16: Connection and position of the cable shield
cable gland
NOTICE
Max. length 250 m
The shield must be grounded on sensor side and
The wires must be connected according to the label- on evaluation side. There must not be a potential
ing on the cover plate (Fig. 10). difference between sensor and evaluation unit.

4.3.4 Cable Glands and Connectors 4.3.5 Anton Paar CANopen

The Fermentation Monitor 5100 sensor can either
be connected to the mPDS 5 evaluation unit or to
the Pico 3000 RC. The mPDS 5 communicates with
one or more sensors. The Pico 3000 can communi-
cate with one sensor only.

NOTICE
Fermentation Monitor 5100 with Pico 3000
RC or mPDS 5
For all details about the installation of a sensor
see Pico 3000 Reference Guide and mPDS 5
Fig. 15: Cable inlet Reference Guide part 2 respectively.

NOTICE Optionally, it is possible to order the connector set

Make sure the cable is mounted with a loop to CAN (Mat. No. 96554) for a sensor.
avoid water ingress.
Make sure to position the cable glands or con-
nectors at the bottom and tighten them correctly. NOTICE
Each sensor is delivered with a default CAN-
address (e.g. Fermentation Monitor 5100 ... 60).
If two sensors of the same type are used in com-
bination with the same mPDS 5, the second sen-
sor must have the consecutive CAN-address
(e.g. L-Rix ... 61).

D32IB003EN-C 19
5 Start-up and Use of Fermentation Monitor 5100

5 Start-up and Use of Fermentation Monitor 5100

This chapter contains the most important applica- - Process optimization: reduction of costs of
tion details for both versions of the Fermentation manpower and operational costs (energy, ...)
Monitor 5100 (using mPDS 5 and using Pico 3000). - Quality control: steady consistency of flavor
Please refer to the instruction manuals and/or refer- - End-point determination: reduction of turn-
ence manuals of mPDS 5 and Pico 3000, especially around time for fermentation tanks and
concerning the details on the communication inter- increase of annual plant throughput
faces (fieldbuses, ...).
Fig. 17 shows the curve of a typical apparent extract
density of a typical fermentation. The wort has an
5.1 General Application Description - initial concentration of about 12 °Plato. After about 3
days the fermentation process has finished and the
Benefits apparent extract (density) is approx. 2.3 °Plato.
The most common reference method in the lab is
The most important step in the production of beer is density measured by digital density meters such as
the fermentation. Controlling the fermentation pro- DMA 35 or DMA 4500 from Anton Paar.
cess using the Fermentation Monitor 5100 has
many benefits: These instruments give fast and accurate results,
however, the increasing alcohol content falsifies the
concentration results. Therefore the term "Apparent
Extract" is commonly used. The real extract concen-
tration is considerably higher.

Fig. 17: "Apparent Extract" trend line - Fermentation speed (increase of alcohol in
% v/v per hour)
The main goal is a repeatable process result and not
- Real degree of fermentation in %
an absolutely accurate result of the extract.
The curves contain more or less the same informa-
The Fermentation Monitor 5100 uses the "Apparent
tion. This means that the extract/apparent extract
Extract RI" (Extract/sugar concentration derived
decreases in the same way as the alcohol increas-
from the refractive index) and the starting extract
es.
concentration (Original Extract) to calculate several
additional results such as: Fig. 18 shows the alcohol curve corresponding to
the apparent extract curve (Fig. 17). Starting at zero
- Apparent Extract Dens. [°Plato]
alcohol the fermentation ends at an alcohol concen-
- Alcohol (%v/v 20 °C)
tration of about 5% v/v 20 °C.
- Alcohol (% w/w)
- Real extract (°Plato)

20 D32IB003EN-C
 5 Start-up and Use of Fermentation Monitor 5100

Fig. 18: Alcohol in %v/v 20 °C trend line those practical cases, where one fermentation
tank is filled by the contents of several brewing
kettles and yeast is added at the beginning
5.2 Application Description: Fermenta- before the fermentation tank has been com-
tion Monitor 5100 with mPDS 5 pletely filled.

B) Automatic method: When the product

1. After electrical and mechanical installation
parameter "Original Extract stored 1" is '0' the
power up sensors and evaluation units.
automatic method is activated. The starting
2. Create a product on the mPDS 5 with product point ("Original Extract 1") is determined auto-
type "Beer Ferment. Ri" in matically after selecting a product of this product
"Menu > Product Settings > Add new type. For a single tank the trigger for starting the
product" automatic method is the product change. For
more than one tank (Fermentation Monitor
TIP The product type "Beer Ferment. Ri" can be
5100) connected to one mPDS 5 the selected
used in combination with 4 # L-Rix (equal to 4 # Fer-
product should stay the same and the triggers
mentation Monitor 5100) installed in 4 different fer-
are the product parameters "Start Tank 1/2/3/4" .
mentation tanks.
See SOP in the appendix C. For a certain period
In the following, the procedure for a single Fermen- after selecting a product (or setting the product
tation Monitor 5100 is explained. parameter "Start Tank 1/2/3/4" from 0 1) the
mPDS 5 monitors the "Concentration Ext.1".
3. The formulas for alcohol, apparent extract den-
The maximum extract concentration is automati-
sity, real extract, etc. need a "starting point".
cally stored as "Original Exract 1".
(Original Extract 1) and use the change of the
refractive index causing a reduction of the
Available product parameters to optimize the
extract value (Concentration Ext.1)
automatic method:
There are 2 methods to get the "Original
Extract1"
"Original Extract Min"/"Original Extract Max" in
°Plato define the allowed range for the Original
A) Manual method: It is necessary to select a
Extract (e.g. 5 … 35 °Plato)
product with the product type "Beer Ferment.
RI" (using the keypad, a digital input or a PLC/
"Original Extract Stability" in °Plato defines the
fieldbus). The operator enters the "Original
range the "Concentration Ext." must lie within for
Extract stored 1". The value of this parameter is
"Original Extract Stability Duration" time (e.g. 0.1
copied to the corresponding measurement
°Plato)
channel "Original Extract 1" used for consecu-
tive calculations. The manual method has the
Original Extract Stability Duration in [s]...defines
higher priority. This product parameter can be
the time the "Concentration Ext." must be sta-
set via PLC and fieldbus or via Davis 5 as well.
ble. (E.g. 10 seconds)
The manual method is also recommended in

D32IB003EN-C 21
5 Start-up and Use of Fermentation Monitor 5100

"Menu > Active Application"

Original Extract Detection Time in [minutes]
3. The formulas for alcohol, apparent extract den-
defines the time for the automatic determination
sity, real extract, etc. need a "starting point"
of Original Extract (after selecting the product or
(Orig. Extract) and use the change of the refrac-
setting the product parameter "Start Tank 1/2/3/
tive index causing a reduction of the extract
4" from 0 1) (e.g. 120 minutes)
value (Conc. Sugar).
4. Fill the tank above the level of the Fermentation
Monitor 5100 and select the product. Enter the There are 2 methods to get the "Orig. Extract:"
known value of the Original Extract (manual
method) or have the program automatically A) Manual method: Set the application "Beer
determine the Original Extract (automatic Ferment. Ri" or select a product using this appli-
method). cation (HMI/DI or PLC). The operator enters the
"Orig. Extract" via a parameter called "OE
5. As soon as the program gets an Original Extract
stored" in
value all calculations are active. A number of
"Menu>Application Config. "Beer Ferment.
results are calculated for the next days or
Ri" >Parameters".
weeks:
The following results are available:
The value of the parameter "OE stored" is cop-
ied to the corresponding measurement channel
App. Extract Dens. 1 in °Plato
"Orig. Extract" which is then used for consecu-
Alcohol 1 in %w/w
tive calculations.
Alcohol 20 °C 1 in %v/v
Fermentation Speed 1 … Change of Alcohol in
B) Automatic method: Set the application
%v/w per hour
"Beer Ferment. RI" or select a product using this
Real Degree of Ferm. 1
application (HMI/DI or PLC). When the parame-
Real Extract 1
ter "OE stored" is '0' the automatic method is
6. Compare results of the Fermentation Monitor activated. The starting point ("Orig. Extract") is
5100 with the lab reference and if needed carry determined automatically after selecting the
out an adjustment of the process results. application or selecting a product using this
application. For 100 minutes after selecting the
application the Pico 3000 monitors the "Conc
Sugar". The maximum "Conc. Sugar" in this
time period is automatically stored as "Orig.
Extract" for this fermentation batch. (Stability cri-
terion: 0.03 °Plato for 20 seconds)
4. Fill the tank above the level of the Fermentation
Monitor 5100 and select the application "Beer
Ferment. Ri" and enter the known value of the
Original Extract (manual method) or have the
application program automatically determine the
Original Extract (automatic method).
5. As soon as the application program gets an
Original Extract value all calculations are active.
A number of results are calculated for the next
Fig. 19: Typical mPDS 5 screen at the end of a fermenta- days or weeks:
tion batch The following results are available:

"App. Extr. Dens." in °Plato

5.3 Application Description: Fermenta- "Alcohol-V 20°"
tion Monitor 5100 with Pico 3000 "Ferm. Velocity" (Change of Alcohol in %v/h per
hour)
1. After electrical and mechanical installation "Extr.red.Speed" (Change of the App.Extr.Dens
power up the sensor with Pico 3000 per hour)
"Real DFM"
2. Select application "Beer Ferment. Ri".in "Real Extract"

22 D32IB003EN-C
 6 Troubleshooting

the "Apparent Extract Density". The Fermentation

Monitor 5100 uses the refractive index as raw value
and special polynomials allow the calculation of the
comparable measurement value "Apparent Extract
Dens." in °Plato.
Deviations between the results of the Fermentation
Monitor 5100 and the reference results are inevita-
ble and there are several sources:
1. Different methods in lab (density) and process
(refractive index) : 0.2-0.4 °Plato
2. Accuracy of the lab method as such:
0.2-0.4 °Plato
3. Difference between filtered and unfiltered wort/
beer - reference method: 0.2 °Plato
4. Different types of wort - raw materials (barley,
Fig. 20: Typical Pico 3000 HMI screen at the end of a fer- wheat, rice, corn, sugar,...): 0.2 ... 0.5 °Plato
mentation batch
(estimated)
6. Compare the results of the Fermentation Moni-
5. Uncertainty of the required original extract of the
tor 5100 with the lab reference and if needed
unfermented wort: 0.2 °Plato (Fermentation
carry out an adjustment of the process results.
Monitor 5100)
TIP: If several types of beer are produced in the
6. Deviation if the reference sample is not mea-
same tanks it is necessary to use the product selec-
sured in time: 0.1 °Plato per hour
tion option or the application must be changed man-
ually via HMI between fermentation batches. 7. Uncertainty of the polynomials used in the Fer-
mentation Monitor 5100: 0.1 ... 0.4 °Plato

5.4 Comparison to Reference Methods It is recommended to perform a product specific ad-

justment at the end of the fermentation process pref-
erably using the gain factor. This would minimize the
The main goal and benefit of theFermentation Mon-
deviations.
itor 5100 is controlling the fermentation process at
every moment during each batch. Possible issues
regarding the process are recognized immediately
TIP For lowest deviations to a specific reference
and counter measures can be taken in time. The
methods it is possible to generate customized for-
end-point of the fermentation process can be deter-
mulas for specific types of wort. This formula can be
mined easily.
entered only into the mPDS 5. Contact Anton Paar
The most common reference method is the density for more information.
(e.g. DMA 35n) and the typical reference result is

6 Troubleshooting
Information on problems with the measurement and
error messages are given in the instruction manuals
and reference guides of Pico 3000 and of mPDS 5.

D32IB003EN-C 23
7 Upkeep and Cleaning

7 Upkeep and Cleaning

The Fermentation Monitor 5100 is maintenance-
free. However, for reliable and trouble-free opera-
7.2 Wetted Parts
tion, it is essential to periodically check the readings
on the display of the Fermentation Monitor 5100 Material Part
with Pico 3000 HMI or mPDS 5.
Stainless steel Sensor module (including
1.4404 sensor head)
The following checks are recommended:
PEEK Flat seal between prism and
• Check the status messages. If the message sensor head
"Maintenance request" is displayed, contact
your Anton Paar representative for the replace- Sapphire Prism
ment of the desiccant cartridge. Al2O3 – 99.997%

• Process instruments like the Fermentation Mon- EPDM 70 O-ring 60x3 (VARIVENT® N,
itor 5100 are often exposed to extreme operat- sealing ring)
ing conditions such as pressure shocks, sudden
temperature changes, aggressive samples, etc.
Although readjustments of Fermentation Monitor
5100 are not necessary we recommend per- 7.3 Storing and Transporting the
forming regular comparison of the measured
results with reference values and readjusting if
Instrument
required.
• Only use the original packaging for the storage
• Check the displayed product temperature. and transportation.
• Check the prism for contamination. • Do not store outdoors and avoid direct sunlight.
Store the instrument in a dry, clean place.
Remove transportation protection not until
7.1 Cleaning in Place (CIP) / Steaming installation. Consider national regulations
regarding the weight and lifting the instrument.
in Place
• The storage temperature is between
The Fermentation Monitor 5100 is suitable for CIP/ -20 and 60 °C.
SIP with max. 145 °C for 30 min (see appendix A).
The instrument is cleaned during the SIP/SIP proce-
dure in the main line. 7.4 Packing the Instrument for Returns
• Clean all parts of the instrument before packag-
ing. Make sure no sample residues or spills
remain on the instrument.
• Return the instrument in the original packaging
material (box, foam piece, transport protection).

24 D32IB003EN-C
 8 Maintenance Work and Repair

8 Maintenance Work and Repair

8.2 Repair Performed by and Autho-
WARNING rized Anton Paar Representative
Maintenance and service work must only be car- In case your instrument needs repair, contact your
ried out by trained and authorized service engi- your Anton Paar representative, who will take care
neers of the necessary steps. If your instrument needs to
be returned, request an RMA (Return Material Au-
thorization). It must not be sent without the RMA and
8.1 Maintenance Performed by and the filed "Safety Declaration for Instrument Repairs".
Please make sure it is cleaned before return.
Authorized Anton Paar Service Engi-
TIP: Find the data of your local Anton Paar repre-
neer sentative on the Anton Paar website (http://www.an-
ton-paar.com) under "Contact".
The Fermentation Monitor 5100 does not require
any regular maintenance by an authorized Anton
Paar Service Engineer.
Following parts are generally excluded from the
warranty (wear and tear parts):
• Desiccant cartridge
• O-rings

D32IB003EN-C 25
Appendix A: Technical Specifications

Appendix A: Technical Specifications

Refractive Index Range 1.3100 to 1.5400
(equivalent to 0% to 100% mass)
Accuracy
nD ±0.0002
(equivalent to ± 0.1% mass)
Repeatability
nD ±0.0001
(equivalent to ± 0.05% mass)

Calibration Anton Paar’s proprietary calibration routine using high purity water
and commercial nD-references

Optical Material Sapphire

Detector CMOS line sensor, 2048 elements

Light Source LED 589 nm

Temperature Control Method Automatic Temperature Compensation; Integrated Pt-100 Class A,

Linearized according to IEC 751

Ambient Temperature Range -20 °C to 60 °C without Pico 3000

-20 °C to 55 °C** with Pico 3000 and Pico 3000 HMI

**) Pico 3000 Version PROFINET IO max. 50 °C

Humidity 0 - 95% (rel. humidity, non-condensing)

Process Temperature -20°C to 105°C

CIP/SIP up to 145°C (293 °F) for 30 min
(at max. ambient temperature)

Pressure Range Absolute 0.1 bar to16 bar (10 bar @ >120 °C)

Weight approx. 7 kg

Wetted Parts - Stainless steel 1.4404, PEEK

Standard Material: Sapphire (Al2O3 – 99.997%), O-ring 60x3 (Varivent N) EPDM 70

Degree of Protection IP65; IP67 / NEMA 6P

Approvals and Certifications Designed according to EHEDG guidelines

Electrical Connections

Power Supply SELV/PELV DC 24 V (range 20 V ... 28 V)

Power Consumption max. 2 W (max. 5 W with Pico 3000 and HMI)

Cable Gland Max. 6 pcs. M16x1.5 EMC, earthing cones acc. to DIN 89345, brass
nickel-plated for cable OD 4.5 to 10 mm

Connection Terminals Push-in spring connection

0.2 to 1.5 mm² / AWG 24 to 16

26 D32IB003EN-C
 Appendix A: Technical Specifications

Cables
Cables must comply with the intended area of use, the cable gland type and the relevant national
regulations and requirements

Power supply Suggested cable type:

LiYCY, shielded 2 pole cable

Wire cross section:

min. 0.34 mm², max. 1.5 mm² without wire end ferrule; max. 0.75
mm² with wire end ferrule

Diameter of cables:
4.5 to 10 mm to ensure optimal sealing against the cable gland

CANopen Cable type:

CANopen/DeviceNet cable,
120 shielded twisted pair

Wire cross section:

min 0.20 mm², max. 1.5 mm² without wire end
ferrule; max. 0.75 mm² with wire end ferrule

Diameter of cables:
4.5 to 10 mm to ensure optimal sealing against the cable gland

Max. length: 250 m

Communication Several fieldbuses and analog interfaces are available depending on

the used version/mPDS 5 board (please see mPDS 5 and Pico 3000
instruction manuals).

Integrated Display Optional (Pico 3000 HMI)

Process Connections Tuchenhagen VARIVENT® Type N

All inputs and outputs (including relay outputs) connected to mPDS 5 or Pico 3000 RC have to be in accor-
dance with PELV (Protective Extra Low Voltage) of EN 61140 or with SELV specification of EN 60950, i.e.
maximum voltage Umax must not exceed 24 V + 20% = 28.8 V and a maximum current Imax = 0.75 A.

D32IB003EN-C 27
Appendix B: Welding Instructions for Housing Connection T and the Prism Wash System

Appendix B: Welding Instructions for Housing Con-

nection T and the Prism Wash System Tank

28 D32IB003EN-C
Appendix C: Fermentation Monitor 5100 / mPDS 5 SOP - Automatic Mode for 4 Sensors

Appendix C: Fermentation Monitor 5100 / mPDS 5

SOP - Automatic Mode for 4 Sensors
This chapter contains an SOP for the modified product type "Beer Fermentation Ri" as part of mPDS 5 FW
Version 6.32. or higher including Davis 5.

Introduction
Changes in FW Version 6.32 and higher:
The modified product type (Application program) "Beer Fermentation Ri" allows the automatic mode for the
determination of the Original Extract for 4 sensors

Original Extract Determination - Automatic Mode - 4 Sensors (Fermentation Moni-

tors) connected to a single mPDS 5

Product parameters of product type "Beer Fermentation Ri"

Name Min Value Max Value Default Value

Original Extract Min 0 99.99 0

Original Extract Max 0 99.99 99.99

Original Extract Stability 0.001 1 0.01

Original Extract Stability Duration 2 20 5

Original Extract Detection Time [m] 1 2000 180

Original Extract Stored 1 0 99.99 0

Original Extract Stored 2 0 99.99 0

Original Extract Stored 3 0 99.99 0

Original Extract Stored 4 0 99.99 0

Start Tank 1 True (=1)

Start Tank 2 True (=1)

Start Tank 3 True (=1)

Start Tank 4 True (=1)

D32IB003EN-C 29
Appendix C: Fermentation Monitor 5100 / mPDS 5 SOP - Automatic Mode for 4 Sensors

Standard Operating Procedure (SOP)

1. 1.Create one product with product type "Beer
Fermentation Ri" and set the 4 product parame-
ters "Start Tank 1/2/3/4" to "False" (uncheck the
box beside the parameter name). Out of com-
patibility reasons with older FW versions these
parameters are checked at start up. E.G. Create
product number "1" and give it the name "Fer-
mentation Monitor"

or via Davis 5 -> "Products"->"product settings" ->

"Product Parameters" . E.G. Tank 1 is filled so set
product parameter "Start Tank 1" to "1".

2. Select the new product e.g. number "1" either

via mPDS 5 or via Davis 5 product selection
menu.

If tank 2 is filled set product parameter "Start Tank

2" to "1", etc. The status of these 4 parameters will
be visible at the appropriate measurement channel
"Tank 1/2/3 or 4 Started". These channels are auto-
matically displayed in the header line:
3. As soon as one tank is filled with wort set the
checkbox beside the product parameters "Start
Tank 1/2/3 or 4".
This can be done via mPDS 5 product settings
menu:

30 D32IB003EN-C
Appendix C: Fermentation Monitor 5100 / mPDS 5 SOP - Automatic Mode for 4 Sensors

4. Immediately after this step the automatic deter-

mination of the Original Extract 1(2/3/4) starts
and it is active for 180 min (by default). The time
can be changed if needed using product param-
eter "Original Extract Detection Time [m]" in min-
utes.
5. When the first Original Extract 1(2/3/4) has been
determined the measurement values such as
"Apparent Extract Dens.", "Alcohol" etc. are cal- 8. Repeat this procedure for every batch and every
culated and displayed as well. tank independently.
6. As long as the wort/beer stays in the tank leave
the product parameter "Start Tank 1" set to "1"
(= ON). NOTICE
This application needs the Original Extract at the
beginning of the batch and calculates the Appar-
ent Extract Density/Alcohol etc. values from the
decreasing "Concentration Ext" value.
If the Concentration Ext. value is higher than the
current Original Extract of the tank than all calcu-
lated values are set to "out of range" (mPDS 5)
7. When the tank is emptied set the parameter or "Invalid" (Davis 5). This may happen for a
"Start Tank 1" to "0". This will set measurement short time at the beginning of each batch e.g. if
values such as "Apparent Extract Dens.", "Alco- the wort in the tank is not perfectly mixed.
hol" etc. to "0".

Explantion of all Product Parameters for Automatic Mode

NOTICE
If you change the product parameters controlling
the automatic mode for determination of the
Original Extract it is necessary to restart the
mPDS 5 or at least switch to product '0' and then
back to the fermentation product.

Name Min Value Max Value Default Value

Original Extract Min 0 99.99 0

Original Extract Max 0 99.99 99.99

Original Extract Stability 0.001 1 0.01

Original Extract Stability Duration 2 20 5

Original Extract Detection Time [m] 1 2000 180

The above parameters are used to control the Orig- nal Extract 1/2/3/4.
inal Extract determination - automatic mode. In most - Original Extract Stability/Original Extract Sta-
cases the default settings are suitable. These pa- bility Duration/ Original Extract Detection
rameters are applied for all 4 tanks! Time [m].
If the Concentration Ext. 1/2/3/4 is stable
- Original Extract Min"/"Original Extract Max"
within +/- 0.01 °Plato (Original Extract Stabil-
… These parameters define the allowed
ity) for 5 seconds (Original Extract Stability
range for the automatically determined Origi-
Duration) then it is compared with current

D32IB003EN-C 31
Appendix C: Fermentation Monitor 5100 / mPDS 5 SOP - Automatic Mode for 4 Sensors

Original Extract 1/2/3/4 and if the Concentra- "1"=ON).

tion Ext. is higher it is used as new Original If filling a tank takes e.g. 10 hours either
Extract 1/2/3/4. This procedure is active for increase the time or don't start the procedure
the first 180 minutes (Original Extract Detec- for automatic determination before the tank
tion Time [m]) ) after the product parameter is completely filled.
Start Tank 1/2/3/4 has been checked (=set to

Calibration and Adjustment Using Davis 5

If the laboratory reference values deviate from the We recommend checking the apparent extract den-
results of the Fermentation Monitor, it is possible to sity only, because this is the result typically used as
adjust the process system. We recommend at least reference method. (E.g. with DMA 35). If you set the
5 calibrations always at the same stage of the fer- adjustability of the channels properly the Davis 5
mentation batch (preferably when fermentation has calibration window looks like shown in Fig. 21.
finished). Davis 5 then automatically uses the aver-
Refer to the Davis 5 manual for further details.
age deviation for adjustment.

Fig. 21: Product calibration and adjustment window

32 D32IB003EN-C
 Appendix D: Document Numbers

Appendix D: Document Numbers

Document Number Date Comment

D32IB003EN-A May 2019 First Release

D32IB003EN-B October 2019 Restructuring of chapters

New: Prism wash system tank
Minor adaptions

D32IB003EN-C January 2020 New features of mPDS 5 product type "Beer Ferment.
Ri" (improved support for 4# L-Rix connected to one
mPDS 5)
SOP (mPDS 5/Davis 5/4# Fermentation Monitor)

D32IB003EN-C 33