b 320009 vendor data catalog vol.5

KINGDOM OF THAllAND PETROLEUM AUTHORITY OF THAILAND

BONGKOT - ERAWAN - KHANOM GAS TRANSMISSION PIPELINE PROJECT

KHANOM ONSHORE FAClLl.TIES

VENDOR DATA CATALOG

Volume 5

Heating Medium Heaters

Saipem S.p.A.

November 1993

Badger Design & Constructors Badger Job No. BH283 1

5.0 VOLUME 5 TABLE OF CONTENTS

5.0 VOLUME 5 TABLE OF CONTENTS

5.1 2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters 5.1.1 Purchase Order 5.1.2 Specification 5.1.3 Handbook of Operating Instructions

5.1 2001-F-03 A&B (HS-101 A&B) Heating Medium Heaters

Badger Oesian 6 Constructors. I ~ c . (713) 272-2400 8313 ~outhGst Freeway Suite 300

FAX (713) 272-2424

Houston. TX 77074

To: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016

Purchase Order No. : BH-2831-~01-10 Revision: 1

File No.: H01 Issue: 3.

Attn: AL BRUHN Date: 06/07/93 Page 1 o f 2

- 7 -

~~~~~ - 1

(The Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the I Ireverse side hereof. Vendor shall sign and return at once to the Purchaser the attached -Vendor's Acceptance of Purchase Order.'[ I J

Item Quantity Description

Previous P.O. Total:

Changes This Revision:

NEW PURCHASE ORDER TOTAL:

Pricing Details: This revision is issued to delete one (1) Combustibility @,

For RICHARD KINATEDER Manager of Procurement

BDC-PP-1-1 (Rev 5191 1

Badger Design 6 C~nSt~ctoIa. InC. (713) 272-2400 831 3 Southwest Freeway FAX (713) 272-2424 Suite 300 Houston. TX 77074

TO: AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016

Purchase Order No.: BH-2831-~01-10 Revision: 1


Date: 06/07/93 Page 2 of 2

r - - - 1

llhe Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the I Ireverse side hereof. Vendor shall sign and return at once to the Purchaser the attached *Vendor's Acceptance of Purchase Order:( 1 1


NOTES

1 All other terms, conditions, and instructions of our original purchase order and subsequent revisions thereto remain unchanged and in effect.

BDC-PP-1-1 (Rev 5/91 1

Badgec Oesign d l Constructors. tnc. 8313 Southwest Fraeway Suite 300 Houston. TX 77074

(713) 272-2400 FAX (713) 272-2424

AGENT F W P A


Purchase Order No.: BH-2831-H01-10

F i l e No.: H01 Issue : 2.

D a t e : 12/21/92 Page 1 o f 11 Attn: AL B R ~ H N

I The Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once to the Purchaser the attached uVendorls Acceptance of Purchase Order." I

Desc r ip t ion

Confirming o u r v e r b a l a u t h o r i z a t i o n d a t e d 12/21/92, p l e a s e e n t e r o u r Purchase Order f o r t h e fo l lowing equipment p r i c e d i n accordance w i t h your proposa l P-6915 da t ed 10-27-92 , r e v i s i o n s da t ed 11-2-92, 11-4-92, 11-9-92 and f a x ( s ) d a t e d 11-20-92,12-3-92,12-10-92 & 12-21-92 exc luding any c o n d i t i o n s o f sale t h e r e i n which c o n f l i c t w i t h o r add t o t h e "Terms and Condi t ionsnas l i s t e d on t h e r e v e r s e s i d e . o f t h i s page, " I n s t r u c t i o n s t o Bidders" included i n o u r o r i g i n a l i nqu i ry , t h e " I n s t r u c t i o n s t o Vendors" as o u t l i n e d on t h e fo l lowing pages and any a d d i t i o n a l terms a s set f o r t h below.

T o t a l I t e m s Cost:

Misc. Costs:

P r i c i n g De ta i l s : MISC. COSTS: ------------ $5,000.00 For l ( o n e ) Combus t ib i l i t y test. $5,324.00 For s p a r e p a r t s a s o u t l i n e d on a t t a c h e d e x h i b i t "A".

Purchase Order T o t a l US$:

) Buyer: C. H. STRAUSS For RICHARD KINATEDER 1

Badger O 4 i n 6 Constructon. Inc. 8313 SarMwed Freeway Suite 300 Houston. TX 77074

(713) 272-2400 FAX (713) 272-2424

AGENT f+PA

To: AMERICAN HYDROTHEFW Purchase Order No.: BH-2831-H01-10 470 PARK AVE. SOUTH NEW YORK, NY 10016 File No.: H01 Issue: 2.

Date: 12/21/92 Page 2 of 11

The Vendor by accepting this order agrees to the several Instructions and Conditions contained herein, including those.on the reverse side hereof. Vendor shall sign and retum a t once t o the Purchaser the attached "Vendor's Acceptance of Purchase Order."


1 HEATING HEDIUM HEATER in strict accordance with the attached Badger specification SPBH-2831-H-101 Issue # 2

Cost Code: HSOOlOl

------------- Schedule Dates -------------- Drawing Fab Re1 Material Shipment from Vendor

01/18/93 04/26/93

HEATING MEDIUM HEATER in strict accordance with the attached Badger specification SPBH-2831-H-101 Issue # 2

Cost Code: HSOOlOl

Schedule Dates -------------- Drawing Fab Re1 Material Shipment from Vendor

01/18/93 04/26/93

REFERENCE SPECIFICATIONS

SPBH-2831-R-1 Issue 1

SPBH-2831-GN-1 Issue 1

SPBH-2831-N-2 Issue 1

SPBH-2831-K-102 Issue 1

SPBH-2831-D-1 Issue 2

SPBH-2831-D-2 Issue 1

SPBH-2831-C-1 Issue 3

SPBH-2831-E-13 Issue 2

Badger Design Jl Constructom. lnc. 8313 Southwe& Freeway Suite 300 Houston. TX 77074

(713) 272-2-

FAX (713) 272-2424

Badger ~ ~ i l ~ m ~ a t ~ o m p a w

AGENT FOR SAIPEM SPA




Date: 12/21/92 Page 3 of 11

The Vendor by accepting th is order agrees to the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once to the Purchaser the attached uVendor8s Acceptance of Purchase 0rder.u


SPECIAL NOTES

1 NOTE: Progressive payment terms shall be as follows: 10% Upon submittal and acceptance of drawings for approval. 35% Upon verification of receipt of major materials. 45% Upon shipment. 10% Upon -commissioning and or plant start-up, not to exeeed 90(ninety) days after delivery.

2 LADDERS and PLATFORMS as outlined in this order are included in the base price of each item.

DRAWINGS:

Drawing for approval are promised 4 weeks after receipt of verbal award, or no later than 01/18/93, or as individually referred to by item. The drawings, manuals, and data required per the attached "VENDOR DATA COMMITMENT SHEETn are integral to this order.

Vendor accepts responsibility for costs of change or cancellation of equipment or materials ordered prior to drawings being reviewed by Badger and returned marked "Proceed with Fabricationn.

*** IMPORTANT NOTES *** 1. All data to be submitted by Vendor must bear on the document itself; P.O. number, item number, client name, and jobsite location.

2. All documents submitted must be clear and legible.

3. All documents submitted must be in the correct number of reproducibles and copies as stated on the "VENDOR DATA COMMITMENT SHEET".

4. Failure to comply with any of the above will delay payment of Invoices and/or result in backcharges to Vendor.

SHIPMENT PROMISED

Shipment sh.all be completed within 18 weeks after verbal award , or no later than 04/26/93, or as individually referred to by item. Partial shipments must have written prior approval from the Project Expeditor

Badger Design 6 Con?rtructofa. Inc. 0313 !Southwest Frwway Suite 300 Houston. TX 77074

(713) 272-2400

FAX (713) 272-2424



Purchase Order No. : BH-2831-H01-10

F i l e No.: H01 I s s u e : 2.

D a t e : 12/21/92 Page 3 o f 11

The Vendor by accepting th is order agrees t i t h e several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once to the Purchaser the attached Wz-ndoras Acceptance of Purchase Order."

1

I t e m Q u a n t i t y D e s c r i p t i o n

INSPECTION REQUIREMENTS

Author ized , P r o g r e s s i v e , F i n a l

F.O.B.:

4 P o r t o f e x i t .

SHIP TO:

1 Badger Design & C o n s t r u c t o r s , I n c - c / o F r e i g h t Forwarder (To f o l l o w )

FREIGHT :

1 F r e i g h t costs are n o t i n c l u d e d i n t h e p u r c h a s e o r d e r t o t a l . F r e i g h t s h a l l b e p r e p a i d and added t o t h e i n v o i c e w i t h s u p p o r t i n g documentat ion.

RELEASE TO SHIP:

1 Vendor w i l l b e r e l e a s e d t o s h i p a f t e r comple t ion and a c c e p t a n c e o f equipment, e n g i n e e r i n g drawings , and any o t h e r r e q u i r e m e n t s o f t h e o r d e r . Vendor must n o t s h i p u n t i l r e l e a s e d by Badger Exped i t ing , o t h e r w i s e t h e material w i l l be r e t u r n e d a t t h e Vendor ' s expense . C o n t a c t M s . Brenda Leared (713)272-2450, f o r s h i p p i n g and i n s p e c t i o n i n s t r u c t i o n s .

TERMS OF PAYMENT:

1 N e t 60 d a y s upon completed shipment o f a l l i t e m s .

RETENTION POLICY

1 Ten p e r c e n t o f t h e purchase o r d e r v a l u e w i l l b e w i t h h e l d from f i n a l payment u n t i l s a t i s f a c t o r y p l a n t s t a r t - u p is performed. I n v o i c e must b e f o r t h e f u l l amount less t e n p e r c e n t r e t e n t i o n n o t t o exceed 90 d a y s a f t e r shipment .

Badger W i n & Const~dors . Inc. 8313 Southwest Freeway Suite 300 Houston, TX 77074

(713) 272-2400

FAX (713) 272-2424





Date: 12/21/92 Page 4 of 11

The Vendor by accepting th is order agrees to the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shal l sign and return at once to the Purchaser the attached *aVendor's Acceptance of Purchase Order."


PRICE BASIS

1 Price is firm and not subject to esclation.

VENDOR ACCEPTANCE

1 No payments shall be made on the Purchase Order until the signed "Vendor's Acceptance Copy" is signed, dated, and returned to Badger Design and Constructors, Inc.

BADGER CONTACT INFORMATION

1 BUYER: C.H. Strauss (713) 272-2469 Fax: (713) 272-2484 EXPEDITOR: Brenda Leared (713) 272-2450 Fax: " " "

INVOICES

1 Invoices shall be submitted, in accordance with invoicing instructions in the "Instruction to Vendors", to: SAIPEM SPA C/O BADGER DESIGN AND CONSTRUCTORS, INC. 8313 SOUTHWEST FREEWAY HOUSTON, TX 77074 ATTN: C. ETHERIDGE

WARRANTY

1 Warranty shall be in effect for Twelve(l2) months from plant start-up or Twenty Four(24) months from date of shipment, which ever occurs first.

INSPECTION REQUIREMENTS

1 This order requires authorized, progressive and final inspections by Badger and/or Saipem SPA.

VENDOR DOCUMENTATION

1 Badger approval required prior to manfacturer.

CONTACTS

Badger W i n & Comt~ctora. Inc. 8313 Southwest Freeway Suite 300 Houston. TX 77074

(713) 2702- FAX (713) 272-2424

AGENT FOR SA-PA

T o : AMERICAN HYDROTHEW 470 PARK AVE. SOUTH NEW YORK, NY 10016

P u r c h a s e O r d e r N o . : BH-2831-H01-10

F i l e No. : H01 Issue: 2.

D a t e : 12/21/92 P a g e 5 of 11

- The Vendor by accepting th is order agrees to the several Instructions and Conditions contained herein, including those on the reverse side hereof. Vendor shall sign and return a t once to the Purchaser the attached "Vendor's Acceptance of Purchase Order."

I t e m Q u a n t i t y D e s c r i p t i o n

1 AMERICAN HYDROTHEW: ------------------- Sales: M r . A. L e d i c (212) 889-7100 F a x : (212) 576-1426

ATTACHMENTS

1 S p e c i f i c a t i o n s as l i s t e d herein.

2 " V e n d o r D a t a Commitment S h e e t "

Badger Design 6. Conot~ctm, Inc. (713) 272-2400 8313 Southwest fre%way FAX (713) 272-2424 Suite 300 Houston, TX 77074

- -

Badger A-Canpany

AMERICAN HYDROTHERM 470 PARK AVE. SOUTH NEW YORK, NY 10016

INSTRUCTIONS TO VENDORS

Page 6 of 11

1. CORRESPONDENCE -------------- All correspondence shall be sent to the following address: Badger Deslgn & Constructors, Inc. 8313 Southwest Freeway Suite 300 Houston, TX 77074 .......................... Commercial Issues: to the attention of Buyer (by name) All Other Correspondence: to the attention of Expeditor as listed in the Purchase Order.

2. VENDOR DOCUMENTATION APPROVAL .............................. The documents listed on the Vendor Data Commitment (VDC) for are subject to approval as noted in the body of the Purchase Order.

3. VENDOR DATA REPORTS AND FINAL DOCUMENTATION ........................................... Final documentation (as required by the VDC form or specification) containinq material certification, results of nondestructive examination, inspection results,reports,etc., shall be submitted in book form.

4. PRODUCTION SCHEDULES .................... The vendor will be required to submit production schedules stating applicable milestones as follows: Issue of drawings, specific-ati- and procedures for approval and certified for manufacture, placement of suborders, receipt of materials, start of manufacture, completion of major manufacturing steps, final assembly, preparation for shipment and delivery date.

When suborders entail manufacture and assembly, similar information shall be included for the subassembly parts.

ORIGIN OF MANUFACTURE

It is understood and agreed that all products used in manufacture of this order will be products of United States manufacture. In the event that the vendor or a subvendor wishes to use products not of United States manufacture, they must obtain specific written authority from Badger prior to the start of manufacture.

Badger Design i% ConstructOfS. Inc. 8313 Southwest Freeway Suite 300 Houston. TX 77074

(713) 272-24M)

FAX (713) 272-2424



Page 7 o f 11

6. SUBORDERS --------- Copies of all orders issued by the vendor in connection with this Bad er order shall be sent to Badger Design t Constructors, Inc., inc?uding copies of any orders placed by a subvendor. Copies of any referenced attachments not in Badger's possession should also accompany the suborders. ........................ All vendor and subvendor orders shall contain the following in£ ormation: a. Complete description including any relevant drawings or specifications. b. Promised delivery date. c. Requirements for origin of manufacture approval (see Paragraph 5). d. For mill ordered material the mill order number and date of acknowledgement. e. Requirements for final documentation. f. A statement extending the required Badger inspection levels, rights and notification of inspection for the subordered material. ------------------ The copies of the vendor and subvendor orders sent to Badger shall be identified with the Badger purchase order and item number(s).

INSPECTION AND TEST REQUIREMENTS ................................ NOTIFICATION of readiness for inspection shall be made by telex, telegraph, telephone or letter at least fifteen (15) working days in advance. Readiness for inspection means either the equipment is complete or that a point in fabrication has been reached which requires witnessed inspection per specification, code requiremen+- or written agreement between Badger and/or vendor and Authorized Inspection Agency.

REVISIONS TO PURCHASE ORDER ........................... Requests for clarification or change to the purchase order requirements shall be made in writing through the Badger or expeditor. Badger will not be liable to the vendor for any claims for reimbursement for additional costs for extra work or changes to the scope of work which have not been approved in advance and in writing by the Buyer.

Badger Design 6 Constructors. Inc. 8313 southwest Freaway Suite 300 Houston. TX 77074

(713) 272-2400

FAX (713) 212-2424


INVOICING INSTRUCTIONS ......................

- -


Page 8 of 11

Payment of vendor invoices will not be made until all documentation required in accordance with with this order is received. ------- The following information must be included in each invoice for each shipment or partial shipment. Equip./MatVl/Services description and pricing used in vendor's invoice are to be identical to those used in this purchase order. .................... a. ~ u a n t i t ~ , description, purchase order number and item number. b. Net unit prices, extensions and total amount. c. Routing, shipping point, FOB point and car number if shipped as a car load. d. Cash discount allowance, if any. e. Invoice shall be marked "Partial" or "Final." ---------------- Mail total, original and copies of invoice with attached supporting documentation as required to the address stated in the body of this order.

PUBLICITY --------- In the event the vendor wishes to obtain any publicity or to indulge in advertising of the products which they are furnishing against the subject purchase order, it is first necessary that they apply in writing, outlining the details of the publicity or advertisement they wish to accomplish, and obtain written permission from Badger. Under no circumstances shall the vendor approach the client to obtain publicity privileges.

OCCUPATIONAL SAFETY AND HEALTH ACT .................................. The vendor further warrants that it, its employees, agents, and suppliers shall comply with the Occupational Safety and Health Act of 1970, any subsequent amendments thereto, or further legislation relating to the subject matter thereof, as well as all applicable standards and regulations promulgated by the United States Department of Labor thereunder. The vendor further agrees that all mechanical design and equipment performance shall comply with all the foregoing requirements and to indemnify and shall hold Contractor and Owner harmless from any and all liablity thereunder for or by reason of any violations, citations thereof or penalties, civil or criminal, arising by reason of any failure so to do on the part of the vendor and/or its employees, agents or suppliers.

Badger Design & Const~ctors. Inc. 8313 Southwest Freeway Suite 300 Houston. TX 77Q74

(713) 272-2430

FAX (713) 272-2424



Page 9 o f 11

EQUAL OPPORTUNITY EMPLOYER .......................... For purchase order made in connection with.a government contract, the vendor, during performance of work under the purchase order, shall agree to comply with executive Order 11246, Section 504 of the Rehabilitation Act of 1973, and Section 402 of the Vietnam Era Veterans Readjustment Assistance Act of 1974, as amended.

VENDOR DATA COMMITMENT FORM INSTRUCTIONS ........................................ Required Documents will be indicated by an "Xu in the approiate column by Badger. ----------------- Document Description describes, in general, the type of document required. More specific and detailed requirements are indicated on the Vendor Data Commitment Form (VDC). ...................................... Number of Copies (Print or reproducible) required for review and final issue will be indicated by Badger. ........................................ ARO/ARRD indicated at the time of quotation, the number of weeks after receipt of Purchase Order (ARO) or after receipt of reviewed drawings (ARRD) that the vendor has commited to issue each document.

Badger Design 6 Constructo(s. I ~c . 8313 Sarthwest Fresway Suite 300 Houston. TX 77074

(713) 272-2400

FAX (713) 272-2424



Page 10 of 11

14. DOCUMENTATION REQUIREMENTS ................................ a. I n a d d i t i o n t o t h e vendor 's name and drawing number; t h e drawing t i t l e block s h a l l inc lude a symbol o r letter i n d i c a t i n g t h e latest i s s u e o r r ev i s ion , t h e Badger Purchase Order Number and Equipment I t e m Number. A 3-inch hiqh by 6-inch wide space above t i t l e block is t o be l e f t blank f o r app l rca t lon of t h e Badger "Action S ta tus" decal . ( I f drawing s i z e a l lows) . ..................................................................... b. Revisions made t o drawkngs between i s sues s h a l l be c l e a r l y i d e n t i f i e d . I n addi t ion , a b r i e f t abu la ted d e s c r i p t i o n s h a l l be g iven f o r each drawing issue . The term "Lates t Revision" s h a l l not be used. ..................................................................... c. I f t h e vendor is submitt ing f i n a l documents a s d i r e c t e d by Bad er, only t h o s e document changes r e s u l t i n from Badger comments ehayl be incorporated. No o t h e r changes shayl be made. ..................................................................... d. Documents s h a l l be s u i t a b l e f o r microfilming, and m e e t t h e fol lowing minimum requirements: - Drawinus s h a l l b e c l e a r and l e q i b l e . Shadinu on drawinss is not p e r m i s s i f h e .

- - - L e t t e r i n a s h a l l be a minimum of 1 / 8 inch hiah. - A reducez p r i n t s c a l e s h a l l be prbvided for-each drawing where s c a l e is e s s e n t i a l .

e. Drawing r e p r o d u c i b l e ~ submitted s h a l l not be folded. P r i n t s s h a l l be folded t o 8 1/2 by 11 inch s i z e , and shipped with t h e reproducibles. .................................................................... f. I f "As-built" drawings a r e requi red it w i l l be s p e c i f i e d i n t h e purchase order . The quan t i ty of "As-builts" drawings requi red s h a l l be t h e same a s f o r f i n a l c e r t i f i e d drawings.

Badger W i n & Const~ctors. Inc. (713) 272-2400 8313 Sournwest Freeway Suite 300 Houston. TX no74

FAX (713) 272-2424

--

Badger A-Company



VENDOR DATA COMMITMENT GENERAL REQUIREMENTS ...........................................

Page 11 of 11

a. The Badger Vendor Data Commitment Form ( M C ) indicates the scope, timing, and quantity of documents required. The documents are divzded into two categories: submitted for review, and submitted for information. Documents submitted for review shall be resubmitted as final after Badger's review.

b. All vendor documents, including transmittals, shall be clearly marked with the Badger Purchase Order Number, Equipment Number and Title. Failure to comply with these requirements may prolong Badger's review. ..................................................................... c. All document requirements for prime vendor shall be equally binding, as applicable, to any subvendor. The prime vendor shall be responsible to ensure that appropriate documentation requirements are contained in the suborders. ..................................................................... d. Vendor should allow three weeks for review'from receipt by Badger to transmittal by Badger, unless otherwise negotiated or stipulated in the terms of the purchase order.

BADGER DESIGN & CONSTRUCTORS, INC. A B . l ( * r a C . m ~ . . 1

Houston, Texas

SPECIFICATION

FOR - HEATING MEDIUM HEATERS

BADGER ITEM NO. HS-101 A/B

TAG NO. 2001-F-03

KHANOM ONSHORE FACILITIES

THE PETROLEUM AUTHORITY OF THAILAND

SAIPEM SPA

BADGER PROJECT BH-2831

PETROLEUM AUTHORITY OF THAILAND

SPECIFICATION NO. SP.G-9210.04-2001-02

TABLE OF CONTENTS

1.0 SCOPE

2.0 CONFLICTING REQUIREMENTS

3.0 REFERENCE SPECIFICATIONS

4.0 SITE CONDITIONS

5.0 ITEMS TO BE SUPPLIED BY VENDOR

6.0 ITEMS TO BE SUPPLIED BY OTHERS

7.0 UTILITIES AVAILABLE

8.0 DESIGN REQUIREMENTS

9.0 CONTROL SYSTEM

10.0 REFRACTORY AND INSULATION

11.0 STRUCTURES, STAIRS AND LADDERS

12.0 DAMPERS

13.0 PIPING

14.0 OTHER VENDOR REQUIREMENTS

15.0 INSPECTION

16.0 PREPARATION FOR SHIPMENT

17.0 GUARANTEE

SPECIFICATION FOR

HEATING MEDIUM HEATERS ITEM NO. HS-1-01 A/B

1.0 SCOPE

This specification covers the requirements for furnishing two (2) horizontal heaters as described in this specification. The heaters shall operate 24 hrs/day continuously. The location of the equipment will be outdoors, unprotected, in an industrial seashore environment. The heater shall be designed, fabricated, inspected and constructed in accordance with API Std. 560. If any portion of API Std. 560 is in conflict with this specification, this specification shall govern.

1.2 Compliance by the vendor with the provisions of this specification does not relieve him of the responsibility of furnishing the unit and accessories of proper design, mechanically suited to meet the operating guarantees at the specified service ,conditions.

1.3 The heaters shall be prefabricated and preassembled in vendor's shop to the maximum extent possible.

2.0 CONFLICTING REOUIREMENTS

2.1 All conflicts between the requirements of this specification, purchase order, specification sheets, and standards shall be referred to the purchaser for clarification before proceeding with the manufacture of the affected parts.

3.0 REFERENCE SPECIFICATIONS Issue Q

SPBH-2831-GN-1 Equipment Noise Level Limits 1 SPBH-2831-R-1 Shop Painting 1 SPBH-2831-D-1 Design of Structures 2 SPBH-2831-D-2 Fabrication of Structural Steel 1 SPBH-2831-C-1 Pip.inq Material Class 2

SPBH-2831-~-2 piping Insulation 1 SPBH-2831-K-102 Instrumentation for Packaged Systems 1 A SPBH-2831-E-13 Low Voltage NEMA Frame Motors 2

4.0 SITE CONDITIONS

Ambient Temperature: 76OF to 91°F Environment : Seashore, Industrial Electrical Area Classification: Class I, Group D, Div. 2

BADGER DESIGN & CONSTRUCTORS. INC.

ISSUE

4 DAIT:

- 1 -&

3 s ~ a of 2 0

SPBH-2831-H-101

5.0 ITEMS TO BE SUPPLIED BY VENDOR

The following shall be included with each basic heater structure:

5.1 Burners with electric ignition pilots 5.2 Platforms and ladders 5.3 Outlet manifold 5.4 Flame safeguard and control system with purged,

weatherproof panel. Panel to display motor on/of f . (system logic)

5.5 Fuel piping trains, including flexible connections at the burner(s).

6.0 ITEMS TO BE SUPPLIED BY OTHERS

6:l ~oundation, support piers and-anchor bolts 6.2 Heater erection 6.3 piping between fuel piping/safeguard manifold and heater. 6.4 Motor starters 6.5 ~ e l e t e d n

7.0 UTILI-TIES AVAILABLE

Power Supply: Controls : Instrument Air:

415V/3 Phase/50 Hertz 220V/1 Phase/50 Hertz 80 psig, -40°F Dew Point Design Temperature - 100°F

FUELS :

Gas to Fired Heater (Stream 5) Design Pressure - 450 psig Design Temperature - 200°F

Cold Stable Condensate (Stream 8) Design Pressure - 125 psig ~esign Temperature - 350°F

Stabilizer Overheads (Stream 12) ~esign Pressure - 125 psig ~esign Temperature - 350°F

8.0 DESIGN REQUIREMENTS

8.1 Each heater shall be designed, fabricated, inspected, and constructed in accordance with the criteria of ASME A oiler and Pressure Vessel Code, Section I.

8.2 Each heater shall be designed to fire the three fuels I described in the data sheets.

8.3 Each furnace shall be furnished with one dual fuelA burner. The burner pilot shall burn fuel gas and shall be suitable for electric igniti0n.n

BADGER DESIGN b ISSUE DATE 1.4 1 3 - ~ 1 - 4 3 1 = ~ OF20 SPBH-2831-H-101 1 CONS TROC TORS. I NC .

8.4 Burner design shall permit a turndown ratio of 4: 1 of design heat load with either fuel .A

8.5 Burners and heaters shall be sized to permit firing at least 120% of design heat liberation. I

8.6 Heater casing temperature shall be calculated based on ambient air to 80°F and a 5 mph wind. Maximum outside casing surface temperature shall be equal to or less than 200°F.

8.7 A complete flame safeguard and temperature control system shall be furnished for each heater by the vendor. The systems shall conform with NFPA standards and shall be FM approvable, Panel mounted items shall be enclosed in a pre-wired and tested fabricated steel panel (NEMA 4X outdoor). All components of the system shall be UL listed and shall i.nclude, but not limited to:

8.7.1 Annunciator (First-out indicating) with auxiliary contacts for purchaser's use. I

8.7.2 High temperature switch with DPDT contacts.

8.7.3 Flame relay w / W scanner on burner(s) with self-checking feature and aux. contacts in local panel annunciator.

8.7.4 Ignition transformer.

8.7.5 Auxiliary relays and selectors. I 8.7.6 Time delay relays for purge and trial for

ignition.

8.7.7 Space heater and thermostat. (If required) I 8-7.8 Indicating lights and pushbuttons. I 8.7.9 The design and supply of instruments and

control systems shall satisfy the requirements of SPBH-2831-K-102 and its annexes.

8.8 Heaters shall be single pass. A11 manifolds shall b e n sized to minimize maldistribution of hot oil through individual parallel heater passes. Manifolds and crossover piping shall be designed in accordance with ANSI B31.3.

8.10 Lancing doors shall be provided in the convection bank for air cleaning of tubes as required. Access to lancing doors shall be from convection section side wall platform.

I

BADGER DESIGN b CONSTRUCTORS* INC.

SHEET ~ a a SPBH-2831-H-101 7-4-93 A

8.11 Heater vendor shall provide one (1) tube skin thermocouple on the outlet tube of each radiant pass located such as to monitor the maximum tube metal temperature for that tube. The thermocouple shall be installed with due consideration for tube movement without causing undue stress on the thermocouple sheathing.

8.13 Structural design conditions shall be per the requirements of Badger Specification SPBH-2831-D-1, Issue 2 and SPBH-2831-0-2, Issue 1.h

8.14 The furnace shall meet the noise level requirements of Badger Specification SPBH-2831-GN-1, Issue 1.

8.15 Overall calculated and guaranteed thermal efficiency for the heater shall be based on LHV (lower heating value). Efficiency shall be based on optimum excess air value with operation at design conditions of duty and temperature rise, using the clean equipment. Efficiency -tests shall be based on the stack losses method as outlined by the applicable ASME power test codes. Excess air will be measured at the base of the stack.

8.16 No copper or copper bearing alloys shall be used in contact with the heat transfer oil.

8.17 Clear access ports and/or doors shall be provided to allow for cleaning, inspection and maintenance. The number, size and location of these ports/doors shall be listed in vendor's quotation. Access doors shall be furnished for each chamber of the radiant section and each convection section and breeching. At least one radiant section access shall have an opening approximately 24 x 42 inches.

Relief provision shall be furnished for each chamber.n

Observation ports shall be provided as required to make all radiant tubes, exposed row of convection section tubes, and the burner flame conditions fully visible. Cast iron observation doors shall be provided with a cast iron closure and cool handle to use.

8.18 When access to the underside of the heaters is required for operation, the minimum clear headroom to and in the access area shall be 6'-6".

BADGER DESIGN b CONSTRUCTORS, lNC.

ISSUE

J. DATE

4 , a 20 SSET SPBH-2831-H-101

8.19 Stack Requirements

8.19.1 Furnace stack height shall be minimized. Stack to be adequate for draft requirements at 120% of design firing. Draft calcu,lations shall assume convection bank losses based on 120% flue gas quantity and the same temperature profile as the design operating case.

8.19.2 The stack shall include 3 inch IPS flanged onnections for EPA type stack sampling, with adequate platforming and ladder access. The connections shall be located approximately 8 diameters downstream of the stack damper and 90 degrees apart.

8.19.3 The stack shall be self-supporting and shall be designed to be all welded construction. All girth and vertical seam welds shall be the full strength, complete penetration, butt groove weld type. If required for shipping purposes the, the stack may be joined to the heater by a flanged connection.

9.0 Control Svstem

9.1 Two hot oil heaters will be operating in parallel to supply hot oil at a constant flow and temperature to a number of process exchangers. The hot oil system will be a closed loop system consisting of the hot oil heaters, the process exchangers, an expansion tank and the hot oil pumps. The system must be capable of operating continuously and automatically.

The Burners and Burner Management Systems shall satisfy the following conditions:

9.1.1 When liquid fuel (Stream 8) is available, it will be fired preferentially. Dry contact signaling that liquid is available will be provided by Badger.

9.1.2 When liquid fuel (Stream 8) is available, a small amount of combustible vapor (Stream 12) will be present and must be burned.

9.1.3 When liquid fuel is not available the heat to satisfy the hot oil heating requirements will be furnished by firing natural gas (Stream 5) .

Natural gas (Stream 5) will only be burned if the combination of the other two fuels (condensate and combustible vapor) is insufficient to provide the required heat.

BADGER DESIGN & CONSTRUCTORS* INC*

of SPBH-2831-H-101

(setting the fuel burning priorities)

9.1.4 Both the liquid fuel (Stream 8 ) and the natural gas (Stream 5) must be capable of operating over the full range of duties.

9.1.5 Turn-down of each heating system shall be 4 to 1.

9.1.6 Each burner shall have a turn-down that will satisfy the conditions listed in 1 thru 5 above.

9.1.7 The system provided must be able to prevent an abrupt opening of the natural gas supply valve if the liquid fuel is shut off.

9.1.8 The stabilized overheads combustible vapor (Stream 12) should be separately piped or vented into the heater burner box. This line should have a check valve and/or other devices installed to prevent back pressure into the system.

9.1.9 The heater control panel shall operate from 4- 20ma supplied signals and shall send out 4- 20ma signals as the output to valves and other devices.

9.1.10 The heater panel shall receive a remote shutdown signal from the SCADA system and contacts shall be provided to the SCADA system to status heater shutdown.

9.1.11 Deleted

10.0 REFRACTORY AND INSULATION

10.1 Type of refractory used shall be suitable for shipment to Thailand.

10.2 Heaters shall be internally insulated.

10.2.1 The hot face layer shall be HYDRECON Franco- Lite #21.

10.2.2 The hot face blocks shall be TR-19.

10.2.3 HYDRECON 186 E.S. shall be used for heater front plate around the burner title.

10.2.4 HYDRECON 2400 shall be used for the outer face of the heater back plate.

10.2.5 FRANSET HI-TEMP mortar (thin layer only) shall be applied between adjacent faces of block insulation.

BADGER DESIGN b CONSTRUCTORS* INC- "ET OF

SPBH-2831-H-101 ISSUE

(I. DATE "-14-7-3

10.2.7 All washers shall be covered with LDS-moldable (or equivalent) or a ceramic fiber patch, after the fasteners are locked in place.

10.3 Deleted A 10.4 ~eletedn

10.5 External insulation is not required.A

11.0 STRUCTURES, STAIRS AND LADDERS A

Permanent steel platforms shal-l be provided for access to points requiring inspection or maintenance. Burners shall be accessible for maintenance and operation. Thermowells and draft control connections shall be accessible. Accessibility by a ladder is satisfactory. Ladders, stairs, etc., shall conform to SPBH-2831-D-1 and SPBH-2831-D-2. All handrails, stairs, ladders, etc., shall satisfy OSHA requirements.

( 12 . 0 DAMPERS (DELETED 1 a

13.1 Piping materials and design shall satisfy the following requirements:

13.1.1 Gas & liquid hydrocarbons (Streams 5, 8 & 12) See Piping Materials - Class: C10 I

13.1.2 Instrument Air See Piping Materials - Class: C10

13.1.3 Heating Medium (Hot Oil) See Piping Materials - Class: E30

I 13.2 All piping terminations shall be flanged. I I 14.0 OTHER VENDOR REQUIREMENTS I

14.1 The heater design shall maximize the extent of shop fabrication and assembly.

14.2 Heater vendor shall state maximum allowable forces, moments, and movements on heater terminal connections on the initial submittal of general arrangement drawings.

14.3 Vendor shall state erection weight of unit and maximum weight of components to assess crane requirements on the initial submittal of General Arrangement Drawings.

I 14.4 The vendor shall submit pressure-temperature curves showing the profile of operating pressure, fluid and I calculated tube wall temperatures, and fluid velocity I ".

7: ~2 L z l - . 3 :, I Q) w e

- along the length of each radiant pass.

BADGER DESIGN & ISSUE DATE I IJ 1 d - , 1 ~ t - 4 3 Ism w 2 d I SPBH-2831-H-101

14.5 In addition to the normal requirements for erection drawings, the furnace vendor shall submit a written erection procedure prior to any shipment of heater sections.

14.6 The vendor is required at the time of the proposal, to submit an estimate of the actual productive man-hours and time in weeks to field erect the unit. Vendor to state the weight of each heater section to allow assessment of crane requirements.

14.7 All openings and flanges shall be covered with plywood to protect from damage during shipping and storage. Vendor will submit for purchaser's review sketches detailing extent of framing and bracing to secure the heater and shop installed refractory for shipping.

15.0 INSPECTION

15.1 Inspection shall be made at the place of manufacture by the purchaser during manufacture and prior to shipment.

15.2 Purchaser's inspector shall have free entry to the manufacturer's plant, including the sub-vendor's plant, at all times, where work on or testing of the equipment is being performed. The vendor shall instruct his sub- suppliers of the inspection requirements of the purchaser.

15.3 In order to reduce purchaser's inspection work to a minimum, the vendor shall supply the inspector without charge: all tools, instruments, and documentation to satisfy him that the equipment furnished is in accordance with this specification with this specification and other supporting documents.

15.4 No surfaces or parts thereof shall be painted until the inspection is completed. The vendor shall notify the purchaser not less than (5) days when the equipment is ready for inspection.

15.5 Acceptance of the equipment does not constitute a waiver of requirements to meet field tests under specified operating conditions, nor does inspection relieve the manufacturer of his responsibilities in any way whatsoever.

15.6 Shop fabricated components shall be hydrostatically tested and code stamped in the shop.

SPBH-2831-H-101 BADGER DESIGN d CONSTRUCTORS. INC.

ISSUE DAE

15.7 ~ l l radiant tube hanger castings shall be given 100% liquid penetrant examination. Any defective areas found near support points shall be given radiographic examination to meet the quality of ASTM E-466, severity level 3 for all defects. ~epair/replacement due to defects found in the castings will require final approval of the client. Any repair procedure will require a final liquid penetrant examination.

16.0 PREPARATION FOR SHIPMENT

16.1 The equipment shall be cleaned to remove all mill scale and other foreign material and painted in the manufacturer's shop in accordance with Badger Specification SPBH-2831-R-1.

16.1.1 Structural steel - shall be painted in accordance with SPBH-2831-R-1D2

16.1.2 Piping shall be painted in accordance with SPBH-2831-R-1C2.

S6.1.3 All exposed. heater surfaces shall be painted in accordance with SPBH-2831-R-1M2, taking into proper account the temperature of the exposed surface.

16.1.4 Other equipment (machinery, instrument hardware. etc. , shall be painted in accordance with SPBH-2831-R-1P.

16.2 Exposed machined parts shall be coated with rust preventive. If vendor considers additional protection is necessary, he shall furnish his recommendations.

16.3 Each separate container shall be marked with the address, purchaser's job number, purchaser order number, item number, and each mating part shall be match-marked for ease of assembly.

16.4 Vendor shall furnish his recommendations for protective measures to be applied by purchaser to the unit after its delivery to the construction site.

16.5 All purchaser connections shall be adequately tagged or marked with a corrosion resistant tag for easy field hook-up.

17.0 GUARANTEE

17.1 All equipment and component parts shall be guaranteed by the Vendor against fault in design, defective materials, and/or workmanship as stipulated in the instructions and conditions section of the Purchase Order.

BADGER DESIGN & CONSTRUCTORS. INC*

ISSUE

h/ SPBH-2831-H-101 DATE

(7. ,)-!-97 -a

11 Of 38 s+ET

SAIPEM S.P.A. KHANOM OFFSHORE FACILITIES

(IIEATING-MEDIUM IIEATER SPECIFICATION)

L, MASS BALANCE Ill h

BADGER DESIGN 8, CONSTRUCTORS* INC. - a

F I R E D H E A T E R D A T A S H E E T

I F I R E D H E A T E R L?b.T,4 Si . !C:C:T I -----

c i e n t S X / P E & S,t?d. I t e m no. MS - / o/A/&

I C O M B U S T I O N D E S I G N C O N O l T l O N S I

I I

9 1 F l ue Gas Quan t i t y : 100% L ibe ra t i on (No rma l ) at I I I

: J I F lue Gas Quan t i t y : 9h L ibe ra t i on (Design) a t !'a X-A i r I I

I :

2

3

a

5

6

7

20 I T y p e o f F u e l 1s~me /L 21 I Heat ing Va lue (L.H.V.). ( B T U I L b ) (BTUISCF) 1

Type o f F u e l

Excess Atr. Percent

E r f ~ c t c n c y Guaranreeo. Percent (L.H.v.) (See L l n a 18)

E f l ~ c ~ e n c y Calculaleo. Percent (L.H.V.)

Raota t lon Loss. Percent o f Hea t Release (L.H.V.)

F lue Gar Temperature. Leav lng Radtant Section. Dag. F.

F lue Gas T e m ~ a r a t u r e . L e a v ~ n g Convect ton S e c t ~ o n . Oeg. F.

1 1

1 2

1 3

14

15

I 2 2 I S ~ e c i f l c G rav i t y L i q u i d a t Deg. F. I I I I I I I

8 I F lue Gas Mass V e l o c i t y t h rougn Conv. S e c t ~ o n . Lb/Sec./Sq. F t . 1

1 23 1 Soecif lc G rav i t y Gas ( A i r = 1.0) I / I I I 1

t

5if#dd5-I /s I

574 /,Lr

960 670

16 Calculated H e a t Release (L.H.V.). M M B T U / H r - 1 7 Vo lume t r i c H e a t Release (L.H.V.). BTU/Hr/Cu. Ft. I I I 18 ~ o t e : A fue l saving o f M M B T U / H r w i l l o f fse t a $1000 increase in t u r n a u cost (erected)

19 FUEL C H A R A C T E R I S T I C S

1

Draugnt a t Burners. Inches o f w a t e r 1 D raugh t a t B r~dgewa l l /En t rance t o COW. Section. Inches o f Water f D . / Draught a t O u t l e t t o Duct lS tack. Inches o f Water -- I A m b i e n t A i r Temperature. Deg. F. 1 76 70 7/ A l t l t u o e A b o v e Sea Level. m. M&?r&S I 5

1 29 / Ash Content . P+rcent b y Weight 1 ! i I I I I 1 30 1 Fue l Gas Compos i t i on . M o l e Percent I \ I 1 I 1 I

z r s & * r

/,Y

1 I

1 3 1 1 ~ u e l as om post ti on. ole percent ! I I I 1 1 I

Sr/r#*.y /2

761;3?/ g

1 3 2 1 F U ~ I G ~ S omp position. M O I ~ percent I / I I I I

I - I

I I - I

I I

: 7~: 70 ?/ i G

3 3

34

35

36

43 1 M i n i m u m Distance Bu rne r Center L i n e t o T u b e c e n t e r L ine: H o r ~ z o n t a l : Verttcal: 7 7 4 1

37

3 8

39

20

11

I u / Oeslqn F u e l Rate. Cb/Hr : Oer iqn A t o m l r i n g S team Rate. L b f H r : N/A 1

Fuel Temperature/Pressure Available. Deg. F./psig

Fue l Pressure Requ i red a t Burner. p r i g

A t o m i z i n g S team Pressure Requi red a t Burner. p r ig CrCj

Manufacturer a n d Type : I Size: FIL). m & PI c.a vr

Locat ion: pLOo - f f f e o i e y . ccrt C ~ + t - ~ r i i f i ~ A Pilot: Manu fac tu re r a& T y w : Nerf h fl-n. r; Size:

F lame Scanner Connect ions. Loca t i on : g4-oCI,@, Size: Number : Q,, ,=,,

Heat Release per Bu rne r at Ossiqn Excess A i r and Draught. No rma l : 3 0 & 0 3 MM BTU/Hr .

ISSUE D A T E I Badger Design 8, Constructors. lnc I I - 2g -cl sHEET OF^ 0 I SPGN- 283,- ,4- 10 , 1

t 4 2 I Heat Releasa oer Bu rne r a t Deslqn Excess A i r and Orauqht. oeslqn: MM B T U / H r . I

BURNER D A T A

/ / / / / ' /

19 Rare Tubes: Numb8r # / I I I 20 Tota l Exoosed Surface. Sq. Ft. 1 1.m T F O

2 1 Extended Surface Tubes: Number N n n a , NnA- 2 2 ~ o t a l ' ~ x o o s e d Surface. So. Ft . I

Client S A ? / P W C.P .4 . Item no. ns- 1 a /A/& MECHANICAL DESIGN CONDITIONS

I I I

23 1 Tube Soacing Ctr. t o Ctr.. In.: Radiant Sact. ( In Lina) (Stag.) I 1 1 1 1 t

1

2

3

4

5

6

7

Convection Sect. ( I n Line) (Equ~l.) (Stag.) --. g Tuba Ctr. t o Furnace Wall. In. (Mintmum)

26 Tube Orientatlon: Verttcal o r Hortzonta l

27 Tuba Material (Soectficatton and Grade) l o 6 ~ c ! R 28 Tuba Outside Diameter. In. I 240 od~?,ko.a 29 ~ u b a Wall Thtcknass, In. (Mintmum) (Average) I 0.2~- I 0.2.r I

I

30 Maxtmum Tuba Wall Temoarature. Deg. F. (Calculated) I I

Plot Llmttat lons. StrCK L l m l t a t l o n r

Tube L~mltat tons: Other L ~ m ~ t a t ~ o n r .

Structural Oeslgn Oata: Wtnd ~ o a a : w t n a Ve loc~ ty : Snow ~ o a a

, ~ ) J s I / / ~ s c e 7- 8 8 ~ a r t h s u a k e Zone ,,,/ , , s e ~ s m ~ c Factor: ~i34--

M E C H A N I C A L DESIGN DETAILS

Haater Sectlon I a r I 4 v I I I ~ a w i c a I HAAT/N~ --

Calculated Inside F i l m Coeff icient

I 8 I C O I L A R R A N G E M E N T A N D OESIGN:

Max imum Tube Wall Temoerature. Dea. F. IDesianb --

Oesiqn Basis l o r Tube Wall Thlcknass

DESCRIPTION O F E X T E N O E O SURFACE:

Tyoe: (Studs) (Serrated Fins) (Solid Fins)

Stud o r F i n Material

Stud o r F i n Olmensions

Stud o r F in Soacina

Extension Rat lo (Tota l Ar8a/Bare Area)

Max tmum Stud o r F i n Tem08rature. Oeq. F. (CdICulatad)

1 41 1 PLUG TYPE HEAOERS I

43 Material (Soeciflcatlon and Grade)

44 Nomina l Ratlng

45 Cocat~on (F.B. = F ~ r e Box: H.B. = Haadar Box)

46 Welded or Rolled

47 ,


client SAIPP' M sk&! I tern no. KS- /e / MECHANICAL DESIGN D E T A I L S (C0NT 'D. l

1 neater Section I b f i l ~ c ~ r I OGNV. I I I - 2 e Sarvice

3 RETURN BENOS:

4 T Y O ~ 3 1 /be ~ h l " , ~ ~ ? o Srr'fic 0- &&/>gg I 5 Material ( S ~ c i l i c a t ~ o ; r and Grade) 5,qk /&76 (/ ) I I I

6 Nominal Rat lng o r Scneau~e I I I I

- -

7 Location (F.6. = Fi re Eon: H.8. = Header Box)

8 1 T E R M I N A L S AND/OR MANIFOLDS:

I I

18 Maximum Al lowable Moment, Ft.-Lbs. I 1 I I I 19 CROSS-OVERS:

20 Welded o r Flanged IIr/b~o&0 I I 1 I 21 Size (I.P.S. o r 0.0.)

Flange Rating and Faclng o r Pi04 Schedule I I I ! I 23 1 Material (Soecl l lcat ion and Grade) sk.f? Ah*. (2 > I 1 24 1 Flu id Ternoerature, Oeg. F. I ! 1 I I I

I I Location I E K T - ~ N ~ u c I I I TUBE SUPPORTS:

Locarlon (Ends. Top. Bo t tom) I =P !&us I Material (Soect l lcat~on and Grade) 25C?,- 2&, ! d. 5. Dsrign Metal Temoerature. Oeg. F.

Thickness. In.

Tyoe and Thickness of tnsulatlon, In.

Insulation Reinforcement (Ty00/Mat9ft.l) I I N T E R M E O l A T E T U B E SUPPORTS: (As de.@ b ) Material (Soeclflcation and Gradel %Sf?&. -~o i ( / , - 1 Cmslgn Metal Temoerature. 0.9. F.

Thlckness. In .

Soaclng. F t .

Type and Thlckness o f lnsulatlon. In.

lnrulat lon Retnforcament (Tyoe/MaterIal)

TUBE GUIOES: I

4 1 Locat ion & r r o ~ 42 Material 2 3 CA: - 7.L)N/ 43 Type

44 Soacing 1

ISSUE

Badget Des~gn & Constructors. Inc I C) I Y ~ J . -q I SHEET /? 0 ~ 2 0 . -. S. -, . ! ., ;? .- -- / - I f - / 9/


Itemno. &-/a / MECHANICAL DESIGN D E T A I L S ICONT'O I

1

2

3

4

5

6

7

8

9

10

11

12

CASING. REFRACTORY A N D I N S U L A T l O N DETAILS

HEAOER BOXES: Location: Ara Header Box Ooors Boltea or Hlnqea:

Sattinq Matortat: Th~ccness. in.:

Casing Material: Thtcknels. In.:

Anchoring Material: Ancnoring Typa: - EXPOSED V E R T I C A L WALLS:

Setting Thickness. In.: H o t Faca Tamparature: Oesign: Oaq. F.Calculatea: Oeq. F.

Wall Conrtructton:

Casing Matarial: Thickness. In.: Outside Temperature: Oag. F.

Tieback Material: Tyoe: Soacing: In.:

Supoort Matarir l :

13

14

15

16

1 7

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

Method o f Fastaning TieOacks t o Structure:

SHIELDED V E R T I C A L WALLS: Dag. F.

Setting Thickness: In.: H o t Face Temoerature: Design: 0.9. F.Calcutataa:

wal l Construction: @&RH/C f ie&/& Caslnq Material: Thickness. In.: Outr ia0 Tarnoeracurs: Oeq. F.

~ i e b a c k Material: ,(?A 33b ~ y w : 4 w ' s ~ d ~ Spaclng: In.:

Support Material:

Method o f Fastening Tiebacks t o Structura:

ARCH:

Setting Thicknass: In.: H o t Face Temoerature: Design: 0.9. F.CaIcutatad Oeg. F.

Arch Conrtructlon: Q&#A*/G C G j ~ 6 . c Casing Material: Thickness. In.: Outsiao Ternoaratore: Oag. F.

Tieback Material: b?d 330 Type: Spacing; In.:

SuPoort Material:

Method o f Fastening Tieoacks t o Structure:

FLOOR:

Setting Thickness; In.: H o t Face Tem~eratura:. Oes~gn: 0cg. ~.€alcutatad: Oeg. F.

Floor Construction: / 2 0 0 ° d &,44y46~4 + g/&& &&~g &/@ L e e s Casing Material: Thickness. In.: Outside Temoaratura: Oag. F.

M in imum F loor Elevation: Free Space Balow Planurn:

CONVECTION SECTION:

Setting Tilicknass. In.: H o t Face Temoeraturec Oesign: Oeg. F.Calculataa: Oeq. F.

- 35

36

37

3 8

3 9

40

A1

A2

43

44

45

4 6

A7

4 8

n 9

5 0

5 1

5 2

wal l construct ion: /too0 c C R ~ ~ R B ~ ~ ThicKness. In.: Casing Material: Outsiae Temperature: Dog. F.

Tieback Material: 3 0 4 ~ ~ Type: Soacing. In.:

Support Material:

Mathoa o f Fastening Tiebacks t o Structure:

I N T E R N A L W A L L :

Tyoe: Material:

Oimens~ons: Haight/Width:

Oatails:

BURNER PLENUM: nvr O e r I'vlSf-d J I p r J : C G ~f-,, !"je i " / w , if Casing Material: Thickness. In.:

L in ing Material: Thickness. In.: Rsinforcemant Type:

Setting Materials ApoIIad I n Shop or at Sita:

Notas:

5 3

sPeiJ-~93/-hj-,-/0/ Badger Design & Constructors, Inc. ISSUE

~ H E E T / @ o F ~ O


Client SA/Pk>? Z,E4, Item no. &'S- /o/ A/& DETAILS OF HEATER APPURTENANCES

1 STACK or S T A C K STUB: w 1 e m t s r p ) , oorf.5

, 2 ~ u ~ o ~ ~ : 0 4 4 MR~I~c' se1f-$uooortin9 or Guyed: ~ ~ y ~ S ~ ~ ~ ~ ~ , ~ ~ o c a t i o n : # r i p

3 Casing Material: h,&rrlsw,L Thickness. In.: 0.3 . < 4 tnrlde Metal Olamerer, Ft.: Helqnt Above Graae. Ft.: Stack Lenoth. Ft.: I r f - .

1

5 Lln ing Material: - Thicknass. In.:

Lintng Rainforcement Material: Tyom: Soaclnq. In.:

7 ~ x t e n t o f ~ i n i n g : /200 OC C ? A d ~ & t 8 DAMPERS:

9 ~ o c a t l o n : stack. s t a c k - ~ t u e o r Bo t tom A i r ~ ~ a n u m : 1

16 ( ~ . t t l n 9 Material: /200Oc C &ST&&&& Thlckn*u. In.:

17 1 Ancnorin9 Materia(: g& _< c TY lw: Soaclnq. l n.: I

10

11

12

13

14

15

I -- r - - -

18 I Sirm o t A c w u D o o r I n Brouklnq. In.: isolation Bl ind 7 I

Matarlal: MUI~IOI~ o r Single s eat: S , m e &4x Oascrlotlon o f Provlrlons for Ooeratlon f rom Grade:

Are Oraught G l u w m d Oamper Positlon I n d l u t o r Readable from D a m w r Control Location:

~ O T DUCT. BREECHING. FLUES AND COLLECTORS: o n PA

Casina Material: Thickness. In.: Size. Ft.:

1 23 1 Heater Overall Dimensions: 1

- - I

Platforms, Location: . . M 131 0 d k7 0r -L - .

25 1

19 C O L D A I R DUCT: h/OVl P A

--

26

27

28

29

1 34 I Oraught: Header B o x Dram: I

20 Caslng Matmrial: Thickness. In.: Slre. ~ t . : I

--- - Platforms. Width:

Ptatforms. Type o f Floorlnq:

Stairs. Location:

b d d e r s . Location:

30

3 1

32

33

1 35 1 Temwrature: Coi l Drain: I

21

Access Doors. Locat ion and Sire:

Observation Doors. Locat lon and Sire: F & ~ ~ Y + - ~ @ . ~ k n.f Heater Exo~os lon Ooors. Locat ion and Sire:

Miscellaneous Connections (Number and Slre): V Smothering Steam:

1 3 6 1 Tube Sk in Terno.: Stack Drain: I

Lin ing Material: - Thickness. In.: Reinforcement T yoe:

- -

Flue Gas Samole:

2 2 1 MISCELLANEOUS:

I . +

38

39

40

4 1

42

4 3

Painting Raquirements: P&& SP&i*'- 2 831 -Re/ Are Paintar's Trollmy and Rail Included? Extent o f Tube Handling Fac~litlss:

Soeclal Equlomont: S o o t b l o w ~ n : &&@o,&&& A l r Prehoater: N o r RL Q J / ~ F.D. Fan(s):

N o i w Supprmssorl:

44 Other:

A 5 Dsaree o f Shoo Fabrlcatlon:

W cr I I m-

BADGER DESIGN &

Phone (211) 889-7100

AMERICAN HYDROTHERM CORPORATION 470 Park Avenue South

New Yo&, New Y d 10016

HANDBOOK OF INSTRUCTIONS FOR:

BADGER DESIGN b CONST- ~UlC- -- FOR

KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND

SAPIEM SPA

Th i s book i s the properhf of Americon Hydrotherm Corporation and i s to be ra turned upon request. It contains confideniial informotion which must not b e dis- c losed to anyone without pr ior written consent. It i s loaned w i t h t h e express

agreement that the book and information therein will not, d i rect ly or ind i rect ly be reproduced, copied or o t h e m i r e disposed of, or be used in whole or part to ass is t i n making or to furnish any information for the making of drawings, p r in ts or other reproductions therein, or t o be used for the molting of systems or par ts thereof, for any other purpose, without prior written consent. The occcptance of t h i s book

constitutes accept once o f the foregoing agreement.

Date: SEPI"I' 1993

Account # AM-2579

P. 0. A' BH 2831-H01-10

American Hydrotherm Corporation 470 Park Avenue South New York, NY 10016

Job No. AM-2579

HYDROTHERM HEATING MEDIUM HEATERS

for

KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND

SAPIEM SPA

BADGER PROJECT BH-2831

DESCRIPTION

The heating medium heaters furnished to The Petroleum Authority of Thailand, Sapiem SPA, Khanom Onshore Facilities, supply heat up to 490°F temperature to users furnished by others. The heaters are designed to use Exxon Caloria HT43 or equal heating mediums at temperatures up to 550°F at the heater outlet.

Please refer to the following American Hydrotherm Corp. drawings when reading this description:

Burner Schematic Heater HSlOlA Burner Schematic Heater HSlOlB Burner Equipment List Heater HSlOlA Burner Equipment List Heater HSlOlB Heater Assembly HSlOlA & HSlOlB Electrical Bill of Material Heater HSlOlA Electrical Bill of Material Heater HSlOlB Electrical Schematic - Heaters HSlOlA & HSlOlB Electrical Control Panel Arrangement, HSlOlA & HSlOlB

WARNING

BURNER SHOULD NOT FIRE UNLESS THE LOW LEVEL IN THE EXPANSION TANK IS SATISFIED AND ADEQUATE THERMAL FLUID FLOW THROUGH THE HEATER COILS ESTABLISHED: MINIMUM FLOW OF 200 GPM THROUGH 3-1/28' COIL AND 150 GPM THROUGH 3" COIL IS REQUIRED AT ALL TIMES WHILE THE HEATER IS OPERATIONAL. HEATER SUPPLIED INTERLOCKS SHOULD BE SET SO AS TO ACHIEVE THESE OBJECTIVES.

AMERICAN HYDROTHERM CORPORATION

Job No. AM-2579

EOUIPMENT DESCRIPTION

1. Heating Medium Heaters: HSlOlA, HSlOlB 2. Stack for Heaters : HSlOlA, HSlOlB

1. Heatins Medium Heaters: HSlOlA, HSlOlB

The Heating Medium Heater is a fully packaged unit manufactured as horizontal version; it is shop assembled, packaged and built on a structural steel base. The shell is internally insulated. It houses two horizontal coils which serve as the combustion chamber. (Each coil is a single tube wound.) The inlet in front of the heater and outlet in rear have 6" manifolds with 6" - 300# flanges. The packaged burner with an integral blower is mounted on the front plate. The Heated Gas (Stream #5) train with all control and safety components is mounted on right side of the heater; the Condensate (Stream #8) and stabilizer Overhead (Stream #12) trains are mounted on heater front base; the Atomizing Air Compressor is mounted on left side of heater base.

Burner Manasement System

The Hydrotherm heater is provided with a burner management system equipped with fluid temperature control, automatic combustion programming and safety controls which eliminate the need for an operator. These controls ignite the pilot, supervise the pilot flame, start the main flame, control the rate of firing, shut off the burner when the lowest firing rate is more than is required by the heat consumers, restart when heat is again required, and stop the burner or prevent start-up in the event any unsafe condition is sensed by the safety controls.

The Heating Medium Heater is provided with a dual fuel burner to burn either one of two fuels at a time: Heated Gas" (Stream #5) or vlCondensaten (Stream # 8 ) . "Stabilizer Overheadg1 combustible vapor (Stream #12) is introduced directly into burner to be burned only when either fuel firing is taking place.

In order to prevent flashing of "Conden~ate~~ (Stream #8), a high pressure burner nozzle is provided. Due to low fuel viscosity of Stream #8, fuel pump has to maintain a required pressure at nozzle.

The fully modulating burner is controlled by the Temperature Indicating Controller TIC-015A/TIC-015B.


Job NO. AM-2579

111. SYSTEM - SUGGESTIONS 1. Heatins Medium Svstem

Basic heating medium system consists of Heater Pumps, Expansion Tank, Users, By-Pass and Piping. 9

Expansion Tank absorbs thermal volume fluctuations between cold and operating conditions.

Ventinq of the system is very important. It is suggested to provide a device or arrangement that will continually vent the system (say into expansion tank) without inducing fluid flow.

2. BY-Pass Control

In case fluid flow to the users is controlled with either manual or an automatic device, the following should be considered:

To protect the fluid and installation, automatic or manual by-pass control has to be installed at the end of main headers (supply and return), in order to provide sufficient and constant circulation of thermal fluid through the heater and main headers. Heater is designed for nominal flow of 450 GPM. However, the minimum total flow of 350 GPM through both coils must be maintained at all times.

3. Heatina Medium System Testins. Ventins. Steamins Out

The system and the piping should be tested with 100 psi dry air or nitrogen (if at all possible avoid testing with water). If the system is tested with water, water should be removed from heater and piping by draining and blowing hot air through piping.

Once the system is tested, cleaned of water and condensate, it can be filled with heating medium. We are recommending that heater be filled with liquid from one end only to avoid air entrapment in the coil. Provide fill connection at the pump suction side (between pump and suction shut off valve). By closing suction side valve and main by-pass valve the system could be filled through the heater and users until liquid appears in the expansion tank (via expansion line) .


Job No. AM-2579

3. Heatins Medium Svstem Testins, Ventinu, Steaminu Out (continued)

First the system has to be circulated cold for a couple of hours without firing, to remove air from the system. It is very important that heater outlet (each coil) is connected with expansion tank with an auxiliary line for the purpose of venting and steaming out.

American Hydrotherm Heaters HSlOlA and HSlOlB have 2" couplings on heater outlet on each coil which has to be piped to Expansion Tank. These 2 " lines have to be provided with 2" isolating valves. 2" valves are kept open only during start-up and heat-up. Once the system is free of air, water and low boilers from thermal liquid and brought at the operating temperature and maintained for a certain period of time, these valves should be closed.

NOTE THAT: Heater has cylindrical coils that could not be effectively drained by gravity!!


1. Turn circuit breaker CB-1A I8ONN located inside the electrical control panel and close the door.

2. Turn SS-1 selector switch ltONru, control power white light L-7 will come "ONn.

3. Start heater circulating pump; green lights L-2, L-3 or L-4 will come "ONn. Minimum one pump for one heater is required. (Start/Stop pushbutton not in panel - by customer).

4. Turn SS-5 selector switch IfHEATER ENABLED" 8tONw in order to open main header hot oil supply valve. This will allow the thermal liquid to start circulatingthrough the heater. Green light L-5 will come on "VALVE OPENI8.

4A. Fuel Selecting:

Fuel selector switch has three positions: Position 1. Fuel : Heated Gas (Stream #5) Position 2. Fuel : Auto Position 3. Fuel : Condensate (Stream #8)

Fuel selector switch in Position 1 will burn Heated Gas (Stream #5) only; fuel selector switch in Position 3 will burn Condensate (Stream #8) only. Fuel selector switch in Position 2 will burn Condensate (Stream #8) if it is available and automatically switch to Heated Gas when Condensate is not available (Stream #5), going through the normal procedure shutting down, post purge, prepurge and starting new burning cycle with Heated Gas. When Condensate (Stream #8) is again available the burner management system will automatically shut down the burner and again go through the complete burning cycle switching to Condensate (Stream #8) fuel burning.

AMERICAN EYDROTHERM CORPORATION

Job No. AM-2579

5. If all limits in operational limit circuit are satisfied and when SS-2 selector switch is in start position, control relay CR2 is energized and its contact closes Fireye terminals L1 and 3, signaling the burner starting firing cycle. (Temperature is below set point). Blower starts to run, closing non-recycling running interlocks which will energize relay CR3 (its contact closes terminals 3-P on I1BC" 1

6. Modutrol motor starts to drive toward high purge position, opens air damper fully for purging. (10-13 terminal made on IIBCII 1

7. When modutrol motor reaches open damper position (fully open) it will close HFS (Hi-Fire Switch) and HFS will close terminals D-8 on "BCI1.

8. After 30 seconds modutrol motor starts to return back towards low fire start position, closing air damper. At low fire start position it closes low fire switch LFS and this closes terminals M-D on l1BCV.

9. After LFS is closed, programmer energizes terminals 6 and X on vlBCw. Terminal X energizes ignition transformer for spark, and 6 energizes pilot gas solenoid valves ESV-005 and ESV-006.

10. Pilot gas is ignited and flame detected by flame scanner.

If during 5 seconds pilot proving, pilot flame does not light, the programmer will de-energize terminals and lock out; the burner shuts down; the programmer switches to post purge of 20 seconds in case of flame failure or ignition failure. Red alarm light L-16 I1Flame Failurev1 and alarm horn will come I1ONn. The operator must silence alarm horn and reset the programmer by pressing pushbutton PB-1 "Reset Flame FailureI1, located on face of control panel. The programmer starts a new cycle.


Job NO. AM-2579

12. Upon detection of pilot flame by scanner, Fireye programmer proceeds to energize terminal 7. SLC input #I11 through SLC logic will energize solenoid valve/valves on fuel oil train which is burning. Depending on which fuel is burning, corresponding pilot light will be lit: L-9 for heated gas, L-10 for condensate.

13. Atomizing air compressor is providing atomizing air for Condensate (Stream #8) burning. When Condensate (Stream #8) fuel is selected for burning at the same time with blower, compressor will start. When selector switch is in Auto position (burning Condensate) compressor will be automatically running when blower is running.

14. Stabilizer Overhead is introduced into burner to be burned two minutes after flame is established, if Stabilizer Overhead low and higher pressure is satisfied. Selector switch SS-3 is provided to turn solenoid valve on or off and pilot light L-11 will indicate if solenoid valve is open or closed.


Job NO. AM-2579

SET POINT SCHEDULE

NOTE : Initial settings listed herein are preliminary and are intended for use by authorized personnel as a reference for start-up. Only final field settings should be used after commissioning for maintenance and operating purposes.

INITIAL FINAL TAG FUNCTION RANGE SETTING SETTING

PCV-025-A Pilot Gas Regulator 411-1211 W. C. 4" W.C. -025-B

PCV-028-A Pilot Gas Regulator -028-B

PSL-003-A Low Combustion Air -003-B Cutout

PRV-001-A Pressure Control Valve -001-B

1811-42" W.C. 30" W.C.

1-16 oz 4.5" W.C.

40 psig

PSL-007-A Low Atomizing Air Cutout 0-60 psig 50 psig -007-B

PSV-018-A Compressor Safety Relief -018-B Valve

PCV-033-A High Gas Pressure -033-B Regulator

PCV-026-A Low Gas Pressure -026-B Regulator

PSH-003-A High Gas Pressure Cutoff -003-B

PSL-004-A Low Gas Pressure Cutoff -004-B

100 psig

15 psig

1 psig

2.5 psig

20" N.C.

PCV-027-A Pressure Reducing 0 - 10 kg/ cm2g 1 psig -027-B Gas Regulator

PSL-002-A Low Oil Pressure Cutoff 0-100 psig 50 psig -002-B


INITIAL FINAL RANGE SETTING SETTING

60 psig

TAG FUNCTION

Fuel Oil Pressure Reducing Valve

Differential Pressure Gage 0-10 psid

Sensitrol Oil Valve

Main Gas Pressure Regulator 1 psig

0-15 psig 2 psig High Gas Pressure Cutout

Low Gas Pressure Cutoff 0-301' W.C. 1511 W.C.

Temperature Controller

High Temperature Cutoff

High Temperature Cutoff

2 psig Low Flow Cutoff

Low Flow Cutoff 2 psig

Differential Pressure Gage 0-10 dpsi

Differential Pressure Gage 0-50 dpsi

150 psig 150 psig Safety Relief Valve

150 psig 150 psig Safety Relief Valve PSV- 15-A 15-B

INPORTANT NOTICE T O OUR CLIENTS

Due t o t h e growth i n claimed product l i a b i l i t y and p ro fess iona l l i a b i l i t y cases , it is imperat ive t h a t t h e following requirements a r e s t r i c t l y observed.

LEGAL LIMITATIONS

American Hydrotherm w i l l no t accept l i a b i l i t y f o r any i n s t a l l a t i o n o r equipment

1) which has been modified i n any form

2 ) i s operated under condi t ions o t h e r than s p e c i f i e d (p ressu re , temperature, flow r a t e , e t c ) .

3 ) which was designed o r suppl ied by o the r s and i s used i n conjunct ion with our system.

American Hydrotherm w i l l no t accept l i a b i l i t y f o r piping i n s t a l l - a t i o n s or p a r t s of them, not designed i n every d e t a i l by American Hydrotherm. A flow diagram supplied by A.H.C. i s not a piping des ign o r layout .

TECHNICAL REQUIREMENTS :

ELECTRICAL DESIGN

S t a r t but tons f o r machinery suppl ied by o thers . Press c los ing o r i n j e c t i o n molding s t a r t but tons should be located wi th in s i g h t of t h e p ress o r t h e i n j e c t i o n molding machine s o t h a t one opera tor cannot c l o s e the equipment while another opera to r has h i s hand i n t h e equipment.

Panels

A l l e l e c t r i c panels s h a l l have door switches t h a t w i l l s h u t o f f t h e power i f t h e door i s opened. The l eads on t h e l i n e s i d e of t h e door switch s h a l l be sh ie lded and inaccess ib le s o t h a t they cannot be touched when t h e door i s opened. A l a r g e warning p l a t e s h a l l be on t h e door near t h e door switch t h a t says "CAUTION - WHEN PANEL I S OPEN CONTROL INTERLOCKS FROM EXTERNAL CIRCUITS MAY BE ALIVE".

Equipment S tar t -S top Buttons

I t i s p r e f e r r e d t o have s t a r t - s t o p but tons wi th in s i g h t of t h e equipment. I t i s imperative t h a t s t o p bu t tons and lock-out switches a r e near t h e equipment,

Grounding

A l l e l e c t r i c a l equipment, panels , motors, e t c . must be grounded. Where water l i n e s a r e used f o r grounding, check t o see t h a t t h e supply system does no t conta in p l a s t i c pipe ! !

MECHANICAL DESIGN

Pipinq Specs

Piping f o r h igh pressure water (50 ps ig o r h i g h e r ) , steam, ho t o i l and s a l t s h a l l be s t e e l and have s t e e l f i t t i n g s , f l e x i t a l l i c gaske t s , high temperature b o l t i n g , p re fe rab ly 300RF f l a n g e s , and be welded i f poss ib le . Flanqes must never be t iqhtened when a system i s under pressure and a t high temperature. This can only be done when pump is off and system i s depressured.

Rotatinq Equipment

Rotat ing p a r t s , such a s couplings and s h a f t s , should have coupling guards t o prevent touching moving p a r t s .

Heat Exchanqers and Vessels

They should a l l be ASME 8 stamped, inspected and hydro- t e s t e d a t l e a s t 1+ times t h e design pressure . Design pressure should be 20% more than t h e maximum pressure t h e equipment w i l l s ee during any abnormal condi t ion , such a s pump shut -of f . Rel ief valves must be provided on t h e water s i d e of h o t o i l coolers and on a l l equipment t h a t could be overpressured during an upset condi t ion.

System Tes t inq

A i r o r h y d r o t e s t p ressu re f o r t h e system is s p e c i f i e d on t h e f lowsheets and/or piping drawings.

Combustion Eauipment

Diaphragm ven t s on gas r egu la to r s and gas a i r r egu la to r s and t h e gas ven t solenoid must be piped away t o a s a f e loca t ion (up, ou t s ide , and a t l e a s t 1 0 f e e t away from a working a r e a ) , There should be a t ag on t h e vent o u t l e t pipe a t t h e o u t l e t t h a t says "DANGER, NO SMOKING, MATCHES OR OPEN FLAME". (Tag a v a i l a b l e from American Hydrotherm Corporation) ,

Piping Desiqn

High temperature p ip ing runs should be checked f o r s t r e s s , expansion and l o c a t i o n of guides, anchors, and supports . Piping, va lves and valve handles should be loca ted so t h e r e a r e no "head knockers" o r low l i n e s t h a t can be t r ipped over. There should be 3 f e e t c l e a r around any r o t a t i n g equipment. S t r u c t u r a l i n t e g r i t y of t h e wa l l o r bui ld ing s t e e l which w i l l t a k e t h e fo rce of t h e p ip ing anchor should be checked.

TYPICAL CONSTRUCTION REQUIREMENTS:

Sa fe ty cage on a ladder t h a t goes above 7 f e e t ; guard r a i l on platforms; avoid piping o r valve handles t h a t can be bumped by opera tors ; header shut-off valves should be a c c e s s i b l e o r be provided with chain wheels t o grade; room or a r e a t h a t has a f i r e d h e a t e r should have two e x i t doors; instruments o r valves t h a t have t o be adjus ted during normal operat ion should be access ib le o r be provided with platforms; f u e l o i l tanks should n o t be indoors unless it meets t h e requirements of NFP, A l l ho t piping and equipment t h a t w i l l have a su r face temperature of 180°F o r h igher , i n l o c a t i o n s t h a t can be touched, should be provided with personnel p ro tec t ion i n s u l a t i o n o r wire p r o t e c t i v e mesh, e t c .

I N D E X

DESCRIPTION INDEX NO.

B-A, B-B AB-A, AB-B BAS-A, BAS-B FCV-001-A, FCV-001-B ESV-001-A, ESV-002-A ESV-001-B, ESV-002-B HIS-A, HIS-B PCV-024-A, PCV-024-B FCV-002B

DUAL FUEL BURNER AIR BLOWER BURNER AIR SHUTTER BUTTERFLY GAS VALVE OIL SHUTOFF SOLENOIDS

11 11 11

HINGE INTERLOCK SWITCH 1 FUEL OIL PRESS. RED. VALVE 1 SENSITROL OIL VALVE 1

NP-A, NP-B GAS PILOT ASSEMBLY

PILOT GAS SOLENOIDS 11 I1 I I

PILOT GAS REGULATOR 11 11 I I

PRESSURE GAGE 5

M-A, M-B LFS-A, LFS-B HFS-A, HFS-B

MODUTROL MOTOR LOW FIRE SWITCH AIR PURGE SWITCH

LOW COMBUSTION AIR CUTOFF 7

AAC-A, AAC-B PSV-018-A, PSV-018-B CFH-A, CFH-B

ATOMIZING AIR COMPRESSOR SET 8 COMPRESSOR SAFETY REL. VALVE 8 COMPRESSOR FLEXIBLE HOSE 8

PRESSURE CONTROL VALVE 9

HIGH PRESSURE CUTOFF 10 LOW GAS PRESSURE CUTOFF 10 LOW OIL PRESSURE CUTOFF 10 HIGH GAS PRESSURE CUTOFF 10 LOW GAS PRESSURE CUTOFF 10 LOW ATOMIZING AIR CUTOFF 10

HIGH PRESSURE REGULATOR 11

LOW GAS PRESSURE REGULATOR 12

MAIN GAS SOLENOID

PRESS. REDUCING GAS REGULATOR 14

DIFF. PRESSURE GAGE 15

I N D E X

TAG - DESCRIPTION INDEX NO.

MAIN GAS PRESS. REGULATOR 16

MAIN GAS SOLENOID 17

TEMPERATURE CONTROLLER 18

HIGH TEMPERATURE CUTOFF 11 II 11

LOW FLOW CUTOFF 11 11 11

DIFFERENTIAL PRESSURE GAGES 21 I 1 I t 11 21 11 I 1 11 21 I 1 11 11 21

FLAME PROGRAM CONTROL SCANNERS

BC-A, BC-B SC-A, SC-B

IT-A, IT-B PILOT IGNITION TRANS. 23

DIG. DISPLAY HEATER STACK TEMP. 24 DIG. DISPLAY FOR HEATER INLET 24 TEMPERATURE

PRESSURE INDICATOR 25

THERMOMETER 11

FLANGED THERMOWELLS 11 II

SAFETY RELIEF VALVE I 1 11 I t

INDEX NO. 1

DUAL FUEL BURNER

B - A , B - B

A I R BLOWER

A B - A , A B - B

BURNER A I R SHUTTER

BAS-A , B A S - B

BUTTERFLY GAS VALVE

O I L SHUTOFF SOLENOIDS

E S V - 0 0 1 - A , E S V - 0 0 2 - A E S V - 0 0 1 - B , E S V - 0 0 2 - B

HINGE INTERLOCK SWITCH

H I S - A , H I S - B

FUEL O I L PRESSURE REDUCING VALVE

SENSITROL O I L VALVE

FCV - 002B

American Hydro therm FY-6033

North American SERVICE MANUAL

Cleveland, OH 44105 USA

APPLICATION American Hydro the rm H e a t e r

BURNER 6131-FA2/P-1

AVERAGE ACTUAL

Pi lot - Regulator lnlet Regulator Outlet

Main Gas - Regulator Inlet Regulator Outlet

Burner Manifold Pressure - High Fire

Light Oil - Pump 1 Regulator Outlet Pressure

Sensitrol Valve Setting - Low Sensitrol Valve Setting - High

Oil Pressure at Nozzle - Low Oil Pressure at Nozzle - High

Atomizing Air Pressure - Low Atomizing Air Pressure - High

Heavy Oil - Grade System Oil Pressure psi Oil Temperature Pump Inlet F Regulator Outlet Pressure psi Oil Heater Outlet Temp. F

Sensitrol Valve Setting - Low Sensitrol Valve Setting - High

Oil Pressure at Nozzle - Low Oil Pressure at Nozzle- High

Atomizing Air Pressure - Low Atomizing Air Pressure - High

Electrical Drawing ZC30-50710 Linkage Drawing 6131-8 System Oil Piping Gas Piping Drawing

14 o s i rnax a d i u s t per Sh. 6131-5

34 p s i 40 p s i

35 p s i 40 p s i

DOES

NOT

APPLY

bustion equipment. Nonh Amadcan urga compliince

Note: The above settings are average and are to be used as a guide only. More precise or actual settings will be made to obtain best results based on CO, check at the time of burner adjustment, and should be entered in spaces provided.

PRINTED IN USA

Features of NORTH AMERICAN Packaged Automatic Burners

' Nortb American ' 4131, 5131, 6131 \ 7

BUILT-IN BLOWER: Delivers 10096 of combustion air required for burner operation. Eliminates need to install an expensive and bulky air delivery system.

Mfg. Co.

CONTROL VARIETY: Building from the basic burner package, control systems are available along with many pre-packaged gas and oil trains, motorized controls, flame safeguard accessories, and programming systems.

Engineering SPECIFICATIONS 6131

WIDE RANGE OF CAPACITIES: 2 500 000 to 30 000 000 Btufhr, in six frame sizes. Typical air turndown is 4:l on standard models. Greater turndowns are available for special applications.

\ Cleveland. OH 44105 USA PACKAGED AUTOMATIC BURNERS 7-89

L 1 J

RUGGED, VERSATILE, A N D RELIABLE: An ultra stable burner designed to operate in chambers at temperatures up to 2000 F and under negative or slightly positive pressures. Cold, tight chambers present no problem for this rugged, low-maintenance workhorse. Proven reliability while operating with natural gas, #2 fuel oil, and #6 fuel oil. Crude oil, and pitch have also been successful, however, these are often application dependent. Consult North American Mfg., Cleveland, for applications with these fuels.

NORTH AMERICAN Mfg. Co. Cleveland, OH 44105 USA

Engineering Specifications 61 3 1 , 7-89 Page 2

The Packaged Automatic Burners are ideal for steel firebox, scotch marine, cast iron sectional, and watertube boilers, and industrial process heating equipment, such as air heaters. dryers, oil heaters, ovens, and incinerators. Six frame sizes produce a wide range or capacit~es (2 500 000 to 30 000 000 Btu/ hr).

Design: The 4131 Burner is for any fuel gas; the 5131 for fuel oils, and the 6131 for dual-fuel (combination gas and oil). All are of the nozzle mix design with an integral blower to supply 10096 combustion air. Oil atomizers are of the tip emulsion design, using steam or compressed air as the atomizing medium. The hinged construction provides quick and complete accessibilitv. Fixed fuel lines need not be broken for service because fuel oil enters through the burner hinge and gas enters through a stationary gas section.

Construction: This rugged burner consists of a cast iron mounting plate, with slotted mounting holes, fitted with a high strength cast refractory burner tile rated for service up to 2600 F. A stainless steel tile support jacket is available as an option. The grade of stainless steel is application dependent. The circular gas plenum has a bottom gas inlet, a combustion air diffuser, and a spark-ignited premix gas pilot (for natural gas or propane).

The hinge-mounted blower section includes the blower motor, impeller, intake guard (or optional intake silencer), a large reinforced glass observation port, provisions for mounting a flame detector, and flange mounted oil atomizer. An accurate linked valve ratio control is provided by a compact arrangement of aircraft-quality linkage rods and swivels that connect the internal main air proportioning shutters with a butterfly gas valve and/or a Sensitrol oil valve and the modulation motor.

Hinged construction provides for complete accessibility to burner internals.

Standard Components: The 4/5/6131 Burner includes the pilot gas regulator, pilot gas solenoid (2nd solenoid optional), 6000 volt ignition transformer, electric modulating control motor (air motor optional), low combustion air interlock, and burner hinge interlock switch. Oil burners also include a solenoid valve (or optional motorized automatic valve), piped between the hinge and atomizer assembly. All electrical components are wired to the burner mounted NENlA 4 junction box.

Turndown: Typical air turndown is 4:l on standard models. Greater turndown can be achieved with an optional blower air inlet controller. Consult North American, Cleveland, for details.

Excess Air: Standard burner linkage is factory set to deliver 20% excess air. Rates greater than 20% are possible through reduction of fuel input.

Flame Characteristics: These burners generate a high degree of turbulance resulting in short, bushy flames. See Supple- ment 6131-1 for flame sizes at various excess air rates for a particular fuel.

Chamber Pressures: Designed for stable operation in chambers with pressures ranging from - 0 . 5 " ~ ~ to 2 . 0 " ~ ~ . The "Nu burner is specified on applications with 0 to - 0 . 5 " ~ ~ chambers (i.e., 2-pass boilers, dryers, heaters, etc.) and the "P" burner is specified on those with 0.1 to 2 . 0 " ~ ~ chambers (i.e., 3-pass boilers, etc.). Consult North American, Cleveland, for burner performance with other pressures.

Underwriters Laboratories Listing: The Model 4/5/6131 Burners have been designed in accordance with the requirements of the Underwriters Laboratories. Consult North American Mfg., Cleveland, for labeling service.

WARNING: Situations dangerous to personnel and properry can develop from incorrect operation of combustion equipment. Nonh American urges compliance wtth Nat~onal Safew Standards and Insurance Underwriters recommendations. and care in operation.

PRINTED IN USA

Instruction Manual

Mfg. Co. Gas, Light Oil & Dual-Fuel Burners I ! 127 Service Manual Cleveland. OH 44105 USA i Norm Full Modulating Operation

Contents

SECTION TITLE

Data Data Sheet

I, Pg. 1, 2 General Description

IT, Pg. 1, 2 Pg. 3, 4

111, Pg. 1, 2 Pg. 3, 4 Pg. 5, 6 , 6 7

IV, Pg. 1, 2 Pg. 3, 4 Pg. 6 Pg. 7, 8 Pg. 9

Initial Starting Procedure - Gas Initial Starting Procedure - Oil

Operating Instructions - Gas Operating Instructions - Oil Operating Instructions - Combination Gas, Light

Oil & Dual-Fuel Burner

Trouble Shooting Trouble Shooting Trouble Shooting - Gas Trouble Shooting - Oil Trouble Shooting

V ....................... No Section V V I Wiring Diagrams

VII, Pg. 1, 2 Pg. 3, 4 Pg. 5 Pg. 6

Pg. 7

Pg. 8 Pg. 9

Spare Parts & Burner Technical Data Gas Pressures for Gas 6 Combination Burners Atomizing Air Compressors for Burners - Oil Atomizing Air 6 Oil Pressures for Oil & Combination Burners Blower Wheels & Motors for Natural Gas 6 Oil Burners Pumps and Pump Motors for Oil Burners Orifice Plate Data

VIII ~anufac turer ' s Data

PRINTED IN USA

NORTH AMERICAN Mfg. Co. Cleveland, OH 44 105 USA

Table 3. Natura l Gas pressures@

Regulator M a n i f o l d Burner pressure pressure Frame "w c

Engineering Supplement 6 13 1-1. 7-89 Page 2

Burner Frame

Table 4. L i g h t Oi l Pressures a n d A t o m i z i n g M e d i u m Requi rements

A t o m i z i n g ~ e d i u m s @

Comp. air f l o w S team f l o w Pressure s c f m Ib /h r ps ig

Oi l pressures@

ps ig

120 90 85 50 55 75

Table 5. Heavy Oi l Pressures and A t o m i z i n g M e d i u m Requi rements

Oi l pressures@

ps ig

70 65 70 60 70 90

Burner Frame

A B C D E FA

as burners are intended for use with natural gas or propane. Listed pressures are for natural gas - consult North American for propane pressures. Pressures liaed are maximum values and are for system sizing only. They are not for ratio adjustment.

A t o m i z i n g ~ e d i u m s @ Comp. air f l o w S team f l o w Pressure

scf m I b / h r ~ s i g

4 30 50 4 50 50 8 70 25

18 130 45 28 168 30 28 200 30

@oil and dual-fuel burners require an accessory package for the atomizing medium. Pressures required at the inlet of that package are 75- 100 psi for air and 50- 125 psi for steam.

@oil and dual-fuel burners require oil delivered to burner hinge at a viscosity below 100 SSU and at pressures listed above. If a liquid fuel other than commercial fuel oil is to be used, consult North American for recommendations of pressure and flow requirements.

WARNING: Siruatlons dangerous to personnel and propeny can develop from incorrect operation of combustion equipment. Nonh American urges com~liance with National Safetv Standards and Insurance Underwriters recommendations, and care in operatton.

PRINTED IN USA

Table 1 4/5/6131 Burner, Blower, and Motor Capacities

North American ' -l \

Mfg. Co.

O ~ o m i n a l capacity for a "C" frame burner when using heavy oil is 8 400 000 Btulhr. @wi th sound level instrument located at the same elevation as the burner center line and 5' away at 45' to the blower inlet-motor center line.

Burner Frame Designation

Table 2. Flame characteristics@

\ Cleveland. OH 44105 USA 7-89

J

4/5/6131 BURNER Capacities, Flame Characteristics, Pressures

Burner % Excess Flame size, dia. (ft.) x length (ft.) Frame ( Air / GAS I LIGHT OIL I HEAVY OIL

Engineering SUPPLEMENT 6131-1

Nominal Developed capacity Blower volume pressure Motor Btulhr cf h "w c hp - rpm

lame characteristics based on firing in a chamber with free air available at atmosphere pressure and without a pilot. With flame supervisory equipment, signal strengths were acceptable over the stability ranges of the burners.

l he burner using this fuel at this excess air rate is not recommended.

Sound level, ~ B A @ w / o silencer with silencer

4/516131-A, B, and C FRAME SIZE BURNERS

North American 3 Engineering \

DIMENSIONS inches

Mfg. Co. 4/5/6131 BURNERS

CAPACITIES million Btu/hr

DIMENSIONS 6131

Frame / gas and light oil I heavy oil

L Cleveland, OH 44105 USA \ 12-90 J

junction box

I Pilot Regulator --/ / 1, 3 , Lifting eye - ,~ Pilot Solenoid valve /

Control motor

''61 \

Air motora w~th high and low switches

131 Series I Burner Frame Size 4131-, 5131-, 6131- A@ B C D E,@ E,@@ F,@ F,@ G H J K@ L M N P Q

@ANSI 125 Ib flanged connection. Not used on 5121 or 5131 Burners. @ Honeywell M941 or M944 motors shown. For other motor types, check with North American. @ Furnace opening for 131-A, B, and equivalent size 121 burners is 16%" dia. (17 % " dia. with jacketed tile).

Furnace opening for 131-C and equivalent size 121 burners is 20"dia. (21" dia. with jacketed tile). @ With stainless steel tile jacket only. @ If one pilot solenoid valve is used, dimension R, applies. Use dimension R, for burners with two pilot solenoid valves. @ Optional, furnished only when ordered. @ If Moore Positioner is used, dimension FF, applies. Use dimension FF, if the Moore Positioner is not supplied. @ If air motor is used, add 50 Ib to these figures. @If burner is gas and/or light oil, dimension F, applies. Use dimension F, if burner is heavy oil.

131 Series Burner Frame Size 4131-, 5131-, 6131 R,@ R,@ S T U W X Y Z AA BB CC DD@ EE FF,@ FF,@

NORTH AMERICAN Mfg. Co Cleveland, O H 44105 USA

Engineering Dimensions 61 3 1, 12-90 Page 2

41516131-D, E, and FA FRAME SIZE BURNERS

DIMENSIONS inches

CAPACITIES mill ion B tu lh r

Pilot Solenotd Valve

!h fpt P~lot gas

Control motor

heavy oil

12.6 to 16.8 21.0 to 25.2

Frame / gas and light oil

Est. Shipping weights@

FA 29.4 to 30.0 29.4 to 30.0

D E

8 slots for U-

12.6 to 18.0 21.0 to 25.2

Blower housrng floor

I clearance

Air motor@ with high and low sw~tches

131 Series Burner Frame Size 4131-, 5131-. 6131-

O A N S I 125 Ib flanged connection. Not used on 5131 Burners. @ Honeywell M941 or M944 motors shown. For other motor types, check with North American. @ Furnace opening for 131-D, E, and FA Burners is 23 K " dia. (24 !h " dia. with jacketed tile). @With stainless steel tile jacket only. @ If one pilot solenoid valve is used, dimension R, applies. Use dimension R, for burners with two pilot solenoid valves. @ Optional, furnished only when ordered. a If Moore Positioner is used, dimension GG, applies. Use dimension GG, if the Moore Positioner is not supplied. @ If air motor is used, add 50 Ib to these figures.

AO B C D E,@ E,@@ F G H J K@ L M N P Q

131 Series Burner Frame Size 4131-, 5131-, 6131

D E FA

DIMENSIONS SHOWN ARE SUBJECT TO CHANGE. PLEASE OBTAIN CERTIFIED PRINTS FROM NORTH AMERICAN MFG. CO IF SPACE LIMITATIONS OR OTHER CONSIDERATIONS MAKE EXACT DIMENSION(S) CRITICAL.

R,@ R,@ S T U W X Y Z AA BB CC DD@ EE FF GG,@ GG,@

29% 33% 14 155/16 'Ig 263/g 7 % 13% 10 28% 85/a 12% 10% 5'18 7 38% 33% 31% 35% 16'1, 18% 7/, 30 8V8 15% 12 29% 8 12'1, 10% 6 % 7 % 35 30 31% 35% 16'/, 18% 7/8 30 8V8 15% 12 36 13 15 9% 1l3Il6 7 % 35 30

WARNING: Situat~ons dangerous to personnel and property can develop from incorrect operation of combustion equipment. North Amencan urges compliance with National Safety Standards and Insurance Underwriters recommendations, and care in operation.

PRINTED IN USA N A 1 2 9 0 ED6131 4000

Mfg . Co. Initial Starting Procedure

Natural Gas Burner Full Modulating Control i 121 Service Manual

Section II December, 1975

\ J Page 1 of 4

1. For a s team b o i l e r , check t o make s u r e water i s a t the p roper l e v e l . For a hot water b o i l e r , t h e system s h o u l d be f u l l o f w a t e r ,

2 . S e t t h e o p e r a t i n g l i m i t s t o t h e d e s i r e d s e t t i n g s . blake s u r e t h a t the s a f e t y h i g h l i m i t , if f u r n i s h e d , i s s e t s u f f i c i e n t l y above the s e t t i n g o f t h e o p e r a t - i n g l ixi t , Be s u r e t h a t t h e modula t ing d e v i c e i s p r o p e r l y s e t .

3. Make s u r e t h a t t h e gas company h a s purged a l l a i r from the main gas l i n e . WARNING: Gas l i n e s a r e t e s t e d w i t h a i r p r e s s u r e s a s h igh a s 90 to 100 p s i , b u t t e s t p r e s s u r e s must no t be a p p l i e d t o burner v a l v e s o r r e g u l a t o r s .

Keep t h e main and p i l o t manual g a s v a l v e s i n t h e c l o s e d p o s i t i o n . P l a c e t h e s t o p - s t a r t s w i t c h i n the "Stop" p o s i t i o n .

C l o s e the wall-mounted power s r v i t c h .

Check the blower r o t a t i o n by u s i n g t h e "Manual Purge" swi tch . Ro ta t ion may be changed by t r a n s p o s i n g any two motor l e a d s a t t h e load t e r m i n a l s o f the blower s t a r t e r . Before changing motor l e a d s , open t h e power e n t r a n c e s w i t c h ,

Open t h e manual p i l o t g a s v a l v e o n l y .

Move t h e manual p o t e n t i o m e t e r t o low f i r e . Move t h e burner swi tch t o s t a r t .

The blower motor w i l l s t a r t , and a f t e r a p repurge p e r i o d , t h e gas p i l o t system w i l l be energized.

S e t t h e o u t l e t p r e s s u r e on t h e p i l o t r e g u l a t o r a t + 1 , 5 t o 2" wc,

I f t h e g a s p r e s s u r e ahead o f t h e p i l o t r e g u l a t o r exceeds 14 o s i , a F i s h e r 3" -7347-0 r e g u l a t o r bushed t o 2" shou ld be i n s t a l l e d i n t h e p i l o t gas l i n e . Out- l e t p r e s s u r e on t h i s F i s h e r r e g u l a t o r s h o u l d be s e t between 4 and 6 o s i .

Check t o s e e t h a t t h e f lame d e t e c t o r g i v e s adequa te s i g n a l when t h e p i l o t is on. See s a f e g u a r d b u l l e t i n f o r d e t a i l s .

Turn the burner swi tch t o s t o p , and remove t h e ad jus tment cap from the main gas p r e s s u r e r e g u l a t o r ,

Open the manual main gas v a l v e .

For a combinat ion b u r n e r , make s u r e the f u e l s e l e c t o r s w i t c h i s i n the "Gas" p o s i t i o n . Turn the b u r n e r s w i t c h t o " S t a r t " .

A f t e r the main f lame i s e s t a b l i s h e d , a d j u s t t h e o u t l e t p r e s s u r e from the main g a s r e g u l a t o r t o the c o r r e c t p r e s s u r e a s shown i n S e c t i o n V I I , Page 2 , o f t h i s manual, by t u r n i n g the r e g u l a t o r ad jus tment sc rew down f o r more p r e s s u r e , o r up f o r l e s s p r e s s u r e .

NORTH AMERICAN Mig. Co. Cleveland, OH 44105 USA

Service Manual 121. Section I1 Page 2 of 4

16. Turn t h e manual p o t e n t i o m e t e r on the c a b i n e t t o the h i g h - f i r e p o s i t i o n , When t h e burner r e a c h e s h i g h f i r e , t a k e a C02 read ing . 1 f the COZ i s low o r h i g h , make an ad jus tment i n the main g a s r e g u l a t o r , Run the burner t o low f i r e and t a k e a n o t h e r C02 r e a d i n g . I f t h e i s low o r h i g h , make an ad jus tment i n the g a s l i n k a g e a t the burner . (NOTE : 032 shou ld be S. 5 - 9 . 5 7 ~ on both h igh - and low f i r e ; oxygen should r e a d about -ILT0.)

1 7 . Check t o s e e t h a t the f lame d e t e c t o r g i v e s a d e q u a t e s i g n a l a t bo th h igh and low f i r e w i t h o n l y t h e main f lame. See f lame d e t e c t o r b u l l e t i n f o r d e t a i l s .

18. With t h e burner i n o p e r a t i o n a t t h e low-f i re p o s i t i o n , check to s e e if the o p e r a t i n g and s a f e t y h i g h l i m i t c o n t r o l s ( i f f u r n i s h e d ) a r e wired c o r r e c t l y by manual ly t r i p p i n g each one. The burner shou ld go off and sequence a new s t a r t when t h e c o n t r o l s a r e r e l e a s e d t o t h e i r normal p o s i t i o n .

19. With t h e b u r n e r a t h i g h - f i r e p o s i t i o n , check t h e modula t ing c o n t r o l by manual- l y t u r n i n g the p o t e n t i o m e t e r t o make s u r e the b u r n e r goes t o low f i r e , then back t o h i g h f i r e .

20 . Blow down t h e low-water c u t o f f w i t h t h e burner i n o p e r a t i o n ( low f i r e ) . I f two low-water c u t o f f s a r e u s e d , check each s e p a r a t e l y , t h e n check t o g e t h e r , The b u r n e r must s t o p and then sequence a new s t a r t when t h e water i n t h e b o i l e r i s r e s t o r e d to the c o r r e c t l e v e l . ( I f t h e second low-water cu to f f i s a manual r e - S e t t y p e , i t w i l l be n e c e s s a r y t o r e s e t i t by hand b e f o r e p r o c e e d i n g . )

21. S t a r t and s t o p t h e b u r n e r s e v e r a l t imes t o make s u r e t h e b u r n e r o p e r a t e s c o r - r e c t l y .

2 2 . With t h e b u r n e r i n o p e r a t i o n ( p i l o t o f f ) and on low f i r e , c l o s e t h e manual main gas v a l v e . The f lame shou ld go o u t i n 2 t o 4 seconds . The blower w i l l c o n t i n u e f o r a pos tpurge . A f t e r t h e f lame d i e s , t h e f lame s a f e t y w i l l l o c k o u t t h e b u r n e r and l i g h t t h e warn ing l i g h t . R e s e t t h e f lame s a f e t y swi tch i n t h e combustion s a f e g u a r d and p l a c e the u n i t i n o p e r a t i o n w i t h t h e normal o p e r a t i n g procedure .

Mfg. Co. Cleveland. OH 44105 USA

Initial Starting Procedure Light Oil Burner

121 Service Manual Section I1

December, 1975

Page 3 of 4

1, For a steam b o i l e r , check t o make s u r e wa te r i s a t the p roper l e v e l . For a h o t water b o i l e r , t h e system shou ld be f u l l of w a t e r ,

2 . S e t the o p e r a t i n g l i m i t s t o the d e s i r e d s e t t i n g s . &lake s u r e t h a t the s a f e t y h i g h l i m i t , i f f u r n i s h e d , i s s e t s u f f i c i e n t l y above the s e t t i n g o f t h e o p e r a t - i n g l i m i t . Be s u r e t h a t t h e modula t ing d e v i c e is p r o p e r l y s e t .

3. C lose t h e manual p i l o t g a s v a l v e , a l l manual o i l v a l v e s , and p l a c e the s t o p - s t a r t s w i t c h i n "Stop" p o s i t i o n .

4. C lose the wall-mounted power s w i t c h .

5 . Check t h e blower r o t a t i o n by u s i n g t h e " m n u a l Purge" s w i t c h . R o t a t i o n may be changed by t r a n s p o s i n g any two motor l e a d s a t t h e load t e r m i n a l s o f t h e blower s t a r t e r . Before changing motor l e a d s , open t h e wall-mounted power s w i t c h .

Open t h e manual p i l o t g a s v a l v e .

7 . Move the manual p o t e n t i o m e t e r t o l o w - f i r e p o s i t i o n . Move t h e burner s w i t c h t o " S t a r t " . The blower motor w i l l s t a r t , and a f t e r a prepurge p e r i o d , the g a s p i l o t sys tem w i l l be e n e r g i z e d .

8, If n a t u r a l g a s i s used , t h e o u t l e t p r e s s u r e on t h e p i l o t r e g u l a t o r should be s e t a t +1.5 t o 2" wc. If propane i s u s e d , t h e o u t l e t gas p r e s s u r e on the p i l o t r eg - u l a t o r shou ld be s e t a t *.Sf' t o 1" wc. (N3TE: - If the i n l e t gas p r e s s u r e ex- c e e d s 14 o s i , a F i s h e r $";-t7347~-0 r e g u l a t o r bushed t o iff shou ld be i n s t a l l e d i n t h e p i l o t g a s - l i n e . O u t l e t p r e s s u r e on t h i s F i s h e r r e g u l a t o r should be s e t between 4 and 6 o s i . )

9 . Check t o s e e t h a t t h e f lame d e t e c t o r g i v e s adequa te s i g n a l when t h e p i l o t i s on.

10. Move t h e burner swi tch t o "Stop" and check t o s e e t h a t the o i l s u c t i o n and r e - t u r n l i n e s a r e c o r r e c t l y p i p e d t o t h e o i l pump and t h a t t h e o i l l i n e s a r e t h e c o r r z c t s i z e .

11. If t h e burner i s f a r F?I a p p r o v a l , make s u r e t h a t the f u s i b l e - l i n k g a t e v a l v e i s i n s t a l l e d and open,

12 . Open a l l of t h e manual o i l s h u t o f f v a l v e s i n the s u c t i o n l i n e .

13. The r e t u r n o i l l i n e f rom t h e pump should n o t have a manual s h u t o f f v a l v e . If a manual v a l v e i s p r e s e n t i n t h i s l i n e , open the v a l v e f u l l y and remove i t s h a n d l e .

14. Disconnect t h e copper o i l tube a t t h e i n l e t t o t h e burner and p u t i t i n t o a l a r g e bucket o r c o n t a i n e r ,

15. If t h e burner i s d u a l - f u e l , s e t the f u e l s e l e c t o r swi tch t o o i l , t hen t u r n t h e b u r n e r swi tch t o " S t a r t " .


Servlce Manual 121, Section I1 Page 4 of 4

16. A f t e r t h e p i l o t i s l i t and t h e f lame s a f e t y s a t i s f i e d , t h e o i l pump w i l l s t a r t . Allow i t t o r u n u n t i l a s t e a d y c l e a r f low of o i l comes from t h e tube. (m: Because t h e r e w i l l be no main f lame wi th t h e o i l tube d i s - connected from t h e burner , t h e f lame s a f e t y w i l l cause a lockou t . Push t h e r e s e t bu t ton . The t i m e r u n i t w i l l r e - c y c l e , a f t e r which t h e p i l o t may be r e l i g h t e d t o g i v e a n o t h e r 10 seconds o i l f low b e f o r e l o c k i n g o u t aga in . Repeat t h i s c y c l i n g u n t i l a c l e a r f low i s o b t a i n e d . )

17 . A f t e r a s a t i s f a c t o r y f l o w i s e s t a b l i s h e d , move the burner s w i t c h t o "Stop" and reconnec t the copper tub ing t o t h e i n l e t o f t h e b u r n e r . Make s u r e the f i t t i n g i s t i g h t .

18 . Move the burner s w i t c h t o " S t a r t " , When t h e main f lame i s e s t a b l i s h e d , move t h e manual p o t e n t i o m e t e r t o t h e h i g h - f i r e p o s i t i o n . A t h igh f i r e , o i l and a tomiz ing a i r p r e s s u r e s shou ld be a d j u s t e d a s shown i n S e c t i o n V I I , Page 2 of t h i s manual. C 0 2 r e a d i n g shou ld be 11 t o 12% with a ze ro smoke s p o t . I f the C02 i s low, i n c r e a s e the o i l p r e s s u r e a t the o i l pump.

19 . Move t h e manual p o t e n t i o m e t e r t o t h e l o w - f i r e p o s i t i o n . A t low f i r e , the o i l and a tomizing a i r p r e s s u r e s shou ld be a d j u s t e d a s shown i n S e c t i o n V I I , Page 2 of t h i s manual, C02 read ing shou ld be 11 t o 12% with a zero smoke s p o t . If t h e C02 i s low, a d j u s t t h e l i n k a g e a t the o i l S e n s i t r o l v a l v e t o open the va lve s l i g h t l y .

2d. With t h e burner i n o p e r a t i o n a t t h e l o w - f i r e p o s i t i o n , check t o s e e if t h e o p e r a t i n g and s a f e t y h i g h - l i m i t c o n t r o l s a r e wired c o r r e c t l y by manually t r i p - p i n g each one. The b u r n e r shou ld go o f f and sequence a new s t a r t when t h e c o n t r o l s a r e r e l e a s e d t o t h e i r normal p o s i t i o n . (NOTE: If t h e s a f e t y h igh- - l i m i t i s o f t h e manual r e s e t t y p e , i t w i l l be necessa ry t o r e s e t t h i s d e v i c e by hand be fore c o n t i n u i n g the work. ) A l s o , check t h e modulating c o n t r o l by manually t u r n i n g t h e p o t e n t i o m e t e r t o make s u r e the burner goes t o h igh and low f i r e .

21. Blow down the low-water c u t o f f . I f two low-water c u t o f f s a r e u s e d , check each s e p a r a t e l y , then check t o g e t h e r . Burner must s t o p and then sequence a new s t a r t when water i n b o i l e r i s r e s t o r e d t o t h e c o r r e c t l e v e l . (NOTE: I f the - second low-water c u t o f f i s o f t h e manual r e s e t t y p e , i t w i l l be necessa ry t o r e s e t t h i s d e v i c e by hand b e f o r e c o n t i n u i n g t h e work . )

22. S t a r t and s t o p t h e burner s e v e r a l t imes t o make s u r e the b u r n e r o p e r a t e s c o r - r e c t l y .

Mfg. Co.

General Description Gas. Light Oil & Dual-Fuel Burners

121 Service Manual Section I

December, 1975

Page 1 of 2

D E S I G N : The 4121 burner i s f o r any f u e l g a s , t h e 5121 f o r Nos. 1 and 2 f u e l o i l , and t h e 6121 f o r d u a l - f u e l ( combina t ion gas o r o i l a s above) . A l l a r e of t h e n o z z l e mix d e s i g n w i t h i n t e g r a l 1% t o 20-hp blower t o s u p p l y 100% combustion a i r . O i l oper - a t i o n i s by medium p r e s s u r e a i r a t o m i z a t i o n w i t h a s i n g l e a i r o r steam atomizing nozz le . The rugged c o n s t r u c t i o n of each burner i s i n t h r e e g e n e r a l s e c t i o n s a s fo l lows :

F r o n t S e c t i o n : C o n s i s t s of t h e round mounting p l a t e w i t h s l o t t e d mounting h o l e s f o r e a s y a l ignment and a p r e c a s t r e f r a c t o r y t i l e t o i n s u r e p e r f e c t f lame s t a b i l i t y and p a t t e r n .

C e n t e r S e c t i o n : C o n s i s t s of a gas plenum wi th bottom gas i n l e t ; a combustion a i r d i f f u s e r , which is r e a d i l y a c c e s s i b l e ; a s p a r k - i g n i t e d , non-plugging, nozz le mix gas p i l o t w i t h a c c e s s o r i e s ; a f lame d e t e c t o r ; and an e l e c t r i c a l o u t l e t box.

Rear S e c t i o n : C o n s i s t s o f a swing-out h inge f o r e a s y a c c e s s i b i l i t y t o t h e burn- e r i n t e r n a l s , blower with motor and i n t a k e s i l e n c e r , l a r g e o b s e r v a t i o n p o r t , o i l meter ing and gas mete r ing v a l v e s , b u t t e r f l y a i r c o n t r o l v a l v e , and a Honey- w e l l modulating motor wi th l i n k a g e s t o t h e a i r , o i l , and gas v a l v e s .

A s e p a r a t e fac to ry-wi red c o n t r o l c a b i n e t of dus t -p roof c o n s t r u c t i o n i s a l s o i n - c luded. The c a b i n e t c o n t a i n s t h e motor s t a r t e r s , e l e c t r o n i c combustion s a f e - g u a r d , on-off s w i t c h , manual purge swi tch and t e r m i n a l s t r i p s . L igh t s t o i n d i - c a t e t h e programming sequence i n c l u d e "Limi t s" , " P i l o t " , "Fuel", "Alarm", and "LOW Water",

A maximum f i r e l i m i t c o n t r o l i s p rov ided i n t h e modulating c i r c u i t . A s e p a r a t e o i l pump and a s e p a r a t e a i r compressor f o r o i l a t o m i z a t i o n a r e provided wi th o i l and d u a l - f u e l models, The compressor and o i l pump a r e remotely mounted and run o n l y d u r i n g o i l o p e r a t i o n .

OPERATION: The burner programming c o n t r o l l e r e n f o r c e s a low-f i re s t a r t wi th f u l l modulat ing c o n t r o l f o r e i t h e r f u e l . One o p e r a t i n g and one modulating s team-pressure c o n t r o l a r e f u r n i s h e d . S i m i l a r c o n t r o l s f o r h o t wa te r a r e a v a i l a b l e .

ELECTRICAL: Blower motor v o l t a g e s a v a i l a b l e a r e 208 v o l t / 3 phase/60 c y c l e , o r 230- 460 v o l t / 3 phase/60 cyc le .

The c o n t r o l sys tem i s always 120 v o l t / s i n g l e phase/60 c y c l e f o r maximum s a f e t y . A step-down t r a n s f o r m e r i s p rov ided on t h e c o n t r o l p a n e l when t h e blower v o l t a g e i s o t h e r than 205 v o l t / 3 ~ h a s e / 6 0 c y c l e ( four wi re ) .

SAFETY FEATURES: The b a s i c s a f e t y equipment i s a Honeywell o r F i reye s e l f - c h e c k i n g , e l e c t r o n i c combustion sa feguard and programming c o n t r o l . I t s maximum s a f e t y c i r c u i t checks a l l i t s own components each second d u r i n g burner o p e r a t i o n , n o t j u s t a t burner s t a r t . Th i s a s s u r e s both f l a m e - f a i l u r e p r o t e c t i o n and component- f a i l u r e p r o t e c t i o n f o r burners t h a t o p e r a t e f o r l o n g p e r i o d s of t ime wi thou t shutdown.

NORTH AMERICAN Mfg. Co. Cleveland. OH 44105 USA

Servlce Manual 12 1 . Sectlon I Page 2 of 2

A synchronous motor -d r iven t i m e r p r o y i d e s f o r a p r e p u r g e , a t r i a l f o r i g i n i t i o n , a t r i a l f o r main f l ame , and a 15-second pos tpurge .

The programmer w i l l r e - c y c l e on power f a i l u r e , bu t w i l l s h u t down and lock o u t on flame f a i l u r e of more t h a n 2 t o 4 seconds w i t h a f lame d e t e c t o r ( f o r g a s o r o i l ) . The model employed meets FIA a i r - f l o w requ i rements .

The swing h i n g e h a s a s w i t c h i n t e r l o c k t o p reven t burner o p e r a t i o n u n l e s s i t i s i n f i r i n g p o s i t i o n . An a i r p r e s s u r e i n t e r l o c k i s p rov ided f o r a u t o m a t i c shutdown i n case of blower f a i l u r e . Automatic shutdown i s p rov ided i n c a s e o f low water l e v e l , flame f a i l u r e , o r power f a i l u r e . Gas p r e s s u r e i n t e r l o c k s f o r h i g h o r low p r e s s u r e can be p rov ided a s an o p t i o n a l f e a t u r e .

I . brake c e r t a i n t h a t t h e "Burner C o n t r o l " s w i t c h i s i n t h e "Stop" p o s i t i o n .

2 , Jlove t h e wal l -mounted f u s e d power s w i t c h t o "On",

3. Open t h e manual main g a s cock and t h e p i l o t g a s cock .

4 . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o " S t a r t " .

B. RESTARTING THE BURNER W E N I N LOCKOUT

' North American ' 7

1. Do n o t s t a r t a b u r n e r when i t s combust iox chamber i s v e r y h o t o r f i l l e d w i t h a s .

Mfg. Co.

2 , Move t h e "Burner C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) t o "Stop".

3 . C l o s e t h e manual main g a s cock and t h e manual p i l o t g a s cock .

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w i t h Full Modulat ing Control December, 1975 1 d

Page 1 of 7 A . STARTING PROCEDURE

Operating Instructions fo r Natural Gas Burners

4 . Move t h e "Blower C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) t o "Purge" and w a i t a t l e a s t t h r e e m i n u t e s .

121 Service Manual Section I l l

5 . Move t h e "Blower C o n t r o l " s w i t c h t o "Auto".

6 , Open t h e manual main g a s cock and t h e manual p i l o t g a s cock .

7. Open t h e d o o r on t h e c o n t r o l c a b i n e t , Push t h e "Rese t B u t t o n " on t h e com- b u s t i o n s a f e g u a r d t o t h e r i g h t and r e l e a s e . T h i s r e s e t s t h e s a f e t y sys t em and t u r n s o u t t h e a l a r m l i g h t .

8 . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o " S t a r t t ' .

SHUTTING DOIJN THE BURNER

1. Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o "Stop".

2 . C l o s e t h e manual main g a s cock and t h e manual p i l o t g a s cock ,

RE STARTING THE BURNER AFTER PROLONGED SHUTDOIJNS - 1, &lake c e r t a i n t h a t t h e "Burner C o n t r o l " s w i t c h i s i n t h e "Stop" p o s i t i o n .

2 , blove t h e wal l -mounted f u s e d power s w i t c h t o "On",

3 , Make c e r t a i n t h a t t h e manual main g a s v a l v e i s c l o s e d .

4. Open t h e manual p i l o t g a s cock o n l y .

5. Move t h e "Burner C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) t o " S t a r t " .

6. Observe t h e p i l o t t h r o u g h t h e o b s e r v a t i o n p o r t on t h e b u r n e r . (m: The t r i a l f o r p i l o t w i t h t h e manual main g a s v a l v e c l o s e d w i l l r e s u l t i n a f l ame f a i l u r e and l o c k o u t . R e s e t by p u s h i n g t h e b u t t o n on t h e combus t ion s a f e g u a r d . Repea t t h e t r i a l f o r p i l o t s e v e r a l t i m e s . )

7. Move t h e "Burner C o n t r o l " s w i t c h t o "Stop".

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Serv~ce Manual 121, Section 111 Page 2 of 7

D . RESTARTING THI? BURNER AFTER PROLONGED SHUTDOIJNS ( con t ' d )

8. Open t h e manual main g a s c o c k .

9, >love t h e "Burner C o n t r o l " s w i t c h t o " S t a r t " .

E . STOPPING THE BURNER IN A N EMERGENCY

1. blove t h e wal l -mounted f u s e d power s w i t c h t o "Off".

2 . C l o s e a l l manual g a s v a l v e s ( i n s t a l l e r t o i d e n t i f y t h e s e v a l v e s ) .

blA1NTENANC.E - DAILY

1. CHECK FOR COMEWSTION SAFEGUARD - See B u l l e t i n f o r Checking Method

a . Wi th t h e b u r n e r i n o p e r a t i o n , c l o s e t h e manual main f u e l v a l v e .

b. The f l a m e s h o u l d go o u t i n 2 t o 4 s e c o n d s . The b lower w i l l c o n t i n u e f o r a p o s t p u r g e . A f t e r t h e f l a m e d i e s , t h e f l a m e s a f e t y w i l l l o c k o u t t h e b u r n e r and l i g h t t h e w a r n i n g l i g h t .

c . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o "Stop".

d. Open t h e manual main f u e l v a l v e which was c l o s e d f o r t h e t e s t , and r e s e t t h e s a f e t y s w i t c h f l a m e s a f e g u a r d .

e . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o " S t a r t " .

2 . CHECK THE ELECTRIC GAS VALVE FOR LEAKAGE ON BURNERS WITH MANUAL CHECKING COCKS

a . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o "Stop".

b , C l o s e t h e manual c h e c k i n g cock .

c . P r e s s u r e gauge s h o u l d n o t r e g i s t e r more t h a n one o s i i n f i v e m i n u t e s .

d . Open t h e manual c h e c k i n g c o c k ,

e . Move t h e "Burner C o n t r o l " s w i t c h ( o n c o n t r o l c a b i n e t ) t o " S t a r t " .

3, CHECK THE LDW-WATER CUTOFF ON THE STEAM BOILER - a . With t h e b u r n e r i n o p e r a t i o n , o p e n t h e v a l v e i n t h e low-water c u t o f f

blow-down l i n e . B u r n e r s h o u l d s t o p f i r i n g and s e q u e n c e a new s t a r t when t h e w a t e r l e v e l i s r e s t o r e d . I f t h e low-water c u t o f f i s a manual r e s e t t y p e , i t must be r e s e t by hand b e f o r e t h e b u r n e r w i l l r e l i g h t ,

MAINTENANCE - PERIODIC

1. C l e a n t h e b lower wheel .

2 . Swing t h e b u r n e r open and c l e a n t h e p e r f o r a t e d p l a t e .

North American Mfg. Co.

Cleveland. OH 44105 USA

A . ST.ARTING PROCEDURE

GAS -

Operating instructions for Dual-Fuel Burner


Page 5 of 7

1. .\lake c e r t a i n t h a t t h e "Burner 1, ,\lake c e r t a i n t h a t the "Burner Cont ro l " s w i t c h i s i n t h e "Stop" C o n t r o l " s w i t c h i s i n the "Stop" p o s i t i o n . p o s i t i o n ,

2 . lzlove t h e wall-mounted f u s e d power 2 , hIove the wall-mounted fused power s w i t c h t o "On". sivitch t o "On",

3. Move t h e "Fuel S e l e c t o r " s w i t c h 3 . Move t h e "Fuel S e l e c t o r " swi tch t o "Gas". t o "Oil".

4 . Open the mazual main g a s cock and 3 . Open the manual p i l o t g a s cock and t h e p i l o t g a s cock. a l l manual o i l v a l v e s .

5 . blove t h e "Burner C o n t r o l " s w i t c h 5 , hlove the "Burner Cont ro l " swi tch ( o n c o n t r o l c a b i n e t ) t o " S t a r t " . (on c o n t r o l c a b i n e t ) to " S t a r t " .

CAWTION: Be s u r e t h a t t h e r e i s o i l i n the c rankcase of t h e compressor be fo re s t a r t i n g . O i l l e v e l must be main ta ined between t h e two marks on t h e bayonet o i l gauge. Refer t o t h e i n s t r u c t i o n manual i n S e c t i o n V I I I f o r c a p a c i t i e s and we igh t s .

B. RESTARTING THE BURNER WHEN I N LDCK@UT

GAS - 01 L - 1, Do n o t s t a r t a burner when i t s 1, Do not s t a r t a burner when i t s

combustion chamber i s v e r y h o t o r combustion chamber i s v e r y hot o r f i l l e d wi th g a s . f i l l e d wi th combust ib le vapors .

2 . Move t h e "Burner C o n t r o l " s w i t c h 2 . Move t h e "Burner Cont ro l " s w i t c h (on c o n t r o l c a b i n e t ) t o "Stop". ( o n c o n t r o l c a b i n e t ) t o "Stop".

3. Close the manual main g a s cock and 3. C lose the manual p i l o t g a s cock and t h e manual p i l o t gas cock. a l l manual o i l v a l v e s .

4 . blove the "Blower C o n t r o l " s w i t c h 4 , hlove t h e "Blower C o n t r o l " switch (on c o n t r o l c a b i n e t ) t o "Purge" (on c o n t r o l c a b i n e t ) t o "Purge" and wa i t a t l e a s t t h r e e minutes . and w a i t a t l e a s t t h r e e minutes .

5. Move t h e "Blower C o n t r o l " swi tch - . 5 bIove the "Blower Cont ro l " swi tch t o "Auto". t o "Auto".

6 . Open t h e manual main g a s cock and 6. Open the manual p i l o t g a s cock and t h e manual p i l o t gas cock. a l l manual o i l v a l v e s .

7 , Open t h e door on t h e c o n t r o l c a b i - 7. Open t h e door on t h e c o n t r o l cab i - n e t , push t h e r e d " ~ e s e t " b u t t o n on n e t , push t h e "Resett ' b u t t o n on combustion s a f e g u a r d and r e l e a s e . combustion s a f e g u a r d and r e l e a s e .

8, Move t h e "Burner C o n t r o l " s w i t c h 8. Move t h e "Burner Cont ro l " swi tch (on c o n t r o l c a b i n e t ) t o " S t a r t " . ( o n c o n t r o l c a b i n e t ) t o " S t a r t " .

NORTH AMERICAN Mfq. C o Cleveland, OH 44105 USA

S e r v ~ c e Manual 121, Sectlon I11 P a g e 6 of 7

0PE.ATING INSTRUCTIONS ( co n t ' d )

C . SHUTTING DOIVN ?HE BURNER

GAS 01 L - - 1 . Move t h e "Burner C o n t r o l " s w i t c h 1, Move t h e "Burner C o n t r o l " s w i t c h

( o n c o n t r o l c a b i n e t ) t o "Stop" . ( o n c o n t r o l c a b i n e t ) t o "Stop".

2 . C l o s e t h e manual main g a s cock and 2 . C l o s e t h e manual p i l o t g a s cock t h e manual p i l o t g a s cock . and a l l manual o i l v a l v e s .

3. Move t h e "Fuel S e l e c t o r " t o c e n t e r 3. Blove t h e "Fuel S e l e c t o r " t o cen - "Off" p o s i t i o n . t e r "Off" p o s i t i o n .

D . RESTARTING THE BURNER AFTER PROLONGED SHUTDOIW

1. Make c e r t a i n t h a t t h e "Burne r C o n t r o l " s w i t c h i s i n t h e "Stop" p o s i t i o n .

2 . Move t h e wal l -mounted f u s e d power s w i t c h t o "On".

3. Move t h e "Fue l S e l e c t o r " s w i t c h t o "Gas" o r "Oi l" .

4 . Be s u r e t h c manual main f u e l v a l v e s a r e c l o s e d .

5. Open t h e manual p i l o t g a s cock o n l y .

6 . Move t h e "Burner C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) t o " S t a r t " .

7. Observe t h e p i l o t t h r o u g h t h e o b s e r v a t i o n p o r t on t h e b u r n e r . (NOTE: The t r i a l f o r p i l o t w i t h t h e manual main f u e l v a l v e s c l o s e d w i l l r e s u l t i n a f l a m e f a i l u r e and l o c k o u t . R e s e t by p u s h i n g t h e b u t t o n on t h e combus t ion s a f e g u a r d . ) R e p e a t t h e t r i a l f o r p i l o t s e v e r a l t imes .

8. Move t h e "Burner C o n t r o l " s w i t c h t o "Stop".

9. Move t h e "Fue l S e l e c t o r " s w i t c h t o "Gas" o r "Oil" .

10. Open t h e manual main g a s cock o r t h e manual o i l v a l v e .

11. Move t h e "Burner C o n t r o l " s w i t c h t o " S t a r t " .

E . STOPPING TWE BURNER I N AN EMERGENCY

1. blove t h e wal l -mounted f u s e d power s w i t c h t o "Off".

2 . C l o s e a l l manual g a s and o i l v a l v e s ( i n s t a l l e r t o i d e n t i f y t h e s e v a l v e s ) .

F . TO CHANGE FUEL

1, Fo1lor.r "A. S t a r t i n g P r o c e d u r e " f o r t h e f u e l t o be bu rned .

G . MAINTENANCE - DAILY

1. CHECK FOR COMBUSTION SAFEGUARD

a . Wi th t h e b u r n e r i n o p e r a t i o n , c l o s e t h e manual main f u e l v a l v e .

b. R e f e r t o M a n u f a c t u r e r ' s b u l l e t i n f o r d e t a i l s .

c. Move t h e "Burne r C o n t r o l w s w i t c h (on c o n t r o l c a b i n e t ) t o "Stop".

PRINTED IN USA N 1 6 9 2 SM121S3P5 6.50

Mfg. Co. Cfeveiand. O H 44105 USA

Initial Starting Procedure Natural Gas Burner


December, 1975

Page 7 of 7

G. bIAINTENANCE - DAILY ( c o n t ' d )

d. Open the manual main f u e l v a l v e which IGas c l o s e d f o r the t e s t , and r e - s e t t h e s a f e t y s w i t c h i n the combustion s a r e g u a r d .

e , Move t h e "Burner C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) to " S t a r t " .

2. CHECK THE E LECTKIC GAS VALVE FOR LEAY.AGE ON BURNERS W I T H PrlANUAL CHECKING COCKS

a , Move t h e "Burner C o n t r o l " swi tch (on c o n t r o l c a b i n e t ) t o "Stop".

b. C l o s e the manual check ing cock.

c . P r e s s u r e gauge should n o t r e g i s t e r more t h a n 1 o s i i n f i v e minutes .

d , Open t h e manual checking cock.

e . Move t h e "Burner C o n t r o l " s w i t c h (on c o n t r o l c a b i n e t ) t o " S t a r t " .

CHECK THE LOW-WATER CUTOFF ON THE SEAM BOILER

a. With t h e burner i n o p e r a t i o n , open t h e v a l v e i n the low-water c u t o f f blow-down l i n e . The b u r n e r should s t o p f i r i n g and sequence a new s t a r t when t h e water l e v e l i s r e s t o r e d . ( I f t h e low-water c u t o f f i s a manual r e s e t t y p e , i t must be r e s e t by hand be fore t h e b u r n e r w i l l r e l i g h t . )

H . MAINTENANCE - PERIODIC

1. Clean t h e blower wheel .

2 . Swing t h e burner open and c l e a n the p e r f o r a t e d p l a t e ,

3 , C lean t h e p h o t o c e l l g l a s s ( o r the U-V g l a s s e s ) .

4 . Remove and c l e a n the o i l n o z z l e s .

Trouble Shooting 121 Service Manual Natural Gas, Light Oil and

Cleveland. OH 44105 USA Dual-Fuel Burner December, 1975

Page 1 of 9

INITIAL CHECKING PROCEDURE

I f burner o p e r a t i o n i s n o t a s d e s c r i b e d under Normal O p e r a t i o n i n S e c t i o n 111, make t h e f o l l o w i n g check, If t r o u b l e p e r s i s t s a f t e r t h i s checking p r o c e d u r e , r e f e r t o i n s t r u c t i o n s on f o l l o w i n g pages .

1. Make s u r e t h e r e i s power from the wall-mounted fused power s w i t c h . Check wi th a v o l t m e t e r f o r an open s w i t c h o r a burned-out f u s e .

2. Make s u r e t h e r e i s power t o t h e c o n t r o l c i r c u i t . This i s a lways 120 v o l t s , s i n g l e phase , 60 c y c l e . Check wi th a t e s t l i g h t f o r power on t e r m i n a l s i n c o n t r o l c a b i n e t . See e l e c t r i c a l drawings f o r t e r m i n a l numbers.

3. Make s u r e t h a t a l l s w i t c h e s a r e i n t h e i r c o r r e c t s t a r t i n g p o s i t i o n s on the con- t r o l c a b i n e t ,

4 , AIake s u r e t h a t t h e sc rew- in c o n t r o l f u s e i n t h e c o n t r o l c a b i n e t i s good.

5 , Make s u r e t h e manual p i l o t s h u t o f f g a s v a l v e i s open,

6, Make s u r e the manual main s h u t o f f gas va lve i s open ( f o r o p e r a t i o n on g a s ) , o r t h a t a l l v a l v e s i n the o i l l i n e a r e o p e n , t h a t s u c t i o n l i n e s a r e t i g h t , and t h a t an adequate s u p p l y o f o i l i s a v a i l a b l e ( f o r o i l o p e r a t i o n ) .

7 . Nake s u r e t h a t a l l o p e r a t i n g l i m i t s and s a f e t y h i g h l i m i t s a r e c l o s e d . Be s u r e t h a t t h e low-water c u t o f f i s c l o s e d .

8. Make s u r e the o i l pump and a i r a tomizing compressor a r e o p e r a t i n g (when i n o i l o p e r a t i o n ) .

9 . R e s e t t h e the rmal s w i t c h on t h e f lame s a f e g u a r d i n c o n t r o l c a b i n e t .

10 . Reset t h e magnet ic blower s t a r t e r i n the c o n t r o l c a b i n e t ( f o r e i t h e r gas o r o i l o p e r a t i o n ) . R e s e t t h e magnet ic o i l pump and a i r a tomizing s t a r t e r s (when on o i l o p e r a t i o n ) . NOTE: Above s t a r t e r s will be l a b e l e d "Blo\\,er Jlo:or", " O i l - Pump", and "Air Co:npressor" i n the c o n t r o l c a b i n e t .

The TROUBLE SHOOTING s e c t i o n i s d i v i d e d i n t o s ix s u b - s e c t i o n s a s f o l l a w s :

. . . . . . . . . . . . . . . . . . A. Program Abnormal i n Opera t ion Page 2 B. Blower Will Not S t a r t (when t h e blower s w i t c h is i n t h e "Auto"

p o s i t ion) . . . . . . . . . . . . . . . . . Page 2-3 . . . . . . . . . . . . . C. Blower S t a r t s , But P i l o t W i l l Not L igh t Page 4-5

D. Blower S t a r t s , P i l o t L i g h t s , But Main Flame Will Not L igh t a as O p e r a t i o n ) . . . . . . . . . . . . . . . . Page 5-6

E. Blower S t a r t s , P i l o t L i g h t s , But Main Flame Wil l Not L i g h t (Oi l O p e r a t i o n ) . . . . . . . . . . . . . . . . Page 6-8

. . . . . F. Main Burner S t a r t s , But W i l l Not Modulate t o High F i r e . Page 7-8

NORTH AMERICAN Mlg. Co Cleveland, OH 44105 USA

Servlce Manual 121. Section IV Page 2 of 9

A. PROGRAM ABNORMAL IN OPERATION

1. Follow checking procedure under "Maintenance and Trouble Shooting" safeguard bulletin, Pages 14-16 (Section VIII of this service manual).

5. BLOWER WILL NOT START

NOTE: Blower has a short delay when the main power switch is first closed. This is built into the timer in the flame safeguard.

POSSIBLE CAUSE REMEDY

1. Safeguard thermal switch is tripped (flame failure light on the control cabinet will be lit.)

2. Control circuit fuse (screw type) in control cabinet is defective.

1. Reset by pushing the thermal safety switch.

2. Replace the screw-type fuse.

3. Hinge interlock switch is not making 3, If the burner is closed tightly contact. Terminal #22 in the control and there is no power on ter- cabinet should show 120 volts to minal #22, replace the defective ground (#2) with test light. hinge interlock switch.

(NOTE: "Limits" indicator light would not be on).

4. Low-water cutoff not making contact 4. because of:

a. Low water level in boiler (low- water alarm light will be lit).

b. Defective low-water cutoff.

c. On boilers equipped with two low- water cutoffs, the second one is frequently a manual reset type.

a. Add water to boiler if level is low.

b. LOW-water alarm light may not be on. Check with a test light for power from terminal 330 to ground (#2). Should show 120 volts. If float is up and there is no power at terminal #30, replace low-water cutoff switch.

c. Check voltage from terminal /I25 to ground (#2). If 120 volts do not appear at terminal #25 and water level is adequate, reset. (NOTE: Low-water alarm light may not be on.) Limit light will not be on.

Mtg. Co.

Trouble Shooting Natural Gas. Light Oil and

Dual-Fuel Burner i 121 Service Manual Section IV

December, 1975

Page 3 of 9

B. BLOWER WILL NOT START ( cont'd)

P O S S I B L E CAUSE

5. Operating control (Pressuretrol or qua stat) mounted on the boiler is not making contact due to no call for heat, too low a setting, a defective control, or a plugged impulse 1 ine.

6. Safety high limit control (Pressure- trol or Aquastat) mounted on boiler not making contact.

7. Defective timer motor in programmer.

8. Control motor will not return to low fire.

9. Heater coils in the magnetic blower starter are off on reset (blower starter wi 11 be marked).

10. Defective coil in the magnetic blower starter.

11. Blower motor is defective. If motor hums and does not start or does not run at full speed, it is defective. (NOTE: Be sure the polyphase motor is not single-phasing.)

12. Start-stop switch on control cabinet is defective (applies only to combination burner).

RENEDY

Remove the cover from the controller and see that the mercury switch (If Pressuretrol) is tripped to the right. If not, readjust the controller. Touch a jumper between terminal /I30 and 31. If the blower starts, replace the defective control. (=: Limit light will not be on.) REMOVE JUMPER. '

6. See "5" above. Touch a jumper between terminals #25 and 26. If the blower starts, replace this con- tro 1. REMOVE JUMPER.

7. Replace the programmer.

8. Check with electric meter across 'IT" and "T" terminals of control motor for power (24 volts). If power is present, jumper R & B terminals of control motor. If motor does not return to low fire, replace defective control motor. CAUTION: When replacing this motor, wire completely, then turn power on to the controls. Wait until the motor comes to low fire before instal 1 ing the 1 inkage. REMOVE JUMPER.

9. Reset by pushing the bar on the magnetic blower starter.

10. Test by putting a test light across both sides of the coil. If it indicates 120 volts and starter does not pull in, coil is defective.

11. Replace defective motor.

12. Put a jumper between terminals /I31 and 32. If the blower starts, replace this switch. REMOVE JUMPER.

NORTH AMERICAN Mfg. Co. Cleveiand. OH 441 05 USA

Service Manual 121, Section IV Page 4 of 9

B. BLOWER WILL NOT START ( c o n t ' d )

POSS I BLE C.\US E REMEDY

Fue l S e l e c t o r s w i t c h on c o n t r o l c a b i - 13. Touch a j u m p t e r be tween t e m i n a l s n e t i s d e f e c t i v e ( a p p l i e s o n l y t o ;I27 and 2 8 i f a g a s b u r n e r , o r be- c o m b i n a t i o n b u r n e r ) . tween t e r m i n a l s #27 and 54 i f a

d u a l - f u e l b u r n e r s e t f o r g a s , o r between t e r m i n a l s #27 and 66 i f a d u a l - f u e l b u r n e r s e t f o r o i l . I f t h e b lower s t a r t s , r e p l a c e t h e f u e l s e l e c t o r s w i t c h . REMOVE JUMPER.

C. BLOWER STARTS, BUT PILOT WILL NOT LIGHT NOTE: Blower w i l l p r e p u r g e b u r n e r b e f o r e t h e p i l o t w i l l i g n i t e . -


1. Carbon b r i d g e on t h e s p a r k e l e c t r o d e . I . Remove and c l e a n t h e s p a r k e l e c - t r o d e and p i l o t t i p .

2. H i g h - f i r e p r o v i n g s w i t c h is d e f e c - t ive .

3. Low- f i r e p r o v i n g s w i t c h is d e f e c - t i v e .

4. No power from t h e s a f e g u a r d t o e n e r g i z e t h e p i l o t s o l e n o i d and i g n i t i o n t r a n s f o r m e r .

5 . No g a s t o t h e p i l o t .

6. Not enough o u t l e t g a s p r e s s u r e f rom t h e p i l o t r e g u l a t o r .

2. I f t i m e r is s t o p p e d a t 1 4 s e c o n d s (FIA b u r n e r ) and r u n s i n p r e p u r g e f o r o v e r 60 s e c o n d s , check f o r power be tween t e r m i n a l /I17 and ground ? / 2 . I f t h e r e i s no power, r e p l a c e t h e h i g h - f i r e p r o v i n g switch..

3. I f t i m e r is s t o p p e d a t 55 s e c o n d s (any b u r n e r ) and t h e b lower c o n t i n u e s t o p r e p u r g e a f t e r r e a c h i n g t h e low- f i r e p o s i t i o n , check f o r power between t e r m i n a l s i l l 8 and #2. I f t h e r e is now power, r e p l a c e low- f i r e p r o v i n g s w i t c h .

4 . R e f e r t o safe-ward b u l l e t i n f o r check.

5. Flake s u r e t h e manual g a s p i l o t v a l v e is open. Gas p r e s s u r e i n l e t t o t h e gas s o l e n o i d v a l v e s h o u l d be 5 " w c minimum, 1 4 ounces maximum.

6. P i l o t r e g u l a t o r is o u t o f a d j u s t - ment. Remove t h e c o v e r from t h e r e g u l a o r . Screw c l o c k w i s e t o i n - c r e a s e t h e gas p r e s s u r e t o 1.5" t o 2" wc o u t l e t f o r n a t u r a l g a s o r .519 t o 1'l wc p r e s s u r e f o r propane .

North American Mfq. Co.

Cleveland. OH 44105 USA

Trouble Shooting Natural Gas. Light Oil and

Dual-Fuel Burner

121 Service Manual Section IV

December. 1975

C. BLOWER STARTS, BUT PILOT WILL NOT LIGHT (cont'd)

POSS IBLE CAUSE REYEDY

7. Gas pilot regulator locking up.

8. Defective pilot solenoid gas valve.

9. Defective ignition transformer.

10. Blower selector switch is set to "Purge".

Page 5 oi 9

7. If gas pressure inlet is over 14 osi install a Fisher 3/4" #7347G-0 high pressure regulator in the pilot gas line ahead of the pilot solenoid gas valve. Outlet gas pressure on this regulator should be 4 to 6 osi.

8. Place a hand on the valve. When the valve is powered, a definite "click" will be felt if the valve opens. If a test light shows power across coil leads and the valve does not open, replace the pilot gas valve coil.

9. Check by grounding an insulated screwdriver from the high voltage terminal at the transformer to ground. The spark should jump a 3/16" to k" gap. (CAUTION: Be sure screwdriver is insulated--ignition transformer delivers 6000 volts. ) If the test fails to produce a spark, replace the ignition transformer.

10. Move the blower selector switch to "Automatic1' position.

D. BLOWER STARTS, PILOT LIGHTS, BUT MAIN F U M E WILL NOT LIGHT (GAS OPERATION)


1. Pilot gas regulator not properly ad- 1. Set the pilot gas regulator from justed. Gas indicator light will 1.5 to 2" outlet pressure for not be on. Check signal from natural gas, or .511 to 1" wc for flame detector. propane gas.

2. Porcelain insulator on the flame rod 2. Remove the flame rod and clean the is dirty or covered with paint or porcelain insulator. moisture. (m: Microammeter will detect this--pointer on meter will quiver back and forth showing grounded-out circuit. Flame relay will not pull in.)

3. Flame rcd is touching and refractory, 3. Remove the flame rod and remove all grounding out the circuit. Flame foreign matter from the flame rod relay will not pull in safeguard. opening (rod should be straight).

NORTH AMERICAN Mlg. Co. Cleveland. OH 44105 USA

Serv~ce Manual 121. Section N Page 6 of 9

D. BLOWER STARTS, PILOT LIGHTS, BUT EL4IN FLAHE WILL NOT LIGHT (GAS OPERATION) c o n t 'd.

POSSIBLE CAUSE

4. Flame rod burned o f f - rod t o o s h o r t . 4. Flame rod s h o u l d be 9" long on a l l d u a l - f u e l and o i l b u r n e r s , and 7%" long on a l l g a s burners . (Rod shou ld be measured from t h e base of t h e p lug w i t h no bend i n i t . )

5. P i l o t is l a r g e enough, b u t f lame r e - l a y is n o t p u l l i n g in.

6. Fuel s e l e c t o r s w i t c h is s e t t o t h e wrong f u e l ( a p p l i e s o n l y t o combina- t i on b u r n e r ) .

7. D e f e c t i v e e l e c t r i c main gas v a l v e , o r , i f two e l e c t r i c g a s v a l v e s a r e used , one may be d e f e c t i v e and t h e o t h e r may be working p r o p e r l y .

8. Manual main gas v a l v e i s c losed .

5 . R e f e r t o f lame d e t e c t o r b u l l e t i n f o r c o r r e c t i o n s .

6. Move t h e f u e l s e l e c t o r s w i t c h t o t h e p roper f u e l p o s i t i o n .

7. check wi th t e s t l i g h t on bo th t e r - mina l s of each g a s va lve . I f t h e v a l v e i s powered and does n o t open, r e p l a c e t h e o p e r a t o r o r c o i l of t h e gas valve . CAUTION: Close manual main g a s v a l v e when r e p l a c - i n g t h e o p e r a t o r o r c o i l .

8. Open t h e manual main g a s valve .

E. BLOWER STARTS, PILOT LIGHTS, BUT PIAIN FWEIE IJILL NOT LIGHT (OIL OPERATION) NOTE: See 1 , 2 , 3 , 4, 5, 6 , and 7 of S u b - s e c t i o n "D" - Troub le Shoot ing.

These w i l l a p p l y f o r o i l o p e r a t i o n .

POSSIBLE CAUSE

8. Flame d e t e c t o r g l a s s o r l e n s is d i r t v o r d e t e c t o r is d e f e c t i v e . (NOTE: Under t h e s e c o n d i t i o n s , main o i l f i r e may i g n i t e b u t w i l l go o u t f o u r o r f i v e seconds a f t e r t h e p i l o t goes ou t . )

9. On models equipped w i t h C7012 u l t r a - v i s i o n d e t e c t o r , t h e l e n s is d i r t y o r t h e t u b e s a r e d e f e c t i v e .

10. On u n i t s o t h e r t y p e of d e t e c t o r - - s e e b u l l e t i n .

REMEDY

8. See D e t e c t o r b u l l e t i n f o r c o r r e c t i o n s necessa ry .

9. Clean t h e l e n s on t h e U-V d e t e c t o r , o r r e p l a c e t h e tubes . (NOTE: Re- f e r t o B u l l e t i n C7012 i n S e c t i o n VIII of t h i s s e r v i c e manual f o r t r o u b l e s h o o t i n g t h e U-V d e t e c t o r . )

10. See Trouble S h o o t i n g s e c t i o n i n t h e b u l l e t i n .

Trouble Shooting 121 Service Manual Natural Gas, Light Oil and

Cleveland. OH 44105 USA Dual-Fuel Burner December, 1975

E. BLOWER STARTS, PILOT LIGHTS, BUT EIAIN F U M E WILL NOT LIGHT (OIL OPERATION) contld.

POSSIBLE CAUSE REPIEDY

11. Defective atomizing air interlock 11. Jumper terminals 363 and 64. If switch. Oil indicator light will not the pump starts, replace the de- be on, air compressor will be ener- fective atomizing air switch. Oil gized, oil pump will not be operating.

indicator light will not be on, REMOVE JUbIPER.

12. Atomizing air switch is not closing 12. Check to see that the air line is because of: clear and that the fittings are a. Insufficient air pressure. tight. (m: Atomizing air b. Compressed air line is kinked, switch is set at the factory to

broken, or fittings are loose. close at 8 to 10 psi (oil indicator light will be on).

13. Coil on the oil pump magnetic starter 13. Check with a test light across the is defective. coil terminals in the control cabi-

net. If it shows 120 volts and the magnetic starter does not pull in, the coil is defective. Replace this 120/1/60 oil pump starter coil. See ''Type A" panel in Section VIII of manual for location of oil pump starter. (NOTE: Oil indicator light will not be on.)


Service Manual 12 1, Section IV Page 8 of 9

BWIVER STARTS. PILOT LIGHTS, BUT FlAIN FIRE \JILL NOT LIGHT (OIL 0PEIWTION)-con't.


13. C o i l on the a tomiz ing a i r compressor 13. Check wi th a t e s t l i g h t a c r o s s t h e magnetic s t a r t e r i s d e f e c t i v e . c o i l t e r m i n a l s i n the c o n t r o l c a b i -

n e t , I f the t e s t shows 120 v o l t s and t h e magnet ic s t a r t e r does not p u l l i n , t h e c o i l i s d e f e c t i v e . Replace t h i s 120/1/60 c o i l . See "Type A" p a n e l i n S e c t i o n VIII o f manual f o r l o c a t i o n o f t h e a i r com- p r e s s o r s t a r t e r . (NOTE: O i l i n d i - - c a t o r l i g h t w i l l no t be o n . )

14. H e a t e r c o i l s i n t h e magnet ic o i l 14 , Reset by pushing t h e r e s c t b a r on s t a r t e r o r magnet ic a i r compressor t h e s e magnet ic s t a r t e r s . s t a r t e r a r e o f f on r e s e t .

15 . O i l n o z z l e i s plugged o r worn

16 . Leak i n s u c t i o n l i n e from o i l pump t o o i l s t o r a g e t a n k .

17. D e f e c t i v e o i l pump motor. I f t h e motor hums and d o e s no t s t a r t , o r d o e s n o t run a t f u l l s p e e d , the motor i s d e f e c t i v e ,

18. D e f e c t i v e a tomiz ing a i r compressor motor ( s e e "17" above) .

19 . O i l pump is d e f e c t i v e , C lose manual o i l v a l v e on the pump i n l e t whi le o i l i s f l o w i n g . Th? s u c t i o n gauge on t h e i n l e t shou ld s h o i ~ 13" t o 22" Hg (mercury column) to be i n good mechanical c o n d i t i o n .

20. ~ e f e c t i v e f u e l s e l e c t o r s w i t c h .

15. Swing t h e burner open and c l e a n o r r e p l a c e the o i l n o z z l e .

16. O i l s u c t i o n l i n e shou ld be capable o f ho ld ing 100 p s i a i r p r e s s u r e f o r 24 h o u r s , If i t c a n n o t , r e p a i r o r r e p l a c e t h e o i l s u c t i o n l i n e .

17. Replace the o i l pump motor. Check t o s e e t h a t c o r r e c t v o l t a g e i s a t the pump b e f o r e r e p l a c i n g .

18. Replace t h e complete compressor. (NOTE: See b u l l e t i n on a i r com- - p r e s s o r i n S e c t i o n V I I I o f manual) .

13. I f the s u c t i o n gauge on the i n l e t shows l e s s than 1 9 " t o 20" H; (mercury column) , r e p l a c e the d e - f e c t i v e o i l pump. (NOTE: Sse b u l l e t i n on t h e o i l pump i n Sec- t i o n V I I I of t h i s manual.

20, Jumper t e r m i n a l s +46 and 65. If a i r compressor s t a r t s , swi tch i s d e f e c t i v e and s h o u l d be r e p l a c e d . REMOVE JUMPER. -- -

Mfg. Co.

Trouble Shooting Natural Gas, Light Oil and

Dual-Fuel Burner

121 Service Manual Section IV

Page 9 of 9

F. MAIN BURNER STA4RTS, BUT WILL NOT blODUWE TO HIGH FIRE

POSSIBLE CAUSE REbEDY

1. Maximum f i r e l i m i t swi tch (on con- 1. Turn the f i r e l i m i t swi tch t o i t s t r o l c a b i n e t ) i s s e t t o i t s minimum maximum s e t t i n g . s e t t i n g ,

2 . Maximum f i r e l i m i t s w i t c h i s d e f e c - 2. Jumper o u t t h i s swi tch . If b u r n e r t i v e . moves t o high f i r e , r e p l a c e t h e

swi tch . REMOVE JUMPER. -- 3, Modulating c o n t r o l (Aquastat o r 3, Read jus t t h e modulating c o n t r o l t o

P r e s s u r e t r o l ) i s o u t of ad jus tment t h e c o r r e c t s e t t i n g . ( s e t t o o low).

4. Modulating c o n t r o l (Aquasta t o r 4 , Jumper "R" and "B" t e r m i n a l s a t P r e s s u r e t r o l ) is d e f e c t i v e . c o n t r o l . If burner t h e n goes t o

h i g h f i r e , r e p l a c e t h e modulating c o n t r o l . REMOVE JUMPER.

5. C o n t r o l motor t r ans former (120 v o l t s 5. Check wi th a meter f o r 120 v o l t s p r i m a r y , 24 v o l t s secondary) i s de- p r imary , 24 v o l t s secondary. I f f e c t i v e . d e f e c t i v e , r e p l a c e t h e c o n t r o l

motor t r ans former . See S e c t i o n V I I I o f t h i s manual f o r the l o c a - t i o n o f t h i s 24-vo l t t r a n s f o r m e r ,

6. D e f e c t i v e o r d i r t y c o n t a c t s i n t h e t i m e r motor o r t h e programmer.

7. C o n t r o l motor i s d e f e c t i v e .

6 . Refe r t o t h e Maintenance & T r o u b l e Shoot ing s e c t i o n o f t h e b u l l e t i n i n S e c t i o n I V of t h i s manual.

7. Make s u r e t h e r e a r e 24 v o l t s t o t e r m i n a l s "T" and "T" a t t h e motor. I f t h e v o l t a g e i s p r e s e n t , jumper "R" and "W" t e r m i n a l s . If t h e motor does n o t go t o h igh f i r e , r e - p l a c e t h e d e f e c t i v e c o n t r o l motor. CAUTION : Before a t t a c h i n g l i n k a g e t o t h e replacement motor , make s u r e t h e c o n t r o l motor i s a t low-f i re p o s i t i o n . REMOVE JUMPER.

PRINTED IN USA

121 Sewice Manual Section VII

North American Atomizing Air Compressors fo r Burners - - Light Fuel Oil

Cleveiand. OH 44105 U S A Full Modulat ing Controls

Page 5 of 10

Boiler Burner hp Model Mode l

COMPRESSOR Relief Valve

Make Setting, ps i cf m

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Open Drip-Proof

Quincy D210UL

Quincv D216UL

Quincy D210UL

Quincy D210UL Quincy D216UL

Quincy D216UL

Quincy D216UL

Quincy D240UL

700 2700 t -121-29.4 Quincy D240UL 3700t AB-121-29.4

t Boiler which has neutral or negative draft in furnace. tThree-Pass Atlas Generator.


Servlce Manual 121. Section VII Page 6 of 10

Boiler Mode l

Atomizing Air and Oil Pressure for Light Oil and Combination Burners for Full Modulation

Burner Model Rate

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Low High

Atomizing Air, psi

19 ' 29

1 Oil Pressure, psi A t Pump A t

Burner

Sensitrol Oil Valve

Number Position


Mfg. Co.

Blower Whee l and B lower M o t o r s f o r Natura l Gas and Light Oil Burners

121 Service Manual Section VII I

February, 1985 I Page 7 of 10

Boi ler Burner B lower MOTOR h p M o d e l M o d e l I Wheel Vo l tage rPm

Revcor R340-5118

G.E. End Mount

Revcor R340-5118

G.E. End Mount

Revcor R340-5118

G.E. End Mount

G.E. End Mount

Revcor R340-5 1 18

Revcor 17340-51 18

G.E. End Mount

Revcor R340-5120

G.E. End Mount

G.E. End Mount

C.R.

Revcor R340-5120

R340-5117

G.E. End Mount

G.E. End Mount

Clarage R340-5127

Clarage R340-5127

G.E. End Mount

G.E. End Mount

Clarage R340-5127

Clarage R340-5135

L.A. End Mount

Clarage R340-5135

L.A. End Mount

L.A. End Mount

Clarage R340-$135

Clarage R340-5 138

L.A. End Mount

Clarage R340-5 138

L.A. End Mount

North America1 11-7183-1

L.A. End Mount



Serv~ce Manual 121. Section V I I Page 8 of 10

Boiler Burner h p M o d e l M o d e l

Oil Pump and Oil Pump Motors for Burners--Light Fuel Oil Full Modulating Controls

Webster 250 65 (2R626C-3DU141

R660-5153

P U M P

M a x . Pres. , M a k e psi gph

Webster 250 65 (2R626C-3DU141

R660-5153

Webster 250 65 (2R626C-3DU14)

R660-5153

M O T O R

Type h P Voltage rP m

Rd30-7657 1.2 230-460/3/60-50 1800 R430-7656 or 208!3160-50

Webster 250 65 (2R626C-3DU14)

R660-5153

Webster 250 65 (2R626C-3DU141

R660-5153

Webster 250 65 (2R626C-3DU141

R660-5153

Webster 250 65 (2R626C-3DU141

R660-5 153

Webster 100 150 (1 HBMFV8-LB)

R660-5138

Webster 100 150 (1 HBMFV8-LB)

R660-5138

Webster 100 198 (2HBMFV8-LB)

R660-5142

Webster 100 198 (ZHBMFV8-LB)

~660.5142

Websrer 100 198 (2HBMFV8-LBI

R660-5 142

Webster 100 243 (3HBMFV8-LBI

R660-5 147

Webster 100 243 (3HBMFV8-LBI

R660-5147

700 2700t -121 -29.4 3700t A8-121-29.4

Webster 100 243 (3HBMFV8-LB)

R660-5147 Boiler which has neutral or negative draft in furnace.

f Three-Pass Atlas Generator. PFIINTED IN USA

Mtg. Co. Cleveland. OH 44105 USA

Atomizing Ai r Pressure (Free) for Light Oil Burners i

Boiler Burner hp M o d e l M o d e l

Compressor Mode l

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

Quincy D210UL

~ u i ~ c ~ D2lOUL

Quincy D210UL

Quincy D210UL

Quincv D216UL

Quincy D210UL

Quincy D210UL

Quincy D216UL

Quincy D216UL

Quincy D216UL

Quincv D240UL

Quincy D240UL

Quincy D240UL

Oil Nozzle

Delavan 3061 5-84

Delavan 3061 5-84

Delavan 3061 5-84

Delavan 3061 5-84

Delavan 306 15-84

Delavan 3061 5-84

Delavan 3061 5-84

Delavan 3061 5-84

Delavan 3061 5-85

Delavan 30616-13

Delavan 3061 5-85

Delavan 306 15-85

Delavan 3061 6-1 3

Delavan 30616-13

Delavan 30616-13

N.A. Diffuser

1 1-8870-4

Cap 1 1-8869-6

121 Service Manual Section VII

Page 9 of 10

A i r Pressure, p5i4

t8oiler which has neutral or negative draft in furnace. S Three-Pass Atlas Generator. 5 Air pressure readings to be taken with only the atomizing air compressor energized. Take readings at pipe tee where air compressor hose connecrs

to oil atomizing assembly at burner.


Service Manual 121, Section VII Page 10 of 10

Spare Parts and Burner Technical Data

ORIFICE PLATE D A T A :

Part No. Part No. Part No. Orifice Plate Support

Orifice Plate and Support Assembly Only

Identif ication Letter for

Orifice Plate Burner

Model No.

"A" "A"

"A" "A"

None None

None "8" "8"

" 8" "8" " 8"

"C" "C" "C"

"C" "C" "C"

"C" " C" "C"

" D" "D" "D"

"D" "D" "0"

" D" " D" " D"

"E2" "E2" "E2"

" E2" " EZ" " E2"

"FA1" "FA1" "FA1"

None None

None None

None None None

None None None

None None None

None None None

Mtg. Co.

Gas Port Informat ion for Series AB6119, AB6120, and AB6121 Burners

(LIGHT OIL) i Drawing SB-3707L 1-85

For f ir ing Atlas Generators and neutral pressure boilers.

Method for closing off gas porrs in Figure 4 is not ident~cal to Figures 1, 2, and 3.

Pipe Tapped SST Cover Gas Port L

Figure 1. Figure 2.

Atlas Boiler No. t

220 230 240 250 260 270 350 360 250 260 270 280

2100 21 25 350 360 380 390

AB6120-4.2-810 All None AB6120-4.2-B11 I Nonet I None

Figure 1.

2 to 6 (inc.) 1 to 6 tubes5

All All

2,4,6 2,4,6

All All All All

2.4.6 2.4,6

Atlas Burner

No.

A861 19-0.8-9 A861 19-1.3-2 A661 19-1.7-10 AB6119-2.1-5 A661 19-2.5-1 1 AB61 19-2.9-8 AB4119-2.1-12 AB41 19-2.5-13 AB6120-2.1-A15 AB6120-2.5-A16 AB6120-2.9-A17 AB6120-3.4-85 AB6120-4.2-63 AB6120-5.2-66 AB6120-2.1-A18 AB6120-2.5-A19 AB6120-3.4-08 AB6120-3.8-89

None 2.4,5,6

5,6 6

2,4,6 2,4,6 5,6

None None None 2,4,6 2,4,6

Figure 3.

Gas Ports Pipe Plug Position

All All All All All 7

All All All All 7

All All All All All All All

Atlas Boiler No. t

2200 2250 2300 3200 3200X

3250

Closed Of f SST Cover

Posit ion

None None None None None None None None None None None 5,6 6

None None None 5,6

None

Atlas Boiler No. t

2350 2400 3300 3350 3400

Atlas Boiler No. t

2500 2600 2700 3500 3600 3700

Atlas Burner

No.

AB6121-8.4-C7 AB6121-10.5-C5 AB6121-12.6-C16 AB6121-8.4-C11 AB6121-8.4-C71

Figure 2.

Gas Ports Closed Off Pipe Plug Position

2,3.4,6,8.9 2,3.4.6,8,9 2,3,4,6,8,9 2.3,4,6,8,9

2.3,7,8

2,3,4,6,8,9

Figure 3.

Tubes SST Cover

Position

2,3 2,3 2,3 2,3

2,3,5,7.8

2,3

Atlas Burner

No.

AB6121-14.7-Dl7 AB6121-16.8-018 AB6121-12.6-D20 AB6121-14.7-D21 AB6121-16.8-D22

Figure 4.

1.5.7 1,5,7 1,5,7 1,5.7

plugs 1,4,5,6,9

1,5,7

Atlas Burner

No.

AB6121-21 .O-E23 AB6121-25.2-E24 AB6121-29.4-FA68 AB6121-21 .O-E25 AB6121-25.2-E26 AB6121-29.4-FA67

Gas Ports Closed Off Pipe Plug Position

2,3 2,3 2 3 2.3 2 3

Gas Ports Closed Of f

3150 1 AB6121-6.3-69 3150X AB6121-6.3-814

SST Cover Position

2 3 2.3 2.3 2.3 2,3

Radial Position

3.4 3.4 3,4 3.4 3.4 3.4

2.4,6 2,4,6 tAll boiler numbers with prefix 2 refer to any 2-pass boiler with 1,2,3,7 Tubes 1 None neutral firebox pressure. 4,5,6 Plugs STubes assembled in all ports.

Horizontal Position

3,4 3,4 3,4 3.4 3.4 3,4

5 Bush holes '1," to % " IPS and install R590-6125s tubes. Orifice Plugs #11-13394-1.

PRINTED IN USA NA792-Sa3707L-600

North American 4/5/6131 BURNERS Linkage and Pressure Sett ings

Cleveland. OH 44105 USA Gas and Light Oil

The four (4) shutters of these units

#2 are vertical.

4131--0 Gas Burners 5131--2 Light Oil Burners ($1, X2, and X3 distillates) 6131--2 Gas:Light Oil Burners (# I , n"2, and #3 distillates)

Adjustment Sequence

1. Disconnect wing nut at gas butterfly valve. 2. Swing burner open. 3. Adjust rod D to dimension A. 8 4. Adjust rod F so that top shutter is Bo from vertical.

5. Adjust rod @so that tip of boaom shutter is C"or C0 from vertical.

6. Adjust rod @ so that oil valve indicator is at position Z at low fire.

7. Swing burner closed. 8. Connect wing nut at gas butterfly

valve.

9. Adjust rod @ so that gas butterfly valve indicator is at position X at

Gas Valve low fire.

Sketch shows linkage in low fire position.

Instructions apply only to burners with Honeywell M941 or M944 control motors. For other motors, consult North American

5 8 2 7 5 3 6 5 8 2 7 5 3 6 5 8 1 7 5 4 6 5 8 1 7 5 4 6

5 8 3 1 1 1 5 5 6 5 8 3 1 1 1 5 5 6

3 7 4 1 0 1 3 4 5 3 7 3 1 0 1 3 4 5 3 7 2 1 0 1 3 4 5

5 8 4 9 4 4 6 5 8 3 9 4 4 6

7 5 4 9 6 3 1 7 5 3 9 1 0 3 1

7 5 3 9 1 0 4 1

(over)

valve indicator positions gas oil oi l l o w high l o w X W Z

hole number settings J K R S T U V

Burner designation (wlcapacity setting in

millions Btulhr)

dimensions shutter & linkage settings

A " Y B ° C

NORTH AMERICAN Mfg. Co Cleveland. OH 44105 USA

Sheet 6131.8, 2-90 Page 2

4131--0 Gas Burners 5131--2 Light Oil Burners (X I , f 2 , and $3 d i s t i l l a t e s )

613;--2 G a s : L i g h t Oil Burners ( X I , 2 , and 83 d i s t ~ l l a t e s )

Pressure settings and capacities when f ir ing into a chamber a t neutral pressure

Burner designation (w/capacity

setting in millions Btulhr)

compressed air

WARNING. S~tuat~ons dangerous to personnel and o r o p e q can develop from incorrect operatlon of cornbusr~on equipment

North Amerlcan urges complnance w~rh Narlonal Safew Standards and Insurance Undemr~ters recommendar!ons. and care In operarlon

nozzle air press., psi no oi l l o w high

f l ow fire f ire

oi l relief valve

setting psi

regulator pressure, psi

l o w high f ire f ire

oi l nozzle pressure. psi l o w high fire f ire

Mfg. Co.

Gas Pressures for Gas and Combination Burners i 121 Service Manual

Section VII December, 1975

Page 3 ot 8

GAS PRESSURE GAS PRESSURE AT BOI LER BURNE R R4TE FROM REG. BURINE R &hi I FOLD

h e SDDE L >ODE L c f h I n c h e s rvc I n c h e s wc

1 OOX 3100"+ AB 121-4,2 4200 3 6 3.0 1003*:':+ AL-121-4. 2 3.6 3.0 -


Service Manual 121. Section VII Page 4 of 8

GAS PRESSURE GAS PRESSURE AT BOILER BUWE R RATE FZOM REG. BURNER ALAN1 FO LD

h P MODE L MODEL c f h I n c h e s wc I n c h e s wi.

* B o i l e r w h i c h h a s n e u t r a l o r n e g l . t i v e d r a f t i n f u r n a c e ** T h r e e - P a s s A t l a s G e n e r a t o r

*+:k T h r e e - P a s s A p o l l o G e n e r a t o r

Mfg. Co.

/

Wiring Diagrams All Service Manuals

Section VI becember, 1975

THlS SECTION CONTAINS WIRING DIAGRAMS THAT APPLY

TO THlS SPECIFIC BURNER

PRINTED IN USA

-6 AWO P I L O T a s m u n E L V U V E *I

w BLOWER MOTOR

3 9 0 / 3 1 5 0 TL.F.C.

AY 2 5 7 3 - 0 1 d A U 2 5 7 3 - 0 2

BURNER H l N a SW.

2 0 w z . .

U ICROSWITCH 4BZE6.2Rl45

COUBUSTlON A1R INTERLOCX

SWITCH 33 -9-34

Lb 8 7 5 7 - A 2 0 2

AU 2573-PSL. I

ASCO .021saz0 A Y 2579-P IP

P I L O T 0 1 s CRW/*EL V U V E 02

36 2

ASCO .0215GIO AM 2579.NP

O I L SOLENOID V u v E *I

6 1 + Z

ASCO .RE266CZIYL AM 2 5 7 9 - 3V - E A

O I L SOLENO10 V U V E * Z

6 1 +2

ASC 0 .RBZ66C219L AU 2 5 7 9 - E V - E B

UO(ULAIION NOTE : COMTROC MOTOR

HONEYWELL ALL TERMINALS SHOWN ARE .Y~UT-1000 JUNCTION 8 0 X TERM lNALS

Isurn LEO BY CUSTOUER U W M T E O 4 WIRE0 BY N A I

SHOWN BELOW

IR- M I N . CONOUIT I L L 5 E A L T I I E I I & 1 1 4 C O N T R O L :

2 2 2 O / I f i O ONLY 1

1 m-k:Fl ) ALL BURNER WIRING SHALL BE -14 AWG MINIMUM.

4 U A CLOSES 2 0 Y A OPEN5 CUSTOMER 1 0 S U P R Y PROPER SIGNAL

T E R U 73 1 0 7 5 4 1 COW

SHOP NOTE: 0 0 NOT CONNEC 7 TERMINAL

BLOWER T E R U I Y U BLOCK- R 8 4 0 - 8 0 1 9

2 T O T E R M I N 4 0

OWG. NO. A l l -5171

N l . m m O - N m P - N m - r l n m r n m r v r ~ - ? m m m f f l l n

Owe. NO. A l l - 5 1 7 0

A S S E M B L Y O F 12 X 10 N E M A 4 X J U N C T I O N B O X F O R BURNERS WITH INTEGRAL F A N

CAO SYSTEM CUAWINO - w nor REVISE UANUULY SHEET 1 OF 1

NO. A l l - 5 1 6 9

no . AII - 5 1 6 8

NORTH AMERICAN uo OUP 44Wb

NOT-\MERICAN ~ i g . CO. Clevc 1, OH 44105 USA

Part name

Air Shutters #2 Oil Modulating 4,5,6

Blower Housing

Blower Motor

Blower Silencer (opt.)

Blower Wheel

Crude Oil Blower Wheel

Blower Velocity Tube Assembly

Bracket - lgnition Transformer Mtg.

Bracket Sensitrol Oil Valve Modulating Motor

Deflectors Vertical Air

Burner size A B C CX (C71) Part name

Burner Compc \; 6131, 8-92 Page 2

Burner size I A B C CX (C71)

Gasket- Gas Sec.

Gasket - Gas Valve

Ignition Cable Assembly

Lifting Eye

Motor - Modulating

Alternate: Motor - -Air

Air Motor Bracket 11 -4902-3 1 1 -4902- 1 1 1-4902-2 1 1-4902-2

Mtg. Plate #2 Oil & Tile Ass'y

1 1-3790-3 1 1-3790-3 11-3712-1 11-3712-1 4.5,6

Mtg. Plate & Tile #2 Oil Ass'ylw SST

11-3165-2 1 1-3165-2 Jacket (opt.) 1 1-3782-1 1 1-3782- 1 - - Obs. Port Ass'y

for UV Detector 1 1-3533-2 1 1-3533-2 11-3213-1 11-3213-1 for Flame Rod

Spark Electrode

Flange

#2 Oil Gas 4,5,6,Cr

Gas Pilot Premix style

Spark Electrode Premix style I 11-10594-1 11-10594-1 1 1 -1 0594- 1 11-10594-1

3" R590-5160 3" R590-5160 4" R590-5170 4" R590-5170 Oil Atomizer #2 Oil Assembly 4 & 5

11-4130-1 11-4130-1 11-4130-1 11-4130-1 #6 with Series Wired 11-4080-1 1 1-4080- 1 1 1-4080- 1 Cartridge Oil Heaters

11-14165-1 11-14165-1 11-14165-2 11-7250-1 11-3762-3 1 1-3762-3 1 1-3762-2 -

11-4255-3 1 1-4255-3 11-4196-1 -

Alternate: Gas Pilot Piping Ass'y, Premix style

Gas Pilot Piping Assembly

Gas Pilot Air Velocity Tube Assembly

1 1-4527-1 11-4527-1 1 1-4527-3 1 1-4527-3

#6 with 115 V Parallel Cartridge Oil Heaters

Crude Oil w1115 V Cartridge Oil Heaters

Oil Nozzle R490-1171 R490-1193 R490-1 203 R490-,200 -

Crude R490-1230 R490-1230 R490-1200

Oil Nozzle Seal R490- 1291 R490-1291 R490-1291 R490-1293

Oil #2 Oil 11-91 12-1 11-9112-1 11-91 12-2 11-9112-2 Shutoff 4,5,6,Cr

Valve FM

11-3501-1 11-3501-1 11-3777-1 1 1 -3777- 1 Oil Valve, #2 Oil Sensitrol 4 & 5

Alternate: Gas Pilot Air Hose Ass'y, Premix style 11~14010~1 11-14010-2 11-14010-3 11-14010-4

#6 wlSeries Heaters & Thermostat

#6 Et Crude with 115 V

Gasket -Mtg. Plate 1 11-5926-4 1 1-5926-4 1 1-5926-5 11 -5926-5 ~ssemb ly Crude 1 11-5259-1 11-12289-1 1 1-3770-1

1813ME-02-8 1813ME-02-C 1813ME-02-D -

Gas Section z

Gas Valve #2 Oil (Butterfly) 4.5.6

n

@ ~ i r Motor with Moore Positioner and with low fire and high fire position switches. If Fisher or no positioner used, omit "P." If high fire switch not required, omit "H." If low fire switch not required omit "L:'

1 1-2334-4 1 1-2334-4 1 1-31 56-4 11-3156-4 Parallel Cart. Heaters (Less Thermostat)

11-3538-2 1 1-3538- 1

11-3310-2 11 -3310-2 1 1-3538-2 Orifice Plate #2 Oil -

& Support 4.5.6

- 1813MV-02-6 1813MV-02-C 1813MV-02-D

1 1-4282- 1 1 1-3528- 1 1 1-4762-1 1 1-7249-1 11-4282-1 1 1-3609- 1 11 -3770-1 -

Junction Box

NORTH AMERICAN Mfg. C o Cleveland. O H 4 4 1 0 5 USA

Parts for 4/5/6131 Burners Sizes CL, D, E, FA Inclusive

~ u k t i o n Box Oil Atomizer Assemblv- 35-4539-2

\ I

Shutter Hous

Blower Silencer-, HE i n g ~ \ A ,,- Junction Box Mounting Bracket

Deflectors - Vertical Air

r Gasket - Mounting Plate I I iri- Blower Air Interlock Switch R830-6733

Blower Wheel

Mounting Plate and Tile Assembly w lSST Jacket (Optional)

Oil Nozzle

Orifice Plate and Support Assembly

Burner Components 6 1 3 1, 8-92 Page 3

/ Oil Shutoff Valve Air Motor Oil Valve- Sensitrol Bracket

Alternate: Air motor with high and low switches

;ket- Gas Section


Blower Housing

\

Bracket- Sensitrol Oil Valve ---j / I , / I I ' Gasket Gas Valve

/ / - Motor - Modulating ---/ / I

Gas Valve Flange (Butterfly)

NQ 'RICAN Mfg Co Cle ., -)H 44105 USA

Burner Compq 31, 8-92 Page 4

Part name Burner size I CL D E FA

Air Shutters Middle Modulating End

Blower Housing Blower Motor

Blower Silencer (opt.) Blower Wheel


Bracket - lgnition Transformer Mtg.

Bracket #2 Oil Sensitrol 4 E t 5 Oil Valve #6

Deflectors Vertical Ail

Flange

Gas Pilot Mixer b Tip Assembly - Premix

Gas Pilot Piping

Spark Electrode Premix style

Gas Pilot Air Hose Ass'y, Premix style

Gas Section

Gas Valve (Butterfly)

Gas Valve Adapter

Gasket - Adapter (Burner Conn.)

Gasket - Gas Valve BurnerIAdapter Conn. Piping Flange Conn.

Gasket - Blower Discharge

Gasket - Mtg. Plate

Gasket - Gas Sec.

Ignition Cable Assembly

Junction Box Mounting Bracket

@Air Motor with Moore Positioner and with low fire and high fire position switches. If Fisher or no positioner used, omit "P." If high fire switch not required, omit "H." If low fire switch not required omit "L."

Part name

Lifting Eye

Motor - Modulating

Alternate: Motor- -Air

Air Motor Bracket

Mounting Plate Et Tile Assembly

Mtg. Plate Et Tile Ass'y with SST Jacket (opt.)

Obs. Port Ass'y for UV Detector for Flame Rod

Oil Atomizer #2 Oil Assembly 4 b 5

#6 with Series Wired Cartridge Oil Heaters

#6 with 115 V Parallel Cartridge Oil Heaters

Crude Oil ~ 1 1 1 5 V Cartridge Oil Heaters

Oil Nozzle #2 Oil 4 Et 5

#6 Crude

Oil Nozzle Teflon Seal Oil Nozzle "0" Ring Seal

Oil #2 Oil Shutoff 4,5,6,Cr Valve FM

Oil Valve, #2 Oil Sensitrol 4 Et 5

#6 wlSeries Cartridge Heaters Et Thermostat

#6 & Crude with 115 V Parallel Cart. Heaters (Less Thermostat)

Orifice Plate Gas Only Et Support Gas b #2 Oil Assembly 4,5,6

Crude

Shutter Housing

Burner size C L D E FA

R064-3021 R064-3021 R064 3030 R064-3030

R410-6329 R410-6329 R410-6329 R410-6329

1600-2-PHL@ 1 6 0 0 - 2 - ~ ~ ~ @ 1 6 0 0 - 2 - ~ ~ ~ @ 1 6 0 0 - 2 - ~ ~ ~ @

11-4921-1 11 -4921 -1 11 -4781 -2 1 1-4927- 1

1 1-6880-8 1 1-6880-8 11 -6880-9 1 1-6880-9

11-11545-6 11-11545-6 11-11545-7 11-11545-7

1 1-4896-2 1 1-4896-2 11 -4896-3 1 1-4896-3 11-5315-1 11-5315-1 - -

- 11 -3365-1 1 1-4208-3 1 1-4208-3 11-4027-4 1 1-4027-3 11-4251-1 11-4251-2

11-4190-1 11 -4190-3 1 1 -4827- 1 11 -4827-2

1-4190-4 11-4190-5 11 -4827-4 1 1-4827-5

11 -4190-4 11-4190-5 11 -4827-6 1 1-4827-6

- R490-1193 11-11421-1 11-11421-1 R490-1200 R490-1201 11-11421-2 11-11421-3 R490-1200 R490-1201 11-11421-6 11-11421-3 R490-1200 R490-1201 R490-1210 R490-1210

13490-1293 R490- 1293 - - - - R520-4417-V R520-4417-V

- 1483-01 1483-01 1483-01 1483-01 1483-01 1483-01 1483-01 1413-01-S 1413-01-5 1413-01-S 1413-01-S

- 1813MB-01 1813MB-01 1813MB-01 1813MB-02-D 1813MB-01 1813MB-01 1813MB-01

1813ME-02-D 1813ME-01 1813ME-01 1813ME-01

1813MV-02-D 1813MV-01 1813MV-01 1813MV-01

- - -- 11-4884-1 --- 1 1-4764- 1 11 -4059-1 11 -5863-1

11-3892-1 11 -5372-1 11 -5863-1 1 1-4008-1 11-5555-1 1 1-4888- 1 11 -5372-1 11-8314-1

1 1-3425- 1 1 1-3425- 1 1 1-4930-2 1 1-4930-2

Junction Box

35-4539-2 Junction Box Mounting Bracket

Deflectors - Vertical Air

Blower Silencer Gasket- Gas Section a

Gasket - Mounting Plate

Mounting Plate and Tile Assembly w/SST Jacket (optional)

Parts for 4/5/6131 Burners Sizes A, B, C, CX (C71) Oil Nozzle Seal

Blower Wheel

and Support Assembly

Blower Motor

Gas Pilot Air Hos Gas Pilot Assembly

Bracket- Ignition Transformer Mounting (Premix option shown)

lgntion Transformer 4065-6N 1 -6A

Piping Assembly

Flame Detector

Sensitrol Oil Val

Motor- Modulating

with high and low switches

SERVICE MANUAL SECTION 16, Page 13 June, 1978 Supersedes

OPERATING AND LUBRlCATlNG lNSTRUCTlONS septemaerv1g66

PANCAKE MOTORS STANDARD - BALL BEARING - WITHOUT GREASE FITTINGS

FRAMES 181 1-3281

1. AMBIENT TEMPERATURE 4. BEARING CONSTRUCTION

The ambient temperature of the air surrounding the motor Pancake motors are equipped with shielded bearings. The

should not exceed 400C or 1040F unless the motor has been end play i s restricred by a loading spring located in the

especially designed for high ambient temperature appli- front bracket bearing chamber. The machining of com-

cations. Obstructions should not be placed around the ponent parts i s such that thermal expansion of the shaft i s

motor to obstruct the k c + flow of air. permitred in thc front bearing bracket

2. WIRING 5. BEARINGS

Check the nameplate to insure that the correct power Bearing s i z e s and types used in this motor are shown on

supply (voltage, frequency, and phase) i s being used and the nameplate. For easy idcntification and simplicity, the

that the motor is connected according to the connecrion type numbers shown use the Fafnir nomenclature even

diagram on the nameplate. though some ocher make of bearing may be supplied.

Replacement bearings may be obtained from any bearing

3. OPERATION manufacturer or supply houee, or from Louia Allis Factory

Stock.

Th i s motor i s designed to operate with a maximum voltage

variation of plus a minus 10% from the nameplate voltage.

If these variations are exceeded, the motor may exc'eed the

nameplate temperature rise. In addition, i t should be

pointed out that the starting and breakdown torques vary

a s the square of the voltage. For example, a t 10% under

voltage, tire torques wi l l be 21% below the values a t

nameplate voltage.

Open G n s u u c t i o n Enclosed Gmstruction

COWRIGHT Q la71 LOUIS ALLIS P R l C U AND OTHER DATA S U W E C T

TO CHANGE WlTHOUT NOTICE Specialty Motors 8 Generators

SERVICE MANUAL SECTION 16, Page 14 June. 1978 Supersedes September. 1966

6. REGREASING

rnder normal operat ing condi t ions , i t i s only n e c e s s a r y t o r e g r e a s e a Louis Al l i s bal l bear ing motor every 2 to 6 years , de- s n d i n g on motor s p e e d and operat ing condit ions. T H E G R E A T E S T CAUSE O F BEARING FAILURE IS OVER GREASING RATHER THAN UNDER GREUISING. T h i s motor i s s u p p l i e d without g r e a s e f i t t ings to prevent t h i s overgreasing. It i s recommended char e a c h time t h e machine being driven by rhe moror undergoes a major overhaul , t h e motor should be d i sassembled , c leaned , and regressed. If the bear ings a re rough, they should be replaced. If new bear ings a r e ins ta l led , make cer ta in tha t the bearing s e a l s a r e on the i n s i d e , towards the rotor.

T h e following s t e p s should be followed: a. Remove the bearing bracke t ( f a n a n d cover on fan cooled units) . b. Remove rotor, shaf t and bearings. c. Wipe out the old g r e a s e from bear ings and bearing chamber. d. Repack the bear ings and bearing chamber with a recommended type of g r e a s e or equivalent . D O NOT pack bearing chambers

more than three-quiirters full. CAUTION: If the bearing chamber is completely f i l led with g r e a s e , overheating may occur.

7. RECOMMENDED REGREASING C H A R T S

For conscant , non-pulsating loads the maximum time recommended before regreasing i s shown below.

PRAM€ RECOMMEMED F R E W E K I O r

LUIIRICATIOY

CWPUD WIVES

mm

Note A: For any of the fol lowing s e r v i c e condi t ions , mulriply the time shown above by a fac tor of 0.75 1) Pulsa t ing or moderate s h o c k loads 3) Operation wirh shaf t vert ical . 2) Operation of more t h a n twelve hours per day. 4 ) High humidity condit ions.

Note B: For unusually s e v e r e operat ing condit ions, s u c h a s cor ros ive a tmospheres of chemica l fumes, ac ids , a l k a l i s , e x u e m e l y high humidity, or high s h o c k loads , more frequent regreasing may b e required or s p e c i a l g r e a s e s wi l l be recommended. Refer to Louis AUia o r consult a lubrication specialist.

i r L, 0

8. RECOMMENDED GREASES

l MOD

Icmo

llDOO

lMW

loam

LWO

ua

It i s recommended that t h e s e g r e a s e s or their equiva len ts b e employed in Louis All is Motors.

moo

-10oF to 1910F Ambient

Sunoco Cont inenta l Oil Co.

*Shell Oi l Co. Socnny Vacuum Oi l Co.

*Standard Oil of Calif.

Note: For high or low ambient temperature g r e a s e s , re fe r t o Factory.

High Humidity Condi t ions -10oF t o 1950F Ambient

Speaalty Motors & Generators

'These g r e a s e s a r e used i n cutrenc production of L o u i s Al l i s Horizontal Motors. t T h i s g r e a s e i s used in cur ren t production of Louis Al l i s Ver t ica l Motors.

Sunaplex 9 9 2 E P Conoco Superlube NlGL r2 Cyprina a 3 Mobilux x 2 C a l o l

P R I C E S A N 0 OTHER D A T A S U U L C T TO C ~ A N O E w t r n o u r NOTICE

Mobilux x 2 Hiremp

Shel l Oi l Co.

tStandard Oil of N.J. The T e x a s Co. T h e T e x a s Co. T h e T e x a s Co.

>

Andok "C" Uniternp Hitemp Regal Starfak A F B x 2

Cyprina ~3 Socony Vacuum Oil Co. T h e T e x a s Co.

P A : Q ~ ~ & TOTALLY SLOS ED I COOLED

REVISION I

1

SIZE OF CCXOUlT

TAP ON

1 D R I V E E N D EXTENSION 1 l l l l ! r l r x , r C y - l ; j A ~ IAK l e r IBE IBF sv PA --- b

3.12 .2%X.125 4.3€ i 3.12 ,230X.X.3

I I p - : 5 7 4 1 . a 4 . 6 2 .375~.18~,5.88/15.0~jifZCj 1.001 .50 1.531 14.561 3.50 5 - 0 3 13.00( . I

4 ,pz01ll5.63 l.6_rjd4.e22 .375~.1$8(5.8~(16.30(18.QX) l.CO1 .62 $6-101 3.691 4.76 6.12 113.501 \ 3202119.62 ;.- 4.62(.375~.l68~5.8~~16.00~1p:~1.~( .62 p ~ - l d 7.70) 4.76 6 - 22 113.54

INSTALLATION AND B U L L E T I N

MAINTENANCE INSTRUCTIONS 2-WAY DIRECT-ACTING SOLENOID VALVES

NORMALLY OPEN AND NORMALLY CLOSED OPERATION LEVER ACTUATED - 318,112 AND 314 NPT - FUEL OIL SERVICE

1 ; FORM NO. V.5987

DESCRIPTION Bulleun 8166 valves are 2-way. normally open or normally closed lever actuated solenold valbes. Valve bodies are o f forged brass construct~on and may be prov~ded with stainless steel or VITON' resilient scaring. The sore and the lever/disc sub-assembly are the only movlng parts. Valvec are offered w ~ t h or without a bypass feature for normally closed operat~on. Standard balves have a General Purpose. NEMA Type I Solenold Enclosure. Valxes may also be equipped u l t h an enclosure which is designed to meet NEMA Type 4 - \Vatert~fht. NEX1.A Type 7 (C or D) Hazardous Locations.Class I. Groups C or D and NESlA Type 9 (E. F or G) Hazardous Locations - Class 11. Groups E. F o r G. Installa- [Ion and Maintenance Instructions for the Explosion-Proof/U'atertight Solenold Enclosure are shoun on Form No. V-538 1. OPERATION Normally Closed: Valve is closed when solenoid is de-energized. Valve opens when solenold is energized. Normally Open: Valve is open when solenoid is de-energized. Valve closes when solenoid is energized. IMPORTANT: No minimum operating pressure differential required. INSTALLATION Check nameplate for correct catalog number. pressure. voltage and servlce. TEMPERATURE LIMITATIONS For maximum valve amb~ent and fluid temperatures, refer l o chart below. Check catalog number and watt rating on nameplate to determine the maxlmum temperatures.

POSLTIONING Valves must be mounted with solenoid vertical and upright above the valve body.

MOUNTING Two holes (201 diameter) are provided in the valve body for mounting. Refer to Figure I. PIPING Connect piping to valve according to markings on valve body (flow arrow). Apply pipe compound sparingly to male pipe threads only; i f applied to valve threads, i t may enrer the valve and cause operat~onal difficulty. Pipe strain should be avoided by proper support and alignment o f piping. \\'hen tightening the pipe, do not use valve as a lever. Wrenches applied to val\e body or p~p ing are to be located as close as possible to connection polnt. IMPORTAXT: For the prntection of the solenoid valve, install a strainer or filter suitahle for the service involved in the inlet side 3s close to the valve as possible. Periodic cleaning is required depending on service conditions. See Bulletins 8600. 8601 and 8602 for strainers.

WIRING Wirtng must comply with Local and National Electrical Codes. Solenoid housings are provided with accommodations or connections for 112 inch conduit. The general purpose solenoid enclosure may be rotated to facilitate wiring by removing the retaining cap or clip. CAUTION: When metal retaining clip disengages. i t will spring upward. Rotate enclosure to desired position. Replace retaining cap or clip before operating.

SOLENOID TEMPERATURE Standard catalog valves are supplied with coils designed for continuous duty service. When the solenoid is energized for a long period, the solenoid enclosure becomes hot and can be touched with the hand only for an instant. This is a safe operating temperature. Any excessive heating will be indicated by the smoke and odor o f burning coil insulation.

'DuPont registered trademark

MAINTENANCE WARSISG: Turn off electrical power supply and line pressure to valve before making repairs. I t is necessap l o remove the piping from the outlet end of the valve body for repairs. CLEANING A periodic cleaning o f all solenoid valves is desirable. The time between cleanings will vary depending on medium and service conditions. I n seneral. i f the voltage to the co11 is correct. slugg~sh valve operation. excessive noise or leakage will indicate that cleaning is requ~red. Clean valve stralner or filter when cleaning solenoid valve.

PREVENTIVE MAINTENANCE I. Keep the medium flowing through the valve as free from dirt and foreign marer~al as

possible. 2. U hile In service. operate the valve at least once a month to insure proper opening and

closlng. 3. Pertodic inspecr~on (depending on medium and service conditions) o f internal valve

parts for damage or excessive wear is recommended. Thoroughly clean all parts. Replace any parts that are worn or damaged.

IMPROPER OPERATION I. Faulty Control Circuit: Check the electrical system by energzlng the solenoid. A

metallic click signifies the solenoid is operating. Absence o f the click indicates loss o f pouer tupply. Check for loose or blown-out futes. open-circulted or grounded coil. broken lead wres or splice connectrons.

2. Burned-Out Coil: Check for open-c~rcu~ted coil. Replace cod i f necessary. 3. I.nw Voltage: Check voltage acros5 co11 leads. Voltage must be at least 85mo of name-

plate ratrng. 4. Incorrect Pressure: Check pressure at solenoid valve. Pressure to rhe valve must be

\rSlthin the range specified on the nameplate. 5. Thick Oil: Check oil viscosity. Some oils may be too thick for the valve to handle i f

the fluid temperature is decreased and may cause clogging and tricking. Oil viscos~ty should nor be greater than 5.000 SSU.

6. Excessive Leakage: Disassemble valve and clean all parts and passageways. Replace worn or damaged parts with a complete Spare Parts Kit for best results.

COIL REPLACEMENT (Refer to Figures 2 & 3.) Turn o f f electrical power supply and disconnect coil lead wires. Proceed in the following manner: I. Remove retaining cap or clip. nameplate and cover. CAUTION: When metal retaining

clip disengages. it wlll spring upward. 2. Slip yoke containing coil. sleeves and insulating washerr o f f the solenoid base sub-

assembly. Insulating washers (2) are omitted when a molded coil is used. 3. Slip coil, sleeves and insulating washers from yoke. 4. Reassemble in reverse order o f disassembly paylng careful attention to exploded

vlews provided for identificatron and placement o f partc. CAUTIOS: Solenoid must be full) reassembled as the housing and internal parts are part o f and complete the magnetic circuit. Place 3n insulating washer at each end o f coil. i f required.

VALVE DISASSEMBLY

Depressurize valve and turn off electrical power supply. For normally closed cnnttruction. refer to Figure 2. For normall) npen const~ct ion, refer to Figure 3. To determine vahe construction. see note under Paragraph 3. Proceed In the fnllnwing manner: 1. Disassemble valve in an orderly fashion paylng careful attention to exploded viewi

probided for identification and placement o f parts. 2. Remove retaining cap or clip and slip the entire solenoid enclosure o f f rhe solenoid

base sub-assembly. CAUTION: When metal retaining clip disengages. it ail1 tprlng upward.

3. Unscrew solenoid base sub-assembly and lift core'cpring assembly up\\ard. RernoLe solenold base gasket assembly. NOTE: A t rh~s polnt. valve construction ma! be determined. I f core assembly has two springs. the val\e consiruct~on is "Xormall> Closed" as sho\\n in Figure 2. I f core assembly hac one spring. val\e construc:ron IS

"Normally Open" as shown in Figure 3. 4. Cnscrejv union nut and disconnect piplng from connector ( i f necessary) at ~a lbe outlet. 5. Remove connector gasket from connector. 6. Holding connector securely. unscrew seat. Remove seat gasket and spacer from

connector. NOTE: I f the seal being removed has a notched groove cur into the hex. the "SPACER" will be omitted.

7. Remove the lever/disc assembly by inserting a stiff piece o f wire (or similar tool) with a hooked end into a hole in the disc guide. Pull lever/disc assembly from valve body. The hole for removal i n the disc guide will be at the bottom for normally closed construction and at the top for normally open construction.

8. Once the lever/disc assembly is removed, be careful not to allow lever pin to slip from assembly. Disassembly o f this part is not required. However. should this pan become disengaged. it may be reassembled by following illustrations provided i n exploded views.

9. Remove core/spring assembly from valve body. NOTE: Upper core spring is only present in normally closed construction.

10. A l l parts are now accessible for cleantng or replacement. Replace worn or damaged pans with a complete Spare Parts Kit for best results.

A S C 0 Valves, Form NO. V-5987 I N U-S.A. h m ~ S m h CU. FLORHAM PARK. NEW JERSEY 07932

. . @ SWftCh Ca 1979.ALL RIGHTS RESERVED

VALVE REASSEMBLY Rcwcmble i n reverse order o f disassembly paylng careful nttrntlon to exploded and cut-away views provided. Determine vslve construction i.e. normally closed or normally open and select the appropriate reassembly instructions below.

NORMALLY CLOSED CONSTRUCTION (Refer t o Figure 2.) 1. I t-bricate all gaskets including soleno~d base sasket assembly with Dow Corning

oration's MOLY KOTE' valve seal silicone compound or equivalent. 2. itancously install core/spring assembly (with upper and lower springs) through

sarrnoid base sub-assembly opening and lever/disc assembly through outlet openin; In valve body. As they are being installed. position lever in hole i n bottom o f core. Be sure to position lever/disc assembly so that the lever pin is at the top.

3. Check the engagement o f the core/spring assembly w ~ t h the leverldisc assembly by lifting the core directlv upward. Core should remain engaged and movement i n the lcver/disc assembly noted.

4. Replace solenold base gasket assembly. Flat surface o f solcnoid basc gasket assembly to seat in valve body. Rounded surface (gasker area) to face solenoid base sub-assembly.

5. Replace solenold base sub-assembly. Torque solenoid basc sub-assembly to 175 i 25 inch-pounds [ I 9 3 c 2.8 newton mctersl.

6. lnstall spacer. seat gasket and seat into connecror. IMPORTANT: Omit "SPACER" when seat with notched groove cut Into hex is supplied i n Spare Paris Kit o r standard with valve. For metal seated valves (Suffix "L" in Catalog Number) torque seat to 110 r 10 inch-pounds I12.4 r 1.1 newton meters]. For resilient seated valves (Suffix "V" in Catalog Numberl torque scat to 90 t 10 inch-pounds [10.2 z 1.1 newton meters/.

7. Replace connector gasker on connko r . 8. lnstall connecror and union nut l o valve body and piping, i f rernoved. Torque union

nut to 50 e 5 foot-pounds (68 i 6.8 newton mctcrsl. 9. .Replace solenoid enclosure and retaining cap or clip.

10. After maintenance. operate the valve a few times to be sure o f proper operation.

r 1

(USE0 ON NORMALLY CL0SE.Q CONSTRUCTION ONLY1

SPARE PARTS KITS

Spare Parts Kits and Coils are available for ASCO XalXes. Parts marked u i th an asterisk (') aresupplied in Spare Parts Kits.

NORMALLY OPEN CONSTRUCTION (Refer t o Figure 3.) I. Lubricate all gaskets including solenoid base gasket assembly with Dow Corning

Corporation's MOLYKOTEa valve seal silicone compound or equivalent. 2. Simuitancously install core/spring assembly (lower spring) through solenoid base sub-

assembly opening and Iever/disc assembly through outlet opening in valve body. .As they are being installed. position lever i n hole i n bottom o f core. Be sure to posit~on Icvcr/disc assembly so that the lever pin is at the bottom.

3. Check the engagement o f the core/spnng assembly with the le\er/disc assembly by lifting the core directly upward. Core should rematn engaged and movement i n thc lever/disc assembly noted.

4. Replace solenoid base gasker assembly. Flat suriace o f the solcno~d base _rasker assembly to seat In valve body. Rounded suriacc (gasket area) to iace io lcno~d base sub-assembly.

5 . Replace solenoid base sub-assembly. Torque solenoid base sub-assembly ro 175 _c 2.' inch-pounds (19.8 = 2.3 newton rnetersl.

6. lnstall spacer. seat gasket and seat into connector. IhlPORTAhT: Omit "SPACER" when scat with notched groove cul into hex is supplied i n Spare Parts Kit o r standard with valve. For metal seated valves (Suffix "Lo in Catalog Number), lorque sear to 110 2 10 inch-pounds (12.4 2 1.1 newton meters]. For resilient seated valve: (Suffix "V" i n Catalog Number) torque seat to 90 1 10 inch-pounds (10.2 + 1.1 newton meters].

7. Rcplacc connector gasket on connector. 8. lnstall connecror and union nut to valve body and to pip~ng. i f removed. Torque

union nut to 50 2 5 foot-pounds (68 2 6.8 newton meters]. 9. Rcplacc solenoid enclosure and retaming cap or clip.

10. After maintenance, operate the valve a few times to be sure o f proper operation.

POSITION LEVER PIN

7

NORMALLY OPEN CONSTRUCTION LEVER/OISC AN0 WREfSPRING ASSEMBLY PLACEMENT

1 OUTLET 1

[@ 5,d r .201 DIA .

2 MOUNTING HOLES \ C38, Jl Fl W- I NCHES * ORDERING INFORMATION

FOR SPARE PARTS KlTS

When Ordering Spare Parts K i t s o r Coils, Specify Valve Catalog Number,

Serial Number and Voltage.

i.

Figure I. Mounting Dimensions

A S C O Valves

S m h CO. FLQRHAM PARK. NEW JERSEY 07932 N0.V.5987 PRINTED IN U.S.A. 1979

RETAINING CLIP*

(NSULATING WASHER(2) (OMITTED WHEN MOLDED COIL IS USED)

SOLENOID BASE SUB - ASSEMBLY

VALVE BODY

IMPORTANT: OMIT SPACER WHEN SEAT WlTH NOTCHED GROOVE CUT INTO HEX IS SUPPLIED IN SPARE PARTS KIT OR STANDARD WlTH VALVE.

U ~ I O N NUT

NOTE: FLAT SURFACE OF SOLENOID BASE GASKET ASSEMBLY TO SEAT IN VALVE BODY. ROUNDED SURFACE TO FACE SOLENOID BASE SUB-ASSEMBLY.

I I Bulletin 8266 - Normally Closed Construction

Cenenl Purpose Solenoid Enclosum Shown. Figure 2. For Explosion Proof/Watenight Solenoid Enclosure. See Form No. V-5381. J

SPARE PARTS KITS*

TORQUE CHART

Solenold Base I Sub-Assembly

Part Name

RETAINING CLIP*

(Foor.Pounds)

NOTE @ Suffix " V " in caralog number indicxec revlirnr teal. - Surf:\ "L" in cnlaiog number indisarec me~ai sear.

INSULATING WASHER (OMITTED WHEN MOLDED COlL IS USED)

SOLENOID BASE SUB- ASSEMBLY

INSULATING WASHER (OMITTED WHEN MOLDED COlL IS USED)

SOLENOID BA GASKET ASSE

VALVE BODY

TO SEAT IN VALVE BODY. ROUNDED SURFACE T O FACE SOLENOID BASE SUB-ASSEMBLY.

IMPORTANT: OMIT SPACER WHEN SEAT WITH NOTCHED GROOVE CUT INTO HEX IS SUPPLIED IN SPARE PARTS K I T OR STANDARD WITH VALVE.

I Bullelin 8266 - Normallv O ~ e n C o n s t ~ c l i o n \ .

Torque Value Inch-Pounds

General Purpose Solendid ~nc losure Shown. Fleure 3. For Explosion Proof/Watenipht Solenoid Enclosure. Set Form No. V-5381.

Torque Value Scuton Melen

A S C O Valves

h m ~ S m h CU. FLORHAM PARK. NEW JERSEY 07932 No' V.5987 PRINTED IN U.S.A. 1979

INDEX NO. 2

GAS PILOT ASSEMBLY

NP-A , N P - B

North American Premix Pilot Assembly 4/5/6131-A th ru -FA

Cleveland, OH 44105 USA Packaged Burners

Ref: Dwg. KC1 1.8139

-, . ., . ,. , . . , . - , , , , L - , , ,,.? I nls pllor IS suppllea as a stanaara on .v , t , ana rn racKagea uurners. nvallaole as a specla1 on A , u , ana L Burners.

; I , , , ,

;,,:::;; ,, ,.%,!- - - - ,- -> -. \2- 2nd Soleno#d Valve 8 , , .-. furn~shed when 1 , ' - cal led for on order

- - - - - - - ' 13' +x - ' Regulator requtred

only when gas pressure exceeds 2 p s ~

% ' for

ITEM

1 2" 3 4* 5 1 61 7 8 9 10 11 12 13 14' 15

DESCRIPTION

Pilot mixer assembly Electrode housing Ignition cable 14 GA. Assy. lgnition electrode Hose fitting % " mpt Quick disconnect hose fitting % " fpt Air hose assembly Pressure gauge 0-5 psi Needle Valve % " Ball Valve 3/," Regulator % " Pilot solenoid valve % " fpt Regulator % " fpt Pilot tip and cap assembly lgnition transformer

PART NO.

1 1-7478-2 1 1-7476-2 11-491 1-4 11-10594-1 R210-2181 R210-2178 See Table 8735-0. 1836-03 1 821 -02 7344-01 1486-01 7345-01 - H 1 1-7558-1 4065-6N 1 -6A t

Air Hose Assembly

Burner Part No.

Included in Item 1. nlncluded in Item 7. t Transformer for 120160. With 110150 Part No. is 4065-5N1-6A.


Sheet 6131-5, 9-89 Page 2

PREMIX PILOT ASSEMBLY AND ADJUSTING PROCEDURE

The following adjustment procedure is recommended: This should be a steady signal of 2 microamps with a Honeywell programmer. With Fireye, refer to the ap-

1. Install a manometer at Item "A". propriate Fireye bulletin for required signal strength. Return test switch to "Normal" position.

2. Turn the burner on manual purge and measure the combustion air pressure at the port on the tee on which the 7. The burner should be recycled a number of times to prove manometer has been installed. This pressure should read pilot reliability. at least 4"wc.

NOTE: When adjusting an 11-7478 Pilot Assembly, the An alternate method for adjusting the premix section of the

spring in ltem #11 17344-01 ) should be completely relaxed. mixer for correct on-ratio firing is to use the following pro-

3. Remove the manometer. cedu,re with an 8666 Pilot Testip:

(a) Remove pipe plug from top of mixer and connect pilot 4. Remove cap and screw in the gas mixer valve (Item "B") testip.

until it bottoms and is closed. The mixer valve is then backed out four (4) complete turns. The raw gas valve (Item "C") located at the back of the mixer should be closed. (b) Firmly bottom mixer valve (Item "B") and back out four

(4) complete turns.

5. Start burner and allow pilot to light. Observe the pilot flame. This flame will be approximately 3-4"long and should have (c) Close raw gas valve (Item "C").

a sharp, blue cone appearance; it should not be fluttery. If the flame appearance is not sharp, turn the mixer valve (d) Turn on pilot and adjust mixer valve (Item "B") by turning

1 >/4 turns either way to achieve this appearance. Replace slowly first one direction and then the other until pilot testip

cap. and pilot light.

6. At this point, the burner will go off on "flame failure." The (el Observe flame on pilot testip. Base of flame should be

burner programmer is then reset and the burner turned on. securely seated inside testip. Adjust mixer valve to make

At this time, the raw gas valve (Item "C") between the mixer sure that base of flame is securely seated in pilot tip.

and the upstream gas pressure is opened so that pressure gauge reads no greater than 1 ?4 psi. The programmer will ( f ) Turn off pilot. Remove testip and reinstall pipe plug. Pilot then recycle to the pilot period and the pilot flame should should now be on-ratio. Proceed as instructed in Item #6. be approximately 9-10" long. Move the programmer test switch to the "test" position so the pilot is held in the pilot (g) Burner should be recycled a number of times to prove pilot cycle. The flame signal strength should now be observed. reliability.

WARNING: Situar~ons dangerous to personnel and properry can develop from incorrect operation of combustion equipment. Nonh American urges compliance with National Safery Standards and Insurance Undemr~ters recommendations, and care In operation.

PRINTED IN USA

I N D E X NO. 3

PILOT GAS SOLENOIDS

INSTALLATION AND MAINTENANCE INSTRUCTIONS

2-WAY INTERNAL PILOT OPERATED SOLENOID VALVES HUNG DIAPHRAGM - 318,112 AND 314 N.P.T.

NORMALLY CLOSED OPERATION

DESCRIPTION Bullctln 8215's arc 2-wa\, n o d l y c l w d . rn~ernal prloc operated solenold valva havlnp drc RSI rlumrnum bodrn Standud valves have a General Purpose. NEMA Type I Sohord Enclosure. Valve may k ayu~pped wtth M enclosure whrch 1s darpned to mcn NEMA Type 4 - Watcmght. NEMA Type 7 (C or Dl H u u d o u s Loattons - C h 1. Group C or D and NEMA Type 9 IE. F or GI H ~ ~ a r d o u s b a t t o n s - Class 11. Croups E, F or G. For l d k t r o n and M~lntenancc Instruarons for Explos~on-PrwfAVatm~@t Solenoad E n d a u r a . see Form No. V-5380

OPERATION hornullv C l d Valve a dosed when soleno~d rs de-cnnpued Valve opens when soienord rr enerpzcd IMPORTAST: h o rmslmum operatrag pranrrc dlflerrntml rcqu~rcd.

INSTALLATION Cntck nameoutc for corrm catalog numbc. prcssurc. vottagc and semcc.

TEMPERATURE LIMITAT IONS For murmurn valvc ambrmt Wd n u ~ d tcmaratures. refer t o chan below. For hinher u n b ~ m r anC nurd ~cmpea tu re I~m~ta t~ons , mnsull faaory. Check u t u o g number on narncplalc to dnnmrne murmurn lcmpcntures.

CLEANING A aerrodrc cleanrnr of all solcno~d valves Ir dcslrahlc. The trme bowccn cleanrngs wit: va; ocpendrng up& meala and scrvlce cond~trons In general. rf t h ~ vollage lo the Cot' IS correc:. sluggish valve opcratIon. excessrve noru or leakage w~ll ~nd~cn lc that c l u n l n ~ n reourred Be sure lo c l a n valve strarner or filter when cluntng rolcnord valve PREVENTIVE MAINTENANCE 1. keep the medrum nowrnp through the valvc zr f r e e from d ~ n and forcrp m a l n l

as poss~blc 2 Whrlc rn servrcc operale the valve at leas: once a month to Insure p r o m O m l n t

and clos~ng 3. Prnodlc rnspcclron idcpend~ng on mcdta and servrcc condruons) of lnlernai valve

pans for aamapc o. exccsslvc wear I< recommended Thoroughl\ c l a n all pan5 Replace an\ panr [ha: are worn or damaped

IMPROPER OPERATION I. Fault* Control CIMII: Checl tne eiectncai svstem b) energlung the roleno~d. A

mnaliic cl~ck srpnifies the solenoid Ir operaung. Absencc of tnc clrcl rndratn loss O! power supply. Cncci: for loose or blown-ou: fuses. opm-c~rcu~ted or grounded coil. broken lead w r n or spllce connecuons.

2. Burned-OutCoil: Check for open-circu~ta coil. Replace coil i f nccerur).. 3. Low Voltuc: C n u ~ for voltage across coil leads. Voltage musl be at 1-1 85% of

POSITIONING A:C Construa~on (Altcmu~nn Currcntl: Valve is da t rned t o d o r m o m a r l v when

Coaamnmn

A-C Construclron (Alternaunp Cunen t~

Lnud in m y poutlon. ~ d w - for opclmum l i f e ' d pchormana.. the solenoid bid k mounted v m r d and upnbht w u t o d u c e the pordbiirty of f o r a p matter

- ~ ~ ~ ~ u L t r n g rn the am lube rrer

D-C Commnron (Direct Current): Valve muR k mounted wirh solenoid vcnlcal m d U ~ t .

MOUNTING For moununp bracket (op~ional feature) dimensions. ref- t o Figure 1.

PIPING

. - M w m u m Mrnmum namcp~a~eAtrng Ambnnl - Prefix

4, lncomct Prarurc: Check valvc pressure. Pressure to valvc must be wtth~n nnFe Temp. O F Temp. O F spmficd on nameplalc

5. -vr Leakate: Dtsasscmble valvc and clean all pans. Replace worn or m e e d

.

b n n e c , plorng to n ) \ e according to nurk~ngs on d v e bod?. Apply p i p compound sponngly lo male p ~ p threads on&; if applred to n l v c threads. 11 m y enter vdve and c r u x o m r ~ o n a l difficult). PI^ n r u n should be avoided by proper suppon and alignment of prpmg. When ufircnrng pip. do not usc valve u a lever. Wrenches applied to vlive body or piping uc to k locud u dQc u possible t o m n n a i o n porn[. CAUTlOk: To m r d d co tk r3rr W.. W NOT OVEKnCHTEN PIPE CONNECflONU- m..rerq. a hbrknt k wed. WR am crr drr I0 r e 4 4 Irkxiom. IMPORTAM: For l b e p r o c e d a of tLc rdadd .rhr. -1 a W w M+s u t u b k f w ~ r ~ h i n r d + + d k ~ ~ r i d c a ~ l o ( k r J ? a ~ o r H L c . P m o d ~ c h m i ~ h ~ . i r c d . ~ a r r r * r ~ ~ & Y + ( m r 1 6 0 0 . ~ 1 and a t lor nniam.

A hone 1 104 1 10c

F I TT 1 I I 12: i

WIRING Wlnng muw comply with W and N u j o d E l a r i d Coda. Housings for all sok- no~ds are made W I I ~ accoMaoduionr or m n n a i o n s for lC! inch condu~r. The p a d purpose solenoid enclosure m y be rowed to fui i iuce wiring by m o v i n g the mainimp cap or c11p. CAUTION: Whm mcul mainjag d i p d i s a ~ p t a it win spring upwud. Route to desired position. R c p b rrrrrining a p or d i p before opaamg. NO- Ahrrutimg C.-t ( A 4 d C u r a t 0 rderddr ~c kYr difkr- attr. To mrcn from ow to tk o(La. k k - to c b q c tbe mmCLdc - . i d . d i g U c r o r r l ~ ~ 8 m d . d a o # L . w a C l l s b l y . e n l E ~ ~

undrrd &og vrlvei are supplied rith & dmgned for amtinoau duty rmia. Whm wlcnoid n rnerpred for a hag paiod. the soleaaid mdowrr kcomer hot and a n be touched with the h.nd only f a M irrcunl. This k a d e 0-n; tcmpcrullre Any exasnn heat~ng will k krdiauod by the smoke .ad odor of burning mil i n ah - aon.

pans wtth a compterc Spare Pans KII for bes: mu l l s

COIL REPLACEMENT (Refer to Froure 1 ) Turn off clectncnl w r c r suool\ and dtsconnst coil Iesd wrm.

MAlNT ENANCE WARNING: Torn off Cora np& ud -* --drs. It b mot vcsy t o rrrorr tk ..)rr lrmm tk dF for * AN ATTACHED DIAPHRAGM DLSC .. .

- -

l . -~cmove retalnrnf car & 'AID. namcpiatc and houslnp CAUTlOh.: When melai rctlrninp clrp drscngapes. I: will sprlne upwart

2. S11p sprrng wasnc:, rnsutatlnf wash& and coil off lhc solcnord bate subasrcmbl!. lnsulal~ng wvhcrr arc omrtted wnen a molded coil Is usec

3. Reassemble In rcvcrsc oroer of drsasumbly pannp careful attcnrron lo exploded view prorided for iaenlifiutron and placement of parts.

C A U n O h : Soknoid must k full! ruscmbkd r r the housing m d intnnll plnr ur . pan of m d compkrr the nmgnau a m t i . P i r c M imulatlng rnkcr in each clld of mu. If ~ u i ~ .

VALVE DISASSEMBLY AND REASSEMBLY (Refer to Figure 1) Deomsmrm valve u d I- off rkclrid p o r n ruppl?. Proceed b Uc fdloricy uucr: 1. Remove retainln~ u p or clip and siip the entire solenoid endosure off the soknoid

base subrrsmbl! . 2. Unscrew solenoid bare subassembly and remove solenoid base w k a . 3. Remove bonnel screws (4). valve bonne:. corc/d~aphngm sub-ruonbl?. and body

pukel. The corcldraphnpm s u b u x m b l ? . is comprised of a rider ring. core sPmb. corc puidc. hanger spnng. corc uwmbl?. and diaphragm assembly. Do not d~ston hanger spnng between corc assembly and d~aphragm assembly.

4. All pans arc now accessible for clanrng or rcplnrrmen~. Rcphcc worn or d m a M pans wrth a complnc Spare Pans Kit for k c raults.

CAUTION: B U L L m h ' n1SC SERIES PARTS ARE NOT INTERCHANCUBLE WITH BULLETIN n l S B V A ~ V E S WHlQI CONTAIN A DIFFEREhT BODY AND - - - - - - - - - . - -

AN AITACHED DU~HRACM DISC CHECX THE NAMEPLATE ON THE VALVE BEING REBUILT FOR PROPER IDENYDWXTION. TD FIGURE 1 FOR YlSUAL I D E K n n C A n O N OF PARTS. . - .~ - -

5. RcasxmSlc in mnre order of d i i b l y ~ * r i g c r~e fu l attcnuon to a p l o d d new provided for idendfiutron and placement of pans.

6. R m k bodv easke! and corr/diaphrapm sub-assembly. Locate bleed hole in dip- 7 - - p h w ass&61! approumately 4 5 O f r o b valve outlet

7. Rcpiacc valve bonnet and bonne: screws. Torque screws In a nrsr rors manner to 95 + I0 ~nch-pounds.

8. Innall solenoid base m k e : and solenoid base subasscmbly. Comprcsr rider ring drghtly to prevent damage when ima l l~ng soleno~d b a u subusrmbls . Torque loie. noid h e s u b - m b l v 10 175 2 25 inch-pounds.

9. Repiace solenoid enclosure and m u n i n g clip or u p . 10. After maintenance. o ~ e the valve a few. times to bc sure of proper opning m d

doring. . SPARE PARTS urrs

Spare Panr,Kits and Coils am avaihblc for ASCO YJvs . Pans marked w t h an m m s k (') are supplred rn Spve P w Kits.

ORDERING INFORMATION FOR SPARE PARTS K I T S

When Ordaring S p m P u t s Kits or Coils, Spec4fv Valve Camlog Number,

ASCO Valves . .Esbp Fom No- Va485R2 PRWlf!O IN U S A 1971 SWftCh CO. FLORHAM PARK. NEW JERSEY 07932 '

obmtammh SIRltch Ca n n . u L - . o u m o

#RTlAL wcw a YOUVTIN@ WIICKET

(OPTlOMAL)

RETAINING CLIP*

RETAINING CAP* * NAMEPLATE

SUB -ASSEMBLY

SOL

INSULATING WASHER (OMITTED WHEN MOLDED COIL IS USED)

112 INCH CONDUIT

1NSIILATl)JG WASHER (OMITTED WHEN MOLDED COl L IS USED\

BASE PLATE (%-fa SUB - ASSEMBLY I I

.ENOI~ BASE GASKETL

E T

(OPTIONAL)

VALVE BONNET

&----.RIDw RING*

IN A CRISSCROSS MANNER

CORE/OIAPHRAGM SUB -ASSEMBLY

CORE SPRING* fll FED HOLE

CORE ASSEMBLY*

HANGER SPRING* BODY GASKET*

DIAPHRAGM ASSEMBLY

VALVE BODY CORE/OlAPIlRAGM SUB.

ABBEMBLY APPnOXlMATELY

SIIOWING TtIE DIFFERENCE BETWEEN BlJLLETlN 8 2 1 K A N D 8215@ PARTS.

BULLETIN 82158 COnEIDIAPliRAGM

BUI I.€TIN 82158 IIAS A N AT'TACIIED DIAPIiRAGM DlSC

NO DIAPIIRA(;M DlSC -

WIIICti CONTAIN A OIFFEHENT BODY AN0 w A 1 IM!++LO DIAPlinAFM DISC.''

Bmlklln 8215 C:rmnl Prr)6.. Poknold F.nrlnrun Shown.

For txptntlnn FrooVW~t t r ( knnlal Kntlnrlln, Str Form NII. V-5380. . . I L- -

INDEX NO. 4

P I L O T GAS REGULATOR

P C V - 0 2 5 - A , P C V - 0 2 5 - B

P I L O T GAS REGULATOR

P C V - 0 2 8 - A , P C V - 0 2 8 - B

Ref: Bulletin 40.15, Supplement 40.15-2

Atmospheric Pi lot Regulators If inlet gas pressure exceeds 1 psi to the 7350-A or 2 psi to the 7218, use a pressure-reducing regulator upstream. 7344

"Zero gas" pilot systems require an atmospheric regulator to Regulators reduce up to 25 psi gas to 4-12"wc-see page 2. supply gas at zero gauge pressure to the pilot mixer. The 7350-A is suitable for single pilot installations; for multiple tips For capacities or inlet pressures beyond the range of 7344 manifolded off a common mixer, use 7218 Regulator. Regulators, see Bulletins 73.37 and 73.49.

7350- -A and 7350

Maximum recommended capacity is 303 scfh for the % " Max imum Inlet Pressure: 7350- -A: 1 psi, 7350: 2 psi regulators and 274 scfh for the 3/,"regulators. These capacities Outlet Pressure Range: 7350- -A, - 1 "wc to 1 . 5 " ~ ~ . occur at 2 . 5 " ~ ~ pressure drop. 7350: 3"wc to 6"wc

Gases: Natural, LP, LP gas-air Max imum Ambient Temperature: 200 F (90 C ) Max imum Emergency lnlet Pressure: 5 psi Instal lat ion Position: No limitation

Gas Gravity Correction Factors--For a gas gravity different from 0.6 multiply the regulator capacity by the appropriate gravity factor.

Capacity. scfh of 0.6 gravity gas

721 8 Max imum Inlet Pressure: 2 psi Outlet Pressure Range: - 1 "wc to + 1 "wc Gases: Natural, LP, LP gas-air Maximum Ambient Temperature: 180 F Maximum Shock Load: 4 psi Installation Position: horizontal run of pipe only, with diaphragm below pipe

Gas gravity 1 0.4 0.6 0.8 1.5 2.0

Pres. Drop Across Regulator. "wc Vent

0.1 0.2 0.3 I/," fpt

Metric Conversions

Wt.

8 8

Regulator Designdtion

7218-0 7218-1

1" = 25.40 mm 1 "wc = 25.40 mm H20

7350-02-A -- 7350-02 7350-01-A

7350-01 60 85 105

Dimensions in inches

Dimensions in inches A B C D E F G H I b

% 211/32 7 % 3l5Il6 l 7 67/8 8% 2% 1 211/32 7 % 315/rs 2l/qe 67/8 815/16 2%

1 osi = 43.94 mm HtO = 0.W 39 kg/cm2 C = 'lg 1F - 32)

1 psi = 0.0703 kg/cmz = 703.1 mm H20 1 scfh = 0.028 26 srn31h = 0.026 86 nm31h

1 Ib = 0.4536 kg

Designation

7350-02/02-A 7350-01/01-A

To Atmosphere

Grav i ty fac tor 1 1.22 1.00 0.868 0.632 0.547

Pressure Drop across Regulator, osi

Capacity, scfh 7218-0 of 0.6 gravity gas 7218-1

A B C D E -

' I s 2 2 'Y16 ?I,8 !h 2 2 'Il 3916

1 2 2.5 3 4 6 8 10 12

176 250 280 305 352 433 560 612 282 400 448 a 564 692 8 0 895 98U

Swing Radius

2$18. 2'Is

Approx. Wt, Ib

!h !h fpt = female pipe thread

NORTH AMERICAN Mfg. Co. Cleveland, O H 44105 USA

Supplement 40.15-1, 9-86 Page 2

Pressure-Reducing Regulators

7344-01 and -1 I--G-cl

B-fpt-Vent to atmosphere

I

7 H

----- - I3=3

A-fpt

i_ _I inlet out let

Max imum ln let Pressure: 10 psi Outlet Pressure Range: 4"wc to 12"wc Gases: Natural, LP, LP gas-air Max imum Ambient Temperature: 200 F Max imum Emergency Illlet Pressure: 65 psi Installation Position: Any position

Regulator Dimensions in inches Wt. Designation 1 A B C D E F G H 1 Ib

Gas c-- ivi ty Correction Factors

For a gas gravity different from 0.6, multiply the regulator capacity by the appropriate gravity factor.

7344- 1 Inlet Pressure, psi

0.5 1 2 5 10

400 495 560 674 660 300 420 550 625 620 200 300 395 500 480

Capacity, scfh of 0.6 gravity

gas

Outlet 4.0 Press., 6.0

"wc 8.0

Gas gravity 1 0.4 0.6 0.8 1.5 2.0

7344-01 Inlet Pressure. psi

0.5 1 2 5 10

180 273 384 428 360 155 243 310 392 340 122 212 263 310 288

- -

Gravity factor 1 1.22 1.00 0.868 0.632 0.547

SOLENOID VALVES 1485-01, 1485-02, and 1486-02

Solenoid Valve Number 1 1485-01 ( % "l 1485-02 (3/8"1 1486-02 (3/8"1

Capacity with 1"wc drop, 0.64 sp gr gas 201 scfh 65 scfh 55 scfh Maximum pressure 10 psi 100 psi Weight % Ib 1 % lb

PRINTED IN USA

a. hole Conduit sides

+ 1 " 4 X 2"/." wide

nnect

-- fpt

id Out

94r x l'ld,,r wide

dia. hole K" Conduit

Specify electrical characteristics: 115/1/60 or 50, or 230/1/60 or 50

propeny can develop from incorrect operation of combustion equipment. Nonh American urges compliance

INDEX NO, 5

PRESSURE GAGE

PI-008-A, PI-008-B

8735 Pressure Gauges with English and Metric Scales

North American 3 \

Gauge designation

Mfg. Co.

Range ( f rom zero)

12"wc (300 rnm H201

+ 30 osi If 1250 mm H201

32 osi (7400 mrn H201 35 osi (60"wc)

PRESSURE GAUGES

5 psi (250 rnm Hgl 15 psi 11 kg/crn21

30 psi 60 psi

BULLETIN 8735

L Cleveland, OH 44105 USA

30 psi (2 kg/crn2/ 30 psi 12 kg/crn21 60 psi (4 kg/crnzl

AND THERMOMETERS

Case

12-91 8737

2% " black steel

2% " chrome

2% " black steel 2% " black steel

\ 1 /

2% " black steel 2% " black steel 15/," black steel 15/," black steel

2% " black steel 2% " black steel 2% " black steel

Male pipe connection

'Ig" bottom

1/4 " bottom

% " bottom % bottom

1/4 bottom % " bottom '1," back 'I," back

1/4 " back 1/4 " bottom 1/4 " bottom

Use

1 air or gas

8735- P 100 psi (7 k g / c d ) 2% " black steel % " bottom 8735- K 100 psi (7 kg/cm21 2% " black steel 1/4 " back 8735-S 160 psi (7 1 kg/cm2) 2% " black steel 1 " /4 bottom

air and gases or liquids not

corrosive to brass

8735-Y 200 psi (14 kg/cm21 2% " black steel Yi " bottom 8735-T 300 psi (20 kg/cm21 2% " black steel 1/4 " bottom 1

monel movement

8735-V { -30'yg ( - 760 mm Hg) 1 2Y. ,, black steel 1/4 " bottom for high + 15 psi ( + 7 kglcmZ1 sulfur oils

@ includes stem dampener @ includes steam dampenerlrecalibrator

Select gauge for double the range of anticipated pressures. 8735-A and -B dials are 1 % " diameter and are English only. All others are 2% "and have black English scales and red metric. All dial faces are white.

Gauges weigh about '/z pound. Maximum ambient temperature 125-150 F.

(Abbreviations are psi = pounds per square inch; osi = ounces per square inch; "WC = inches of water column pressure.)

For shutoff when gauge is not being read, install a valve ahead of each gauge. An 1836-03 ( 5/4 "mpt x % "fpt) brass needle valve is useful for shutoff, also to dampen excessive pulsations by partially closing.

INDEX NO. 6

MODUTROL MOTOR

M-A , M - B

LOW F I R E WITH SWITCH

L F S - A , L F S - B

A I R PURGE SWITCH

HFS-A, HFS-B

THE M7284 AND M7285 ARE ELECTRONIC MODUTROL MOTORS USED TO CONTROL DAMP- ERS AND VALVES. THESE MOTORS ACCEPT A CURRENT SIGNAL FROM AN ELECTRONIC CON- TROLLER TO POSITION A DAMPER OR VALVE AT ANY POINT BETWEEN OPEN AND CLOSED.

Replace M744S,T,Y and M745S,T,Y motors.

M7284, M7281 are non-spring return; M7285, M7282 are spring return.

Oil immersed motor and gear train for reliable performance and long life.

Wiring box provides NEMA 3 weather protection.

Actuator motor and circuitry operate from 24 volts AC. Models available with factory mounted transformer, or internal transformer can be field added.

Quickconnect terminals standard-screw terminal adapter available.

Adapter bracket for matching shaft height of older motors is standard with replacement motors.

Nominal timing of 30 seconds for 90" and 60° seconds for 160" stroke.

Die cast magnesium housing.

Available accessories include valve and damper linkages, explosion proof housing, and auxiliary switches.

Models available with integral auxiliary switches.

Spring return models are rated for 60 Ib.-in. torque.

Non-spring return models are rated for 150 Ib.-in. torque.

Models with adjustable zero and span.

S.M. Rev. 11-00

Form Number 63-2202-1 Q Honeywell Inc. 1990

Q601, Q618, and Q455 Linkages. Order separately from Nelson Electric Co. Requires Honeywell 761 6DM Coupling.

0607 External Auxiliary Switch--Controls auxiliary equipment as a function of motor position.

0605 Damper Linkags--Connects motor to damper. INCLUDES MOTOR CRANK ARM.

Q618 Linkage-Connects Modutrol motor to water or steam valve.

Q601 Bracket and Linkage Assembly-Connects Modutrol motor to water or steam valve.

0100 Linkage-Connects Modutrol motor to butterfly valve.

221 455A Motor Crank Arm-Infinitely adjustable crank arm. Approximately 0.75 inches shorter than the 4074ELY crank arm, can rotate through downward

position and clear base of motor without requiring use of adapter bracket.

7617ADW Motor Crank Arm-Approximately 0.75 inches shorter than the 7616BR crank arm, can rotate through the downward position and clear base of motor without requiring use of adapter bracket.

220741 A Screw Terminal Adapter--Converts the standard quickconnect terminals to screws terminals.

Transformers-Mounted internally, provide 24 Vac power to motor.

1981 62JA-24 Vac; 50160 Hz (for electrical iso- lat ion).

1981 62EA-120 Vac; 50160 Hz. 1981 62GA-220 Vac; 50160 Hz. 1981 62AA-120/208/240 Vac; 50160 Hz.

I I TOP VIEW OF BRACKET ONLY

I [l 001 I ' : I

8-

POWER END

4.88 [124]

I .r------ 5.37 [I 36) - I C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

SPRING RETURN MODEL SHOWN FOR SPRING RETURN MODELS 3.9 [98]; FOR NON-SPRING RETURN MODELS 2.4 [61].

FOR SPRING RETURN MODELS 8.76 (222.51; FOR NON-SPRING RETURN MODELS 7.3 [185].

FIG. 1-M7284, M7285 DIMENSIONS IN In. [mm IN BRACKETS]. NOTE: M7281, M7282 models do not have auxiliary shaft. All other dimensions are the same.

3 63-2202-1

WHEN INSTALLING THIS PRODUCT ... 1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazardous condition.

2. Checkthe ratings given in the instructions and on the product to make sure the product is suitable for your application.

3. Installer must be a trained, experienced service technician.

4.After installation is complete, check out product operation as provided in these instructions.

I 1. Disconnect power supply before beginning installation to prevent electrical shock and equip- I ment damage.

2. Never turn the motor shaft by hand or with a wrench--this will damage the motor.

LOCATION Install the Modutrol motor in any location except where

. , , . . . . . . . e . . . . . . .

a c l n rllrnas nr nrnnr o n r a r l n r a r l n n vannrs r n l n n r a n a c K rna --.- ............... --.-..-.- .... .-r- .- ""J'" -..--" "'-

metal parts, or in atmospheres of escaping gas or the explosive vapors. Motors are rated for ambient temperatures between -40" F and 150" F [-40" C and 66" C].

In excess salt environments, mounting base and screws should be zinc or cadmium plated, not stainless steel or brass: Use the 220738A adapter bracket for mounting on these surfaces.

Allow enough clearance for installing accessories and servicing the motor when selecting a location. See Fig. 1. If located outdoors use liqlid- tight conduit connectors and wiring box to provide NEMA 3 weather protection.

MOUNTING Always install motors with the shaft horizontal. Mounting flanges extending from the bottom of the

motor housing are drilled for 114 inch [6.4 mm] machine screws or bolts.

These motors are shipped from the factory in closed position (at the limit of counterclockwise rotation as viewed from the power end of the motor, as shown in Fig. 2).

ADAPTER BRACKET The220738A Adapter Bracket, positioned between the

motor and the equipment, raises the shaft height of the motor by 0.75 inch to match that of the former Modutrol motor. This is required on all valve linkage applications, (2607 External Auxiliary Switch applications, and on some damper linkage applications (either to provide clearance for the crank arm to rotate through the downward position, or to allow the damper linkage to reach the shaft).

To mount the motor with the bracket: 1. Mount the bracket to the equipment with existing or

standard bolts. 2. Mount the motor to the bracket using the bolts pro-

vided to the threaded holes in the bracket. See Fig. 3. For valve linkage applications, the bracket should first

be mounted to the linkage. The bracket then provides a convenient base on which the motor can be positioned. Afterthe motor shaft is aligned to the linkage, it can then be attached to the bracket with the 4 bolts provided. For the

M7285, M7282

VERTICAL VERTICAL REFERENCE REFERENCE

FULL CLOSED

, ktoo 90 DEGREE STROKE FULL OPEN

160 DEGREE STROKE

E I I I I C

SPRING RETURN MOTORS

VERTICAL

OPEN

90 DEGREE STROKE

I60 DEGREE STROKE

NON SPRING RETURN MOTORS EJ,JC

FIG. 2-LIMITS OF ROTATION FOR 90" STROKE AND 160" STROKE MOTORS AS VIEWED FROM THE POWER END.

M7284 & M7281 these bolts go through the inner set of back slots of the motor flange and into the threaded holes of the bracket. See Fig. 4. For the M7285 & M7282, these bolts go through the outer set of back slots of the motor flange and into theouterthreaded holes of the bracket. See Fig. 4.

DAMPER LINKAGES A 220738A Adapter Bracket is packed with replace-

ment motors. Use of this bracket is optional for many damper applications. The bracket is needed in damper applications requiring the crank arm to rotate through the bottom plane of the actuator. If the bracket is not used in a replacement application, the damper linkage will have to be adjusted to the new shaft location.

The motor comes without a crank arm. The crank arm is included in the (2605 linkage or may be ordered separately (see Accessories).

For detailed instructions on the assembly of specific linkages, refer to the instruction sheet packed with each linkage. In general, however, check the following points of operation when installing a motor and linkage.

n # 1 2 0 ~ 114" MACHINE SCREWS OR BOLTS

M 4520 NON-SPRING RETURN SPRING RETURN

FIG. 3-MOUNTING MOTOR WITH ADAPTER BRACKET.

1. Linkages for valves and louver type dampers should be adjusted so that the damper or valve moves through only the maximum required distance when the motor moves through its full stroke.

2. With modulating control, maximum damper opening should be no more than 60". Little additional airflow is provided beyond this point.

3. The motor must be stopped at the end of its stroke by the limit switch and must not be stalled by the damper or valve. The motor will be damaged if it is not permitted to complete its full stroke.

4. Do not exceed the motor ratings in any installation. 5. Do not turn motor shaft manually or with a wrench-

this will damage the motor.

trical shock or equipment damage. All wiring must agree with applicable codes, ordinances, and regulations.

An integral transformer is used to supply 24 Vac power to the motor. Make sure that the power requirements stamped on the motor correspond to the characteristics of the power supply.

Access to the wiring compartment is gained by removing the 4 screws in the top of the wiring box and lifting ofl the cover. See Fig. 5 for terminal locations. See Fig. 6 for internal schematic.

Fig. 7 shows connections for typical system applications. Fig. 8 shows parallel motor connections.

WIRING BOX VALVE LINKAGES When used with liquid-tight conduit connectors, the

The 220738A Adapter Bracket must be used with the wiring box provides NEMA 3 weather resistance for the Q100, 0601 and 061 8 linkages in all valve applications. motor. The box, standard with replacement motors, also

provides knockouts for wiring conduits and encloses ter- WIRING minals. The wiring box is required for housing an internal

Disconnect power supply before wiring to prevent elec- transformer or internal auxiliary switches.

T T u BOLTS PROVIDED (4)

u WIRING BOX

A#I.?OR 114 ZINC PLATED MACHINE SCREWS OR BOLTS.

AFIRST HAND TIGHTEN BOLTS SECURING BRACKET TO LINKAGE. TIGHTEN AFTER SECURING MOTOR TO THE BRACKET USING FOUR BOLTS PROVIDED.

M 453C

- FIG. &MOUNTING MOTOR ON Q618 VALVE LINKAGE.

SPAN ADJUST

INNER AUXILIARY SWITCH CAM (BLUE)

OUTER AUXILIARY SWITCH CAM (RED)

NOTE: FEATURES AVAILABLE ON SOME MODELS ONLY.

M 4546

FIG. 5-TERMINALS AND ADJUSTMENTS.

WINDING

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DIRECTION OF MOTORTRAVEL AS VIEWED FROM POWER END.

3 INTERNALLY MOUNTED TRANSFORMER. DO NOT CONNECT POWER SUPPLY TO T I AND T2.

A BRAKE CIRCUITRY ONLY ON M7185 MODELS. E1093B

MOTOR -

I 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

CONNECTING F TO EITHER +OR - WILL DRIVE MOTOR TO FULL OPEN.

1 I

FIG. 7-TYPICAL SYSTEM WIRING.

MOTOR

4-20 mA

MOTOR h

&---JlIr- +

on t

POWER SUPPLY. PROVIDE DISCONNECT MEANS AN0 OVERLOAD PRO. TECTION AS REQUIRED.

CONNECTING F TO EITHER + OR-WILL DRIVE MOTOR TO FULL-OPEN.

El0968

FIG. 6-INTERNAL SCHEMAIC OF M7284AND M7285 FIG- &DRIVE UP TO 6 MOTORS IN UNISON FROM MOTORS. ONE CONTROLLER.

ZERO AND SPAN ADJUSTMENT FOR M7284W M7285Q MOTORS AUXILIARY SWITCHES

The auxiliary switches are actuated by adjustable 1. Refer to Fig. 5, adjust the zero potentiometer (P3) ---- ,,--- ---- --- ,- ..... --,..-.- .,- -...I.-,-- .. fully clockwise (maximum zero) and the span potentiometer (P l ) fully counterclockwise (minimum span).

2. Set thecontrollercurrenttothevalue requiredtodrive the motor to the closed position.

3.Turn the zero potentiometer (P3) slowly counterclockwise until the motor begins to open. This is defined as the zero setting.

4. Set the controller current to thevalve required todrive the motor to the full open position. The motor will open.

5.Turn the sDan Ddtentjometer ( P l l clockwise until the motor starts to clo'se. The difference between the full (open) span position current and the zero position current is defined as the operating span.

6. Re-check the zero and readjust the zero potentiometer (P3) if necessary. Turn (P3) clockwise to increase the zero position.

7. Recheck the span and readjust the span potentiometer (PI) if necessary. Turn (PI) clockwise n t o increase the full span position.

8. For sequential operation (as shown in Fig. 9), repeat above steps for each motor.

SEQUENTIAL OPERATION OF 3 M7284QIM7285Q MOTORS.

18-

CLOSED OPEN CLOSED OPEN CLOSED OPEN

MOTOR 1 MOTOR 2 MOTOR 3

AA A A MOTOR 1 PROPORTIONS BETWEEN 4 AND 12 mA: FULL CLOSED AT 4 mA. FULL OPENED AT 12 mA.

MOTOR 2 PROPORTIONS BETWEEN 8 AND 16 mA; FULL CLOSED AT 8 mA; FULL OPENED AT 16 mA.

MOTOR 3 PROPORTIONS BETWEEN 12 AND 20 mA SIGNAL, FULL CLOSED AT 12 mA; FULL OPEN AT 20 mA.

UP TO 6 MOTORS CAN BE DRIVEN SEQUENTIALLY OR IN UNISON FROM ONE CONTROLLER.

ADJUST ZERO ADJUST AND SPAN ADJUST POTENTIOMETERS TO a ACHIEVE DESIRED SEQUENCE. El9284

FIG. 9-SEQUENTIAL OPERATION OF MOTORS.

c a m s . I n e s e c a m s can oe ser ro acruare rne swlrcnes ar any angle within the stroke of the motor. Also, switch differentials of 1 " or 10" can be selected.

Motors with factory added auxiliary switches are shipped in the closed position (counterclockwise , as viewed from power end) with auxiliary cams set to actuate switches 30" from the closed position, and to provide 1" differential. With motor in closed (full counterclockwise 0 ,) position, auxiliary switch breaks R-B.

Disconnect all powerto auxiliary switches be adjust- I ing.

AUXILIARY SWITCH SElTlNG PROCEDURE See Fig. 10

1. Remove top cover to gain access to motor terminals and auxiliary cams.

2. Disconnect controller from motor and connect a current source to the + positive and - negative terminals.

3. Drive motorto the position where auxiliary equipment is to be switched by adjusting the current source.

4. For switch differential of 1 ", check continuity of auxiliary switch R-B contacts and rotate cam as follows:

a. If contacts are open, rotate cam clockwise n u n t i l R-B contacts close.

b. If contacts are closed, rotate cam counterclockwise f until R-B contacts open.

5. or switch differential of 10" rotate cam approximately 180" so that slow-rise portion of cam actuates switch, then check continuity of auxiliary R-B contacts and rotate cam as follows:

a. If contacts are open, rotate cam counterclockwise f until R-B contacts close.

b. f contacts are closed, rotate cam clockwise until R-B contacts open.

c. Final adjustment in the proper direction should be made to obtain contact make or break at the desired position.

6. Check for proper differential and switching of auxiliary equipment by driving motor through full stroke in both directions.

7. Disconnect current source, reconnect controller, replace top cover of motor.

NOTE: If differential ischangedfrom 1 "to 1 OOthe switching action is reversed, thus; switch contacts R-B make and R-W break on a counterclockwise (closed) rotation.

FIG. 10-AUXILIARY SWITCH AND ADJUSTABLE CAMS.

LEFT SWITCH RIGHT SWITCH (OUTER CAM) (INNER CAM) <fl pc-J ;;I;;E

YELLOW BLACWELLOW

/;\ MAKES R TO B AS MOTOR OPENS. M 458

The motor feedback potentiometer and control current input circuit form a bridge circuit. As long asthe final control element remains at the position proportional to the input current from the controller, the circuit is balanced, and the motor does not run. When the value of the controlled medium changes, the current from the controller changes, and unbalance is amplified to energize the triac switching to run the motor in the proper direction to correct the change in the temperature or pressure. The motor turns the feedback potentiometer to rebalance the circuit and slop the motor.

MOVE SCREWDRIVER AT TOP ONLY TO ADJUST CAM.

118 IN. STRAIGHT-BLADE SCREWDRIVER

I

POWER END NOTE: CAMS ARE OFFSET VERTICALLY TO

PROVIDE BETTER VIEW OF BACK CAM. M 3060

CHECKOUT When the motor has been installed and the auxiliary

switches have been adjusted, check the motor operation to ensure that the motor operates the valve or damper

properly and that the motor responds accurately to the controller signal.

Inspect the motor, linkage and valve or damper to see that all mechanical connections are correct and secure. In damper installations, the pushrods should not extend more than a few inches past the ball joints. Check to see that there is adequateclearance for linkage to move through its stroke without binding or striking other objects. Check that cams operate the auxiliary switches, if used, at the desired point of motor operation.

MOTOR OPERATION CHECK 1. To close the motor, open terminals +, -, and F., 2.To open the motor, connect terminal F to either the

positive (+) or negative (-) motor terminal.

Honeywell Inc. U.S.A.: 1885 Douglas Drive N.

Golden Valley, MN 55422-4386 CANADA: 740 Ellesmere Road Scarborough, Ontario MI P 2V9

International Sales Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.

PRINTED IN U.S.A. QUALITY IS KEY

INDEX NO. 7

LOW COMBUSTION A I R CUTOUT

P S L - 0 0 3 - A , P S L - 0 0 3 - B

Honeywell THE C437 AND C637 GAS PRESSURE SWITCHES ARE PRESSURE-ACTUATED SWITCHING DEVICES USED IN INDUSTRIAL GAS SYSTEM APPLICA- TIONS FOR SAFETY SHUTOFF, PRESSURE CON- TROL, AND DIFFERENTIAL-PRESSURE CONTROL.

C437 models have direct- and reverse-acting (spst) switching; C637B has single-pole, double- throw spdt) switching.

Pressure ranges: 1 /2 to 5-1 /2 in. of water [ l o to 140 mm of water, or 0.1 to 1.4 kPa]; 1 to 26 in. of water [50 to 700 mm of water. or 0.5 to 7 kPa]; 1 /2 to 5 psi [300 to 3500 mm of water, or 3 to 35 kPa]; 1 to 10 psi [500 to 7000 mm of water, or 5 to 70 kPa].

Models intended for lockout applications must be manually reset before resuming operation.

Trip-free mechanism on manual reset models ensures that the limit function of the switch cannot be defeated by jamming the reset lever.

External manual reset button on side of models with lockout.

Enclosed setting impedes tampering and provides dust-resistant operation.

Buna-N fiber-reinforced material for increased strength of control diaphragm.

o Two Buna-N fiber-reinforced seal-off diaphragms for added reliability.

Clear glass cover allows observation of interior mechanism to aid in setting and checkout.

Mercury switch provides visual indication of switch position.

Heavy die-cast case increases durability and resistance to corrosion.

Main control diaphragm is completely enclosed in a leak-proof chamber; may be vented to a safe area.

0 Models with a pressure range of 1 to 26 in. of water [50 to 700 mm of water, or 0.5 to 7 kPa] have a restrictive orifice in their inlet pressure channel to compensate for momentary surges in gas pressure.

Field-addable orif ices of various sizes are available.

Models available with rainproof, dustproof, sleet- and ice-resistant enclosure; meets NEMA 3R specification.

T.M. Form Number 60-2320-7 REV. 3-67. O Honeywell lnc. 1987

MODELS:

eathe her proof enclosure (NEMA 3R) available

'9esignated "Manual Reset 2"; the trip-free reset mechanism does not permit the switch to function as an ailtomatic-reset device if the manual reset lever is held in the "reset" position.

'TWO separate switches are contained in the same mercury bulb.

MODEL NUMBER

C437D C437E ~ 4 3 7 ~ ~ ~ 4 3 7 ~ ~ C437tIa C437J C437K - -- C;637B -

SWITCH RATINGS (in amperes):

SWITCH ACTION (Response at set point to

pressure change) spst, breaks on rise spst, breaks on fall

2 spst circuitsc, breaks one, makes one spst, breaks on rise spst, breaks on fall

2 spst circuitsc, breaks one, makes one 2 spst circuitsc, breaks one, makes one spst, breaks R-W and makes R-B on fall

C637B-62.5 VA at 120 and 240 Vac, pilot duty.

(continued on page 3)

MANUAL RESET^ (Locks out on switch break)

Yes yes no no no

yes (lockout on rise) yes (lockout on fall)

no

WHEN PURCHASING REPLACEMENT AND MODERNIZATION PRODUCTS FROM YOUR TRADELINE WHOLE- SALER OR YOUR DISTRIBUTOR, REFER TO THE TRADELINE CATALOG OR PRICE SHEETS FOR COM- PLETE ORDERING NUMBER, OR SPECIFY-

VOLTAGE 120 Vac 240 Vac 120 Vdc 240 Vdc

1. Order number. 2. Pressure range. 3. Replacement parts, if desired. 4. Accessories, if desired.

C437F,J,K

IF YOU HAVE ADDITIONAL QUESTIONS, NEED FURTHER INFORMATION, OR WOULD LIKE TO COMMENT ON OUR PRODUCTS OR SERVICES, PLEASE WRITE OR PHONE:

1. YOUR LOCAL HONEYWELL BUILDING CONTROLS DIVISION SALES OFFICE (CHECK WHITE PAGES OF PHONE DIRECTORY).

2. BUILDING CONTROLS DIVISION CUSTOMER SERVICE HONEYWELL INC., 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS, MINNESOTA 55422-4386 (612) 542-7500

(IN CANADA-HONEYWELL LIMITED/HONEYWELL LIMITEE, 740 ELLESMERE ROAD, SCARBOROUGH, ONTARIO M I P 2V9) INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.

C437D,E,G AND H RESISTIVE

LOAD 10.0 5.0 8.0 4.0

FULL LOAD

8.0 5.1 2.4 1.2

FULL LOAD

8.0 5.1 2.0 1 .O

LOCKED ROTOR

48.0 30.6 20.0 10.0

LOCKED ROTOR

48.0 30.6 24.0 12.0

RESISTIVE LOAD 10.0 5.0 5.0 2.0

SWITCH: Mercury switch (C437F,J, and K have 2 spst switches in one mercury bulb). DIFFERENTIALS (fixed, nominal; measured at pressure indicated):

sin. = inches of water; mm = millimeters of water.

b ~ o t available for C437K.

' ~ o t available for C437J.

d~estrictive orifice in inlet pressure channel to compensate for momentary surges in gas pressure.

e~ubtractive models: switching action occurs on pressure rise to the set point. Additive models: switching action occurs on pressure fall to the set point.

MODEL NUMBERS C437D.J C437E,F,

H,K C637B C437G

PRESSURE RANGES (scale range): Specify one.

1 /2 to 5-1 /2 INCHES OF WATER [ l o to 140 mm of water, or 0.1 to 1.4 kPa].

1 to 26 INCHES OF WATER [50 to 700 mm of water, or 0.5 to 7 kPa].

1 /2 to 5 LB PER SQ IN. 1300 to 3500 mm of water, or 3 to 35 kPa].

1 to 10 LB PER SQ IN. [500 to 7000 mm of water, or 5 to 70 kPa].

MAXIMUM SUSTAINED OPERATING PRESSURE:

1 I2 TO 5-1 I2 in. [lo-140 mm, or 0.1 -1.4 kPa]

DIFFERENTIAL MEAS. AT 112 in.

PIPE CONNECTIONS: Main or High Pressure-1 /2 in. NPT, female. Vent or Low Pressure-1 /8 in. NPT, female. Electrical Wiring-hole tapped for 1 /2 in. conduit.

in. -

0.25~

0.15 -

PRESSURE RANGE

1 /2 to 5-1 /2 in. of water

1 to 26 in. of water 1 /2 to 5 psi 1 to 10 psi

MAXIMUM AMBIENT TEMPERATURE: 125 F [52 C].

TYPE" Subtractive

Additive

Subtractive

PRESSURE RANGE^

MINIMUM AMBIENT TEMPERATURE: 32 F [0 C].

mm -

6.4b

3.8 -

MAX PRESSURE

APPROVALS: UNDERWRITERS LABORATORIES INC. LISTED: File

No. MP2168, Guide No. MFHX. CANADIAN STANDARDS ASSOCIATION CERTIFIED:

File No. 1620, Guide No. 380-W-1.16. FACTORY MUTUAL APPROVED: Report Nos.

13031 -S5 and 19291.

kPa -

0.06~

0.04 -

1 TO 26 in.' [SO-700 mm, or 0.5-7 kPa]

DIFFERENTIAL MEAS. AT 15 in.

psi 3.0

5.0

15.0 30.0

REPLACEMENT PARTS: 106729 Cover Glass, 6 in. [152.4 mm] diameter. 139870A Cover Glass, for rainproof enclosures. 106747 Cover Retaining Ring, for models manufactured

before 1973. 137631 Cover Retaining Ring, for models manufactured

in 1973 and 1974. 137558 Retaining Clip, for Retaining Ring on models

manufactured in 1973 and 1974. 118733 Retaining Clip, for models manufactured since

1975.

in. 1 -3/4 1-1 /4

1-1 /4

kPa 20.7

34.5

103.4 206.8 ACCESSORIES:

4074BWK Bag Assembly, contains two 137755 Mount- ing Brackets and four self-tapping screws-for surface mounting (standard on C437G and H). Mounting brackets are shown by dashed lines on Fig. 1.

4074BWN Orifice Tool-required for mounting orifices in the field.

Field-addable orifices as follows- Part No. 388448U-0.006 in. [0.15 mm] dia. Part No. 388448N-0.008 in. [0.20 mm] dia. Part No. 388448C-0.011 in. [0.28 mm] dia. Part No. 388448E-0.018 in. [0.46 mm] dia.

112TO 5 psi [300-3500 mm,

or 3-35 kPa] DIFF. MEAS.

AT MIDSCALE mm 44.5 31.8

31.8

psi 1 /2 1 /4

1 /4

1 TO 10 psi [500-7000 mm, or

5-70 kPa] DIFF. MEAS.

AT MIDSCALE kPa 0.44 0.31

0.31

mm 352 176

176

kPa 6.8gL 3.45D

3.45

psi lL

1 /2D

1 /2

kPa 3.45 1.72

1.72

mm 703L 352b

352

137755 MOUNTING BRACKET (2). IN 4074BWK BAG ASSEMBLY-STANDARD AND H; OPTIONAL ON OTHER MODELS.

A VENT TAPPING. REMOVE DUST-SEAL LABEL BEFORE MOUNTING.

1 I FIG. 1-INSTALLATION DIMENSIONS OF THE C437 AND C637 GAS PRESSURE SWITCHES, IN in. [mm IN

BRACKETS].

WHEN INSTALLING THIS PRODUCT . . . 1- IMPORTANT I

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.

3. Installer must be a trained, experienced, flame safeguard control technician.

4. After installation is complete, check out product operation as provided in these instructions.

Disconnect all power to the pressure switch before beginning installation to prevent electrical shock and equipment damage.

1. Remove the dust-seal label from the vent tapping before mounting.

2. The pressure switch must be accurately leveled for proper operation.

3. The C637B pressure .switch is a low differential device and must be mounted in a vibration- free location to prevent chattering.

4. Do not tighten the pressure switch by hand by holding the case.

Follow local codes or ordinances in all cases if different from these recommendations.

Fig. 1 shows the mounting dimensions for the C437 and C637 models, and for the accessory mounting bracket (standard on C437G and H). Fig. 2 shows a phptograph with components defined.

LOCATION The gas pressure switch should be mounted down-

stream from the pressure regulator. Low gas pressure switches should be mounted upstream of any shutoff valve. High gas pressure switches should be mounted just upstream from the burner. When pipe mounting, locate the device on the portion of the pipe that is most level because the mercury switch requires level orientation. See step 4 under Mounting.

SETTING SCREW UNDER RETAINER. MANUAL RESET I

MERCURY SWITCH

INDICATOR

SCALEPLATE

TERMINAL STRI

VENT TAPPING TAPPING

'LENS GASKET (G.H ONLY)

REMOVE DUST-SEAL LABEL BEFORE MOUNTING. E2077 I

FIG. P-PRINCIPAL PARTS OF THE GAS PRESSURE SWITCH.

MOUNTING 1. REMOVE THE DUST-SEAL LABEL FROM THE

VENT TAPPING. 2. Remove the screws and retainers, and the cover

glass. 3. Mount the device on the pipe or nearby vertical

surface. Use a nipple and "T" for pipe mounting or the mounting bracket for surface mounting. If a mounting bracket is used, install the bracket before making piping connections (standard on C437G and H). The bracket is horizontally mounted with four 10-24, flathead, tapping screws provided.

4. Level the device carefully using the level line on the back of the device.

a. When pipe mounting, install the device at right angles to the pipe so that it may be leveled by additional tightening of the pipe fittings.

b. The surface mounting bracket has elongated holes which allow limited leveling after the mounting screws have been started.

c. Accurate leveling is most essential at very low pressure settings.

d. If necessary, make arrangements to hold pipe- mounted units steady and level with bracing.

IMPORTANT To avoid leaks and case damage, use a parallel jaw wrench on the hexagonal part of the case close to the pipe. Make all connections carefully and test for leakage. DO NOT tighten the pressure switch by hand by holding the case. r-

5. Complete the main piping. 6. Connect piping to the pressure switch. Select the

application from the following, and proceed as instructed.

a. HAZARDOUS-GAS APPLICATIONS Install a 1/8 in. NPT pipe at the vent tapping on all hazardous-gas applications.

The vent must be installed so that any gas leakage will be vented into a safe place in case of a diaphrasm failure.

b. DIFFERENTIAL-PRESSURE APPLICATIONS (1) Connect the high-pressure side of the sys-

tem to the 1/2 in. NPT main pressure tapping on the gas pressure switch.

(2) Connect the low pressure side to the 118 in. NPT vent tapping.

No venting is possible in this case. Do not use this device for differential pressure control with hazardous gases.

C. NEGATIVE-PRESSURE APPLICATIONS Connect the low pressure side to the 1 /8 in. NPT vent tapping.

This application is for use with nonhazardous gases only. Do not use this device for negative- pressure applications with hazardous gases.

7. Install other controls in the system. Connect wiring, and complete setting and checkout before replacing the cover glass and retainers. See SETTING AND CHECKOUT section.

WIRING

1. Disconnect all power to the pressure switch before connecting wiring to prevent electrical shock and equipment damage.

2. When using a C437F,J, or K, both ends of the switch (W-R and B-R) must be used at the same voltage in the same branch circuit.

All wiring must comply with local electrical codes, ordinances, and regulations. The switch ratings given in the SPECIFICATIONS section must not be exceeded.

Wiring diagrams for the different models are shown in Figs. 3, 4, and 5. The switches make or break as indicated in the diagrams. Connect the wiring to the screw terminals on the terminal strip after the cover glass is removed. Route the wires through the conduit tapping.

C437D.G: BREAKS ON PRESSURE RlSE C437E.H: BREAKS ON PRESSURE F A L L

TERMINAL STRIP

E2169

MAKES ON PRESSURE FALL

MAKES ON PRESSURE RlSE

lL@ STRIP

C437F.J.K

BOTH ENDS OF THE SWITCH (W-R AND 8-R) MUST BE USE0 AT THE SAME VOLTAGE I N THE SAME BRANCH CIRCUIT. E2170

FIG. 4-WIRING DIAGRAM FOR C437F,J,K.

MAKES R TO B MAKES R TO W ON PRESSURE FALL ! ON PRESSURE RlSE

' 3 C637B TERMINAL STRIP E2l68

FIG. 3-WIRING DIAGRAM FOR C437D,E,G,H. FIG. 5-WIRING DIAGRAM FOR C637B.

SETTING In the C437D,G, and J models, the differential is

subtractive. The upper operating point is determined by the set point, while the lower operating point is determined by the set point minus the differential. In the C437E,F,H,K and C6376 models, the differential is additive. The lower operating point is determined by the set point, while the upper operating point is determined by the set point plus the differential. Operating points are shown in Fig. 6.

Remove the retainer and adjust the set point for the desired operating pressure (cutout pressure on a C437D, E,G, or H spst model) by turning the setting screw (Fig. 2) clockwise 0 to increase the set point and counterclockwise r? to decrease it.

TRIP-FREE MANUAL RESET FEATURE (C437D,E,J, and K only)

The C437D breaks and the C437J breaks R-6 and makes R-W when the pressure rises to the set .point. The C437E breaks, and the C437K breaks R-W and makes R-6 when the pressure falls to the set point. None of these pressure switches will return to their former positions automatically.

To reset one of these pressure switches, wait until the pressure falls to the set point minus the differential (C437D or J), or rises to the set point plus the differential (C437E or K). Then depress the manual reset button (Fig. 2) and release it. The pressure switch will not be reset until you release the manual reset button. This prevents the switch from becoming an automatic-reset device if the reset button is stuck, held in, or tied down.

c437D,G 'n~~.%REAKS,C437D SUBTRACTIVE LOCKS OUT)

DIFFERLNTIAL

SET POlNT MINUS DIFFERENTIAL (SWITCH M A K E S ) A

SUBTRACTIVE DIFFERENTIAL

SET POlNT MINUS

MAKES R.8)

I SET POlNT PLUS

c437E,H R E ' ~ D ~ ~ : ~ ' " ~ l " s w l ~ c H MAKE') A DIFFERENTIAL

+ I SET POlNT (SWITCH BREAKS. C437E LOCKS OUT)

I SET POINT PLUS PRESSURE c 4 3 7 F,. FALi ' ~ F ~ ~ ~ ~ ~ ~ ( B ' ~ ~ ~ s '."A

C637B

I + ' SETPOINT

(BREAKS R-W. MAKES R-8. C437K LOCKS OUT)

I C437D AND J ARE MANUAL RESET MODELS; THEY CAN BE MANUALLY RESET WHEN THE PRESSURE FALLS TO THE SET POlNT MINUS THE DIFFERENTIAL.

2 C437E AND K ARE MANUAL RESET MODELS; THEY CAN BE MANUALLY RESET WHEN THE PRESSURE RISES TO THE SET POlNT PLUS THE DIFFERENTIAL. ~ 2 1 7 2

I FIG. 6-C437 AND C637 OPERATING POINTS.

CHECKOUT Adjust the set point for normal operation and check

to see that the gas pressure switch performs as intended. Use a manometer or accurate pressure gauge connected upstream from the switch to measure the actual pressure.

The most likely cause of inaccurate operation is off- level mounting. Refer to step 4 under Mounting, on page 5, and correct any installation that doesn't check out satisfactorily.

C437D,G, OR J (Subtractive Differential) 1. Put the system into normal operation, and set the

pressure switch at the normal set point (above the normal operating pressure).

2. Turn the setting screw (Fig. 2) slowly toward a lower pressure setting (counterclockwise n ) to simulate a pressure increase.

3. When the set point is approximately equal to the pressure indicated on the pressure gauge, the C437D or G should break contact and turn off the controlled equipment; the C437J should break R to B and make R to W.

4. The C437D or J should lock out. 5. Turn the setting screw toward a higher pressure

setting (clockwise n ) to simulate a pressure decrease greater than the differential. The C437G should make contact and turn on the controlled equipment.

6. Push the manual reset button (Fig. 2) on the C437D or J; the C437D should make, and the C437J should break R to W and make R to B.

COMPLETING THE INSTALLATION 1. Remove the pressure gauge or manometer used

for testing. Visually recheck the piping, wiring, and setting.

2. Replace the cover glass and retainers. 3. Return the system pressure to normal. 4. Push the manual reset button (C437D,E,J, or K

only).

INSTALLING A PRESSURE ORIFICE (Fig. 7)

To compensate for momentary surges in gas pressure, a restrictive orifice can be installed in the inlet pressure channel of the pressure switch. (Refer to Accessories in the SPECIFICATION section for the orifice sizes available.)

Screw the bushing into the main pressure tapping with your fingers until it is tight. Press the selected pressure orifice over the slotted end of the orifice tool. With the tool, insert the orifice into the main pressure tapping until the tool threads mate with the threads in the bushing. With your fingers, screw the tool into the bushing (turn clockwise P ) as far as possible; then continue turning with pliers to seat the orifice. Seating will have occurred when the turning comes to an abrupt halt. Unscrew the tool and bushing and complete the connection.

C437E,F,H,K OR C637B (Additive Differential)

1. Put the system into normal operation and grad- ually close the upstream gas shutoff valve to cause a pressure decrease.

2. When the pressure gauge indicates that the pressure is approximately equal to the set point, the C437E or H should break contact and turn off the controlled equipment; the C437F,K or C637B should break R to W and make R to B.

3. The C437E or K should lock out. 4. Open the gas shutoff valve to increase the pres-

sure again. When the pressure rises to the set point plus the differential, the C437H should make contact and turn on the controlled equipment; the C437F or C637B should break R to Band make R to W.

5. Push the manual reset button (Fig. 2) on the C437E or K; the C437E should make, and the C437K should break R to B and make R to W.

118 IN.

I J FIG. 74NSTALLING A PRESSURE ORIFICE TO COM-

PENSATE FOR PRESSURE SURGES.

Honeywell Inc. I International Sales Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland. 1885 Douglas Drive N. France, Germany, Japan, Mexico, Netherlands, Spain. Taiwan, United Kingdom. U.S.A.

Golden Valley, MN 55422-4386 PRINTED IN U.S.A.

INDEX NO. 8

ATOMIZING A I R COMPRESSOR SET

AAC-A, AAC-B

COMPRESSOR SAFETY REL IEF VALVE

COMPRESSOR FLEXIBLE HOSE

CFH-A, CFH-B

Instruction Manual for QR-25 Series Compressors

serious injury or death if operated improperly. Before installing or operating this compressor, read

and understand this manual, and follow all safety precautions!!

Part # : 52201 -1 04 Date of lssue :August 1992

WARRANT) QUINCY COMPRESSOR DMSlON RECIPROCATING PRODUCT

QR-25 SERIES AIR COMPRESSOR

I GENERAL PROVISIONS Coltec Industries ! Quincy Compreuuor Iliviaion ('The Seller') warrnnb to each original ntail pzuch-r (-i producta of the Seller'. own ~ u f ~ againat defects in material and wo ' kp.

I With mpect to pmducta not manufsctured by Seller, Seller will, if practical, paan dong the warranty of the oxigina manufacturer.

I Seller warranta repaired or replaced p- of ita own manufactura wainat defecta in material and wo '

b'p unde normal use and eervica for ninety (90) days, or for the remainder of the warranty on the buic annpmsor being ~pa irec whichever in longer.

I Ths Seller'a mb obligation under thin warranty Id be, at ib option, to q&, place, or refund the purehaae pria o. any product or part thexwf which is deemed to be &fecLive, provided the Avrbaner meeta d of the applicable requirement: of thin warranty and none of the limitations apply.

WARRANTY PERIODS PRawrne-Basice- Sirty (60) months tmm date of f a c t ~ y Ihipment the following parka: head, cghder, crdume, oil pump, clankrh.it, pistons, colutecting rod ummblicw and bearing.. labor and tmvel will will be wananted for twelve (12) monthr h m atart-up or twenty-four (U) month frum f & y shipment, whichever occurs firrt.

N o d maintenanat itemu and pmceduxw us not warranted onlsM found to be defective in mnteri.1 or

w o Up i.e. but not l imiu to, atem, e e t s , rings, v d v r and control ilnr

I Splash r.lllnicated Basic Chnpmmm 'helve (12) month from start-up or twenty-four (24) months from factory ohipment, whichever occurs fixat.

includea labor and applmrad travel.

I R e x m n ~ B a s i ~ ~ ~ Six (6) month. h m date of -up or twelve months (12) months from date of f . c b y Ihipment, whichever occurs tint. Thin i n c l u b labor and approved travel.

Limitatiow The following models are & eligible for travel arpenae w h n the Seller rupplim u bask X2, X3, XS. 108,206,210,216, and lalo.

Notice of the alleged Mec~ muat be given to Seller in writ* with all iden- debh, includiag: mdal number, mo&l number, type of equipment and date of puxdmw within thirty (30) &ya of diemvey of aanm.

I If.aplested by Seller, mch product or product thereof mu& be pmmptly returned to Seller. bight mllect for hpection.

I The Seller mu& have the w m t y mghmtbn card on file d Quinep, n. within h n (10) d.yr of starbup or the warranty may be declared null and void.

The above warrantien Iall not apply and Seller Id not be mponaible nor liable fox (3 Consequential, collateral or specid lo- or damages. (b) Equipment mnditiom c a d by fair wear and tear, abnormal mnditiom. &dent, neglect or misum

of equipment, improper atorage or damagen n?eulting during shipment. (c) Deviation h m operating instxuctiona, apedicatiom or other tannr of d e n . (dl kbor chaqea, loan or damage d t i n g from improper operation, or repain made by

person(a) other than Seller or Selleia authorized aervice atation. (el Zmpmper application or installation of product.

I In m event Id Seller be liable for any claim^, whether d h g from bma& of contract or w-ty of claims of negligence or negligent mamrfacftuF, in in of the w. Thin warranty ir the mle warranty of Seller m d any other w u r a n t h , axpra~, impbd in law or implied in fact, including any warranties of merchantabiity and fitnesa for particular use, are hereby ape.cifically excluded.

SECTION 5

TABLE OF CONTENTS

MAINTENANCE & LUBRICATION

stopping for ~ a * - ----------------..--------- 23 Ma*- & . -- -- ---- a L & M n -..-n--..----o-----n-----M--------------- a6

27 PuUey / Sheave Alignment & Belt Tension --------- Pressure sw&h telj~-nts-------------------- S *aJ of&rnpre~or &t&n -.----------------- 3O y - ! ~ Specfsc&m ---------n--n----------IuI-IuI-IuI- 31

SECTION 6 TROUBLESHOOTING Troubleshooting---------32

SECTION 7 REFERENCE INFORMATION

Apprm#*mute Capaciiy Corntion fir AWude ----38 Average In$mmkr hSslCm 2B -& *&m ------------ ------------- -- ----

SECTION 1

TABLE OF C O N T E N T S

SAFETY

SECTION 2 SYSTEM DYNAMICS k n * P h n & A p p M n -----u--------------n---n-- 5 Pn'nciples of Compression Cycles ----------------- 5 pn'ItM*Pb of ------------------ 5 Principks of CwZing Systems 6 Conhu,l Compom& ----------------------------- 6 Co-l V e d o ~ 7 &&-m -..---------------- I-- - - - n - - - - - - - g

SECTION 3 INSTALLATION *iuL.'ng &fivery -.--------..----------------------------m M g h t Damage .---I-----.----------I---n-----------A kdon---------------------------------------n Electrical Supply Requirements ...--.I) -13 Mounting--..---------------n----..-----n-----M System COmpo~nts----~------ne~ne~---~--------n-n--~ Induction System---------------- I6 Compressed Air Discharge System-----------------I7

SECTION 4 START-UP & OPERATION

h & d w aC- --------------------------- w In- s m * n g & W n g a0 Daily Starting Checklist Zl

QR-2!5 S e M gUlNCY COMPRESSOR

52201-104 i AugW 1992

SECTION SAFETY

At Quincy Compressor safety is not only a primary concern, but a faithfully performed practice. Beginning with the design stage, safety is built into T h e World's Finest Compressor". I t is the intention of this manual to pass along the 'safety first ' concept to you by providing

--safety precautions throughout ibpages.

'WARNING I", "CAUTION I", and "DANGER F are displayed in large bold capital letters in the left hand column to call attention to areas of vital concern. They represent different degrees of hazard seriousness, as stated below. The safety precaution is spelled out in bold upper and lower case letters in the right hand column.

DANGER ! Immediate hazards which w i l l d t in severe w n a l iqjrny or death.

Hazardsorunsafepnidces t h a t a n a l d ~ i n ~ n a l i n j u x y a r WARNING ! dea*

Hazards or unsafe pmctioes which could m s d t in minor personal CAUTION ! , ~ . , ~ ~ Each section of this instruction manual, as well as any instructions

supplied by manufacturers of supporting equipment, should be read and understood prior to starting the compressor. If there are any questions regarding any part of the instructions, please call your local Quincy Compressor Distributor, or the Quincy Compressor factory before creating a potentially hazardous situation. Life, limb, or equipment could be saved with a simple phone call.

Compressors are precision high speed mechanical equipment requiring caution in operation to minimize hazard to property and personnel. There are many obvious safety rules that must be observed in the operation of this type of equipment. Listed below are some additional safety precautionsthabmust be ebserved.

*Transfer of toxic, dangerous, flammable or explosive substances using Quincy Compressor products is a t the user's risk.

*Turn off and lockout/tagout (per 0.S.H.A regulation 1910.147) the main power disconnect switch before attempting to work or perform any maintenance.

QR-25 Series QUlNCY COMPRESSOR

52201-104 1 h f p t 1992

D o not attempt to service any part of the unit while it is operating.

*Per 0.S.H.A regulation 1910.147, relieve the system of all pressure before attempting to service any part of the unit.

*Do not operate the unit with any of its safety guards, shields, or screens removed.

*Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or instructional materials attached to the compressor. Lack of information regarding hazardous conditions can cause property damage or personal injury.

*Periodically check all pressure relief valves for proper operation.

*Do not change the pressure setting of the pressure relief valve, restrict the function of the pressure relief valve, or replace the pressure relief valve with a plug.

*Do not install a shutoff valve in the compressor discharge line without first installing a pressure relief valve of proper size and design between the shutoff valve and the compressor.

*Do not use plastic pipe, rubber hose, or lead-tin soldered joints in any part of the compressed air system.

*Alterations must not be made to this compressor without Quincy Compressor's approval.

*Be sure that all tools, shipping and installation debris have been removed from the compressor and installation site prior to starting the compressor.

*Do not operate the compressor in excess of the AS.M.E. pressure vessel rating for the receiver or the service rating of the compressor, whichever is lower.

*Make a general overall inspection of the unit daily and correct any unsafe situations.

*Reckless behaviour of any kind involving compressed air is dangerous and can cause very serious injury to the participants.

*Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If for any reason any part of the manual becomes illegible or the manual is lost, have it replaced immediately. The instruction manual should be read periodically to refresh one's memory. I t may prevent a serious or fatal accident.

*Never use a flammable or toxic solvent for cleaning the air filter or any parts.

817-25 Series WlNCY COMPRESSOR

52201-104 2 August 1992

DANGER ! Air used for breathing or food proceasing must meet 0S.H.A 29 C3.R. 1910.134 or F D A 21 C3.K 1785570 regulations. Failure todosomaycauge~iqjlnyardeath

Do not operate a Quincy Compressor in excess of 250 pe.i.g. WARNING ! d m i t h a s b e e n W a n d ~ b ~ ~ a p p l i c a t i 0 1 1 b Y & u i n c y ~ M P - = * ~ ~ ~

The owner, lessor or operator of any compressor unit manufactured by Quincy Compressor is hereby warned that failure to observe the above safety precautions may result in serious injury to personnel andlor damage to property.

Quincy Compressor neither states as fact, nor in any way implies that the above list of safety precautions is an all inclusive list, the observance of which will prevent all damage to property or injury to personnel.

Every effort has been taken to ensure that complete and correct instructions have been included in this manual. However, possible product updates and changes may have occurred since this printing. Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold.

817-25 Series QUlNCY COMPRESSOR

52201-1M 3 &@ 1992

SECTION SYSTEM DYNAMICS *Description & Application 5

*Principles of Compmssion Cycles 5

ContrvZ Versions 7

Fig. 2-1 Cross SectionofTypical&R.25

2 Stage Pressufe Lubricated Cylinder & <=rankcase

QR-25 Serles WlNCY COMPRESSOR

Wl-104 4 AugLst 1992

The Quincy Compressor QR-25 Series consists of heavy duty industrial, belt driven, single or two stage compressors. Single stage compressors are capable of delivering up to 100 P.S.I.G. continuously. Some single stage compressors are capable of delivering up to 150 P.S.I.G. intermittantly (with proper controls and modifications). Two stage compressors can deliver up to 200 P.S.I.G. continuously, and up to 250, 350 or 500 P.S.I.G. intermittently depending upon the model, controls and configuration.

*Principles of Compression Csles

During the downstroke of a single stage compressor, air is drawn through an intake valve in the head of the compressor and into the cylinder. At the bottom of the stroke, the intake valve closes and air is trapped in the cylinder. The air is then compressed in the cylinder during the upstroke of the piston. Total compression, from atmospheric pressure to the final discharge pressure, is accomplished in one stroke of the piston.

During the downstroke of the piston of a two stage compressor, air is drawn through an intake valve in the head of the compressor into the low pressure cylinder and compressed during the upstroke of the piston.

The compressed air is then released through a discharge valve in the head of the compressor to an intercooler (usually finned tubing) where the heat resulting from compression is allowed to dissipate. The cooler compressed air is then drawn into a second compression cylinder, the high pressure cylinder, for compression to final pressure.

From there the compressed air is released through a discharge valve to an air receiver tank or directly to a network of compressed air supply lines. In one revolution of the crankshaft a compression cycle is completed.

*Principles ofLubrication Systems

Witfr-each stroke-of the eompre~sor~ a d i p p attached to-the bottom of the connecting rod*, dips into an oil bath at the bottom of the crankcase. This dipper splashes oil throughout the interior of the crankcase, lubricating all moving parts.

h he model 108 incorporates a splash ring IOCOtCd ~mund the end of the uwhhaf? Ihs a~nkctatw.

I t is important with this system that the oil level be maintained between the high and low level marks on the dipstick. If the oil level is too high, excessive oil carryover could result. If the oil level is too low, or the compressor is not operated within the correct R.P.M. range, the moving parts will not be adequately lubricated.

Moving parts within the crankcase are supplied with lubrication by a positive displacement, gerotor type oil pump. Oil is drawn up from the bottom of the crankcase to the oil pump through an oil sump strainer screen. The oil is then forced under pressure through the oil filter (if so equipped). Oil travels under pressure through drilled journals in the crankshaf't and connecting rods to lubricate crankshaR bearings, wrist pin bearings and the cylinder walls.

*Principles of Cooling Systens

Fan blades of the compressor sheave force ambient air across fins of the cylinder head(s), and intercooler fins of two stage compressors, to cool the compressor. QR-25 series compressors are normally set up at the factory with a sheave that turns in a counterclockwise rotation. For special applications, clockwise rotation compressor sheaves are available as optional equipment on some models. Due to standard drive motor limitations, it is recommended that the compressor be operated in temperatures & 104°F.

In addition to cooling action provided by the fan blades of the compressor sheave, cool water is circulated throughout an internal water jacket surrounding the cylinders and heads of watercooled models.

Unloader Towers: Provided as part of the basic compressor when control version is specified.

Pilot Valve: Used in conjunction with unloader towers when the compressor is to run continuously and an operating pressure range is to be maintained. Refer to your parts manual for correct pilot valve, ranges and-setting%

Hydraulic Unloader: Used on pressure lubricated compressors to protect the compressor in the event of a potentially damaging oil pressure drop. Also ensures that the compressor does not begin to produce compressed air until there is sufEicient oil pressure.

I?mssure Switch: Used for stadstop applications (usually accompanied by a hydraulic unloader). The pressure switch detects the demand for compressed air and allows the unit t o start. When the demand is satisfied, the unit stops.

Control Versions

FROM THE I1 -+ AIR RKENW

Various control versions are available for the model QR-25 series compressors. The control version required is determined by how frequent there is a demand for compressed air. The idea is to create compressed air on demand, but to limit the number of times a motor must start the compressor in a given time period. To prevent motor burnout, the motor should be limited to no more than six (6) starts per hour.

Control Version P : Describes a basic compressor with no added control features.

I Control Version L : Consists of unloader Fig. 2-2 Phlm tower(s)* located on the head of the compres-

CatmlVersion L sor, a hydraulic unloader mounted on the bearing carrier, and a pressure switch. This

version is recommended for those applications where the compressor will not be required to start more than six (6) times per hour. A compressor equipped with control Version L is sometimes referred to as a "start'stop machine".

P AUTOMATIC PRESSURE

I To AIR

RECOVER

I I

Fig. 2-3 ~ h ~ l ~ b

ContrPl Version L Variation ( D h h r g e Line Check Valve & Pllessure Switch)

The pressure switch detects the demand for compressed air and allows the unit'to start. When - the demand is satisfied, the unit stops.

The hydraulic unloader allows the compressor to start in an "unloaded" state, that is, the compressor starts but does not begin to create compressed air until oil pressure is established. The hydraulic unloader also guards against excessive damage in the event of an oil pressure drop.

Control Version L Variations: Variations of Control Version L are illustrated in I3g.s 2-3 & 2-4. Fig. 2-3 shows how a discharge line check valve, pressure switch, & pressure relief valve are combined to provide startJstop operation. Fig. 2-4 is an example of how a Model 108 compressor is equipped with a flyweight controlled three-way valve and

* 1,s. or 4 unlcuder bwts on employed &pending on the 4 of wmpnmor.

QR-25 Series WlNCY COMPRESSOR

5ZaD1-104 7 AugW 1992

UNLOAOER X m E R S

I - - - - 1 ----,--- I

AIR RECEIVER

i

head unloader for stadstop operation.

Control V d o n S : This version is best suited for 'continuous run" applications (whenever the compressor must start more than six [61 times per hour). If the demand for compressed air is continuous and exceeds one half or more of the compressor's capacity, Control Version S should be used.

Once the compressor is started, it continues to run until it is manually turned off. Whenever there is a demand for compressed air, the pilot valve closes, allowing the unloader in the unloader tower to actuate. At this point, the compressor starts making com-

Fig. 2-4 ~k 1166 pressed air. As soon as the demand for com- Contml VeFSion L Variation

(Model lo8 S ~ t o p ) pressed air is met, the pilot valve opens, allowing air pressure to de-actuate in the unloader tower. The compressor continues to run but does not compress air.

Control Version LS: This version consists of a head assembly with unloader toweds)* a

pilot valve and a hydraulic unloader. I t is usually applied to gas or diesel engine driven units. Virtually the same as Control Version S, but with a hydraulic unloader added to protect the compressor in the event of an oil pressure drop.

Control Version LVD: Unloader towedsl* , a pilot valve with a manual shut-off, a hydraulic unloader, a check valve assembly, and a pressure switch make up the LVD Control Version. This version is recommended wherever the degree of demand and usage is variable.

The manual shutoff allows for the selection of either 'start/stopn or 'continuous run"

Fig. 2-6 ='On control. In either situation, the hydraulic Conlm1 Version S unloader protects the compressor from

excessive damage caused by a drop in oil pressure.

* 1,2, or 4 unicuder towem are employed depending on the model of wmpmamr.

QR-25 Series QUINCY COMPRESSOR

52231-IW 8 August 1992

UNLOADER PILOT rrlh CHECK VALVE

(1 11422 w)

CONNECTTO AIR RECEIVER WITH A MINIMUM OF W OD. COPPER TUBING.

Fig. 2-6 pn 1070

~ntnolVerSia~ Is

I / UNLOADER TOWERS

HYDRAULK: UNLOADER

wirh UNLOADER CHECK V A L E PILOT 6 MANUAL SHUTOFF VALVE

(1 11423 w f k )

nm

I '. I ---cO ' I WllH A MINIMUM OF 3W OD.

C , CoPPERNBlffi I

Fig. 2-7 pi. 1071

Contml V d o n LVD

Bamw RPM Madmum Model Stroke L.P. - H2. Range P.s.I.G.*

*Maximum continuous pressure i s indicated on Icp side, d m u m intermittent high prrsswr on right side.


5ZdOl-1W 9 August 1992

SECTION 3 INSTALLATION *Receiving Delivery 10

*Freight Damage lZ

Electrical Supply Requirements 13

Mounting M

*System Components M

Induction System 16

Compressed Air Discharge(System 17

Immediately upon receipt of compressor equipment and prior to completely uncrating, the following steps should be taken:

-1) Inspect compressor equipment for damage that may have occurred during shipment. If any damage is found, demand an inspection from the camer. Ask the camer how to file a claim for shipping damages. (Refer to SECTION 3, *Freight Damage for complete details.) Shipping damage is not covered by Q u b c y c o m p - ~ t y .

Step21 Insure that adequate lifting equipment is available for moving the compressor equipment.

Improper lifting can result in component or system damage, or ! ~ n a l ~ u x y . F o l l o w g o o d s h o p ~ c e s a n d s a f e & ~

when maTing the unit.

Step31 Read the compressor nameplate to verify the model and size ordered.

Step4 Read the motor nameplate to be sure the motor is compatible with your electrical conditions (volts, phase, hertz).

817-25 Series QUINCY COMPRESSOR

SZaD1-1W 10 August 1992

-6') Read the pressure relief valve nameplate to be sure it does not exceed the working pressure shown on the compressor or any other component in the system.

Sbep G) Read and undemtand the safety precautions contained within this manual. The successful and efficient operation of compressor equipment depends largely upon the amount of care taken to install and maintain the equipment. Quincy Compressor strongly recommends that any or all person(s) in charge of installing, maintaining, or servicing one of our compressors read and understand the & contents of this manual in order to perform such duties safely and efficiently.

I t is extremely important that you examine every carton and crate as soon as you receive it. If there is any obvious damage to the shipping container, have the delivering camer sign the freight bill, noting the apparent damage, and request a damage report.

Ifamadeddamageisdhummdatalaterda~thecarriermustbe notified within 15 days ofinitialdpt of&ei@t. Concealed shipping damage is not covered by Quincy Compressor W m t y . Contact the camer as soon as possible, giving them an opportunity to inspect the shipment a t the premises where the delivery was made. Do not move the damaged freight from the premises where the original delivery was made. Retain all containers and packing for inspection by the carrier.

A claim fonn can be requested from the camer: Standard Form for Presentation of Loss and Damage Claims (form # 3208). Your claim will need to be substantiated with the following documents:

a.) form #3208 b.) original bill of lading c.) original paid freight bill d.) original invoice or certified copy e .) other particulars obtainable in proof of loss or damage (photos, damage inspection, etc.)

The proper description and classification of our product in the National Motor Freight Classification 100-H, contained in item 118100, reads as follows:

'Compressors, air, or air ends: with or without air tanks, hose or nozzles, mounted or not mounted."

We suggest that these instructions be circulated to your shipping and receiving personnel.


52201- 1M 11 Au~lsr 1992

Quincy air compressors should be installed in an area that is clean, well Lighted, and adequately ventilated. Inspection and maintenance checks are required daily. Therefore, sufficient space needs to be provided around the compressor for safe and proper inspection, cleaning, and maintenance.

The compressor must not be installed closer than 15 inches to a wall, or 24 inches to another compressor. This allows ample circulation of air across the compressor cylinders, heads and cooler (if so equipped). If at all possible, the pulley drive system (i.e. motor pulley, compressor sheave, belts and guard) should be located next to a wall to minimize any danger created by the drive system while the compressor is operating.

Due to standard drive motor limitations, it is recommended that the compressor be operated in temperatures under 104OF. In cold climates, the compressor should be installed in a heated building.

Do not operate this compressem in ambient temperatures lower

that is to operate in trmpemhnw under 320 F.

not stare toxic, volatile!, ar amwive agents near the ampmsm.

Noise

Noise is a potential health hazard that must be considered. There are federal and local laws governing acceptable noise levels. Check with local officials for specifications.

Excessive noise can be effectively reduced through various methods. Total enclosures, intake silencers, baffle walls, relocating or isolating the compressor can reduce noise levels. Care must be taken when constructing total enclosures or baffle walls. If not properly constructed or positioned, they could contribute to unacceptable noise levels or overheating. Consult your local Quincy Compressor Distributor if assistance is required.

Unusual noise or vibm$ion indicates a pmblem. Do not aperate the CAUTION ! ,2oqmmm,til,-,,k-d-

QR-25 Series WlNCY COMPRESSOR

52201-la 12 A ~ l r s t 1992

eElectriid Supply Reqzhments

The electrical installation of this unit should be performed by a qualified electrician with knowledge of the National Electrical Code (N.E.C.), O . S U code andlor any local or state codes having --

Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. A suitable circuit breaker or fused disconnect switch should be provided. When a 3 phase motor is used to drive a compressor, any unreasonable voltage imbalance between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. Note: This unit must be punded

The installation, electric motor, wiring, and all electrical controls must be in accordance with NFPA 70-1984 National Electric Code, National Electric Safety Code, state and local codes. (See Fig* 3-1 thru 3-7 for Wiring and Piping Schematics). Failure to abide by the national, state and local codes may result in physical harm and/or property damage.

DANGER ! High yoltage may awe persmal injury or death. Ditxonnect and lockoutltagout per O.S.H.A. regulation 1910.147 all electrical power supplies before opening the ehchical enclosure or d c - ing.

Never assume acamprresearissadetowoxkon justbecause it isnot WARNING operating. It could re, at , time. Follow saiee pnxautions outlined in SECIlON 6, *Stopping For Mainteruurce.

QR-25 Series W I N O COMPRESSOR

52201-1W AuW 1992

Roper mounting of Quincy compressors is crucial to the safe operation and longevity of the equipment. The installation requires a flat and level concrete floor or pad. Satisfactory results can usually be obtained by mounting the compressor on vibration isolating pads available from your local Quincy Distributor.

State or local codes may mandate that the compressor be bolted to the floor. In this case the unit must be leveled and bolted making absolutely certain the feet are not stressed in any manner. Uneven feet drawn tightly to the concrete pad will cause severe vibrations resulting in cracked welds or fatigue failure. The customer is responsible for providing a suitable foundation.

Mounting Mobile Units

Gas engine driven compressors mounted to truck beds should be fastened in such a way so as not to create any stress to the air receiver tank. Truck beds, characteristically, have a tendency to flex and could cause damage to the receiver tank if the tank is fastened directly to the truck bed. I t is the User's responsibility to provide an adequate means of fastening the unit in these applications.

*System components

Efficiency and safety are the primary concerns when selecting components for compressed air systems. Products of inferior quality can not only hinder performance of the unit, but could cause system failures that result in bodily harm or even death. Select only top quality components for your system. Call your local Quincy Distributor for quality parts and professional advice.

Drive Pulleys 1 Sheavea

Various pdley and sheave combinations are available to obtain the desired air pressure and delivery rate of your compressor. Consideration must be given to these combinations to ensure that the motor is not overloaded by operating above or below the designed speed range.

Whatever combination is employed, the drive pulleys & compressor sheaves must be properly aligned and drive belt tension set to specifications (refer to SECTION 5, *Pulley 1 Sheave Alignment & Belt Tension). Improper pulley/sheave alignment and belt tension can cause motor overloading, excessive vibration, and premature belt and/or bearing failure.

Excessive compressor RPWs (speed) could cause a pulley or WARNING ! ~ e a v e , ~ t t e r . ~ a n i n s t a n t , ~ e ~ a r * e a v e - ~ into hgments capable of penetrating the belt guaxd and causing bodily harm or death. Do not operate the camp- above the recommended RPM (&er to SECllON 2, *Spci@dmu).

All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guards should be designed to achieve the required degree of protection and still allow firll air flow from the compressor sheave across the unit. Guards shall be in compliance with OSHA safety and health standards 29 CFR 1910.219 in OSHA manual 2206 and any state or local codes.

Guards must be fastened in place befom darting the cmqmsam ! a n d m removed b e h ~ cutting offand locking out the main p0wcrs-e

Checkvalves

Check valves are designed to prevent back-flow of air pressure in the compressed air system (air flows freely in one direction only). The check valve must be properly sized for air flow and temperature. Do not relyuponacheckvalvetoisolateaa,mpmssarhma~tank a r c o ~ a i r d e l i v e r y s y s t e m d u r i n g ~ ~ * d

Manual ShutaffValves

Manual shutoff valves block the flow of air pressure in either direction. This type of valve can be used to isolate a compressor from a pressurized system, provided the system is equipped with a pressure relief valve capable of being manually released. The pressure relief valve should be installed between the manual shutoff valve and the compressor (refer to Fig. 3-9, Typical Dmp Leg & Component Location).

Pressure Relief Valves

Pressure relief valves aid in preventing system failures by relieving system pressure when compressed a 5 reaches a determined level. They are available in various pressure settings to accommodate a range of applications. Pressure relief valves are preset by the manufacturer and under no circumstances should the setting be changed by anyone other than the manufacturer.

QR-25 Serles eUlNCY COMPRESSOR

mU1-104 15 Auglrst 1992

DANGER ! Pressure relief valves are designed to protect compressed air systems in 80cordance with- B19 d t y standank Fail- t opmvidepmper iYs i zedpa~ssurere l i e f~maycauae~ damage,geverepexmnsliqjuxyarevendeath.

*Induction System

Air Intake

A clean, cool and dry air supply is essential to the satisfactory operation of your Quincy air compressor. The standard air filter that the compressor is equipped with when leaving the factory is of sufficient size and design to meet normal conditions, when properly serviced, in accordance with the maintenance section of this manual.

If, however, the compressor is to be installed in a location where considerable dust, dirt and other contaminants are prevalent, consult your local Quincy Distributor for advice and optional filters. I t is the user's responsibility to provide adequate atration for those conditions. Oil bath filters are not to be used. Warranty will be void if a failure is determined to be caused by inadequate filtration.

Remote Inlet Filters

Depending on the size of the compressor and the size and construction of the room in which the unit operates, the air inlet may have to be located outside of the room. If it is necessary to remotely install the air filter, make the inlet piping as short and direct as possible. Remotely installed air filters can lead to vibrations in the inlet piping. These vibrations can be minimized by adding a pulsation dampener in the inlet piping between the remote inlet filter(s) and the compressor.

If the intake is piped to outside atmosphere, a hooded filter should be installed to prevent water or snow from being ingested into the compressor.

All inlet piping should be at least the same size (or larger) in diameter as the inlet connection to the compressor. For every 10 feet of inlet piping or every 90' bend, increase the inlet piping diameter by one pipe size. The inlet piping must be thoroughly clean inside. Remove all weld slag, mst or d i r t Galvanized pipe with threaded or flanged fittings is preferred.

Never locate the compmssor air inlet system where toric, volatile CAUTION ! ar ammsiw m- airtempemturee I m , water, m ex tmdydir tya i rcou ldbe inges t ed .Theae typeso f~ c a u l d ~ a f f e c t t h e p e r f a r m a n o e a f t h e ~ s y s t e m .

817-25 Series BUINC4 COMPRESSOR

5m1-104 16 Mw 1992

Compnessed Air Dischazge System

The discharge piping should be of the same diameter as the compressor discharge connection, or sized so that the pressure drop a t any point in the system does not exceed 10% of the air receiver pressure. Install auxiliary air receivers near heavy loads or at the far end of a long system. This will insure s&cient pressure if the use is intermittent, or sudden large demands are placed on the system.

r

IPROTFCIS CWDRESSOI 1)IIIERSTAGE I

l COLLECTS M REMOVES YUSl lRE FROl s m E Y I

REUEF VAL- I W)OTECTS RECUVW)

I C O L L ~ S WO (IEuowzs UOlSnmE CROW STSTCYI

IFULITATES REYOVN OF ~ ~ s A T I * l

Fig. 3-9 Typical Dmp Ieg & C o q n e n t baation

Discharge piping should slope to a drop leg (refer to Fig. 3-9, Typical Dmp Leg & Component Location) or moisture trap to provide a collection point where moisture can be easily removed. All service line outlets should be installed above the moisture traps to prevent moisture from entering the tool o r device using the air. Manual shutoff valves, protected by pressure relief valves, should be installed at all service line outlets to eliminate leakage while the tools are not in use.

As with any piping, all parts of the discharge piping should fit so as not to create any stress between the piping and components.

Pnuematic Circuit Breakers or Velocity Fuses: The Occupational Safety and Health Act (O.S.H.A.), Section 1926.303. Paragraph 7, published in the Code of Federal Regulations 29 CFR 1920.1, revised July 1, 1982 states that 'all hoses exceeding 1/2" inside diameter shall have a safety device at the source of supply or branch line to reduce pressure in case of a hose failure".

These pnuematic safety devices are designed to prevent hoses from whipping andlor the loss of hnzardous or toxic gasses, all of which could result in a serious or fatal accident.

Never join pipes or fittings with lead-tin soldering. Welded or WARNING ! tbreacled steel pipes and cast iron fittings, designed for the pressures and t e m p x x ~ t ~ ~ ~ ~ , am mmmended.

Pressure Vessels

Air receiver tanks and other pressure containing vessels such as (but not limited to) pulsation bottles, heat exchangers, moisture separators and traps, shall be in accordance with ASME Boiler and Pressure Vessel Code Section VIII and ANSI B19.3 safety standards. They should be equipped with a pressure relief valve, pressure gauge, tank drain, & manual shutoff valve (refer to Fig. 3-9, Typical Drop Leg & Component Location).

ASME coded pressure vessels must not be modified, welded, WARNING ! mpahd, madud m subjeoted 1D operating mnditions outsid. the nameplate ratings. Such actions wi l l negate code status, affect insurance status and may cause p~0pext.y damage, sevem injury a r m death.

A drain valve should be located in the bottom of the air receiver to allow for moisture drainage. Extend piping away from the unit to provide safe and convenient removal of excess moisture. An automatic drain valve is recommended.

If the air receiver is going to be subject to temperatures of 32°F or below, provisions must be made to guard against freezing of the pressure relief valves, pressure gauge, and moisture drain.


52201-104 18 AUQ& 1992

SECTION 4 START-UP & OPERATION

Never assume a amqmsuxis srde to wodc an just because it is not WARNING operating. 11 t o u ~ restart at my time. FOUOW safety ~ u t i o n s outlined in SECTlON 6, *Stbpping Far Maintenance.

WARNING ! Failure to perhrm the pre9tarting checklist may result in me- c3mnirnl Mum, plrrrperty damage, serious injury or even death.

S t e p s l t h m u g h 1 2 a h a U l d b e p c ~ i ~ t o o h ~ ~ t h e u n i t t o a power source. If any condition of the checklist is not satisfied, make the necessary adjustment. or corrections before starting the compressor.

Sbepl) Remove all installation tools from the compressor and check for installation debris.

Step21 Unless 0th- specified, Quincy compmmm are normally shipped without lubricant in the <Tankcase, Add correct amount of specified oil to the crankcase. (Refer to SECTION 5, *Lubrication for quantity and types of lubricant to be used)

-3) Check motor pulley and compressor sheaves for alignment and tightness on shaft. (Refer to SECTION 5, *Pulley / Sheave Alignment & Bdt Tension.)

-4%-.. Manually rotate- the compressor-..sheave -several rotations to be sure there are no mechanical interferences.

-5) Check inlet piping installation (Refer to SECTION 3, *Induction System.)

Check belt tension. (Refer to SECTION 5, *Pulley / Sirecrve Alignment & Be& Tension.)

Step3 Check all pressure connections for tightness.

96ep8) Make sure all pressure relief valves are correctly installed. (Refer to SECTION 3, *System Components.)

-9) Be sure all guards are in place and securely mounted. (Refer to SECTION 3, *System Compnenfs.)

Sbq 10) Check fuses, circuit breakers, and thermal overloads for proper size. (Refer to SECIlON 3, *Electrical Supply Requirements.)

Stepll) Open all manual shutoff valves at and beyond the compressor discharge.

Stepl2) On watercooled units, open the water valve to fill the cooling system. Check for leaks.

If a manual water valve is used, a@ust the valve to maintain an adequate flow of water.

If a water temperature regulator valve is used, install a small bypass orifice in front of the regulator valve to allow heated water to circulate around the temperature sensing bulb at all times.

SbqlS) ARer all the above conditions have been satisfied, the unit can be connected to the proper power source.

-14 Jog the starter switch to check the rotational direction of the compressor. It should agree with the rotation arrow embossed on the compressor sheave.

SbeplS) Check for proper rotation of the cylinder cooling fan (fins inside sheave). The fan should blow cooling air across the cylinder.

This instruction manual, as well as any instructions supplied by manufacturers of supporting equipment, should be read and understood prior to starting the compressor. If there are any questions regarding any part of the instructions, please call your local Quincy Distributor, or the Quincy Compressor factory.

With the pre-starting checklist completed and satisfied, start the compressor. Watch and listen for excessive vibration and strange noises. If either exist, stop the compressor. Refer to SECTION 6, *Troubleshooting for help in determining the cause of such problems.

QR-25 Serles GXIINCY COMPRESSOR

5ZZ01-104 P Augist 1992

If you are starting a pressure lubricated model, check the oil pressure. Compressors producing up to 250 p.s.i.g. of discharge air pressure should maintain 18 to 20 p.s.i.g. of oil pressure. High pressure rated compressors producing more than 250 p.s.i.g. of discharge air pressure should maintain 22 to 25 p.s.i.g. of oil pressure.

Normally the oil pressure does not need to be aGust6d. But if it does, loosen the locknut on the adjustment screw located on the left side of the oil pump housing (see Fig. 4-1, Oil Pressure Adjustment). Increase the oil pressure by turning the adjustment screw clockwise - decrease the oil pressure by turn-

Fig. 4-1 ph 1068

Oil Pressum Adjustment ing the adjusting screw counterclockwise. After adjustment tighten the locknut.

Check the air receiver pressure gauge or system pressure gauges for proper readings. If inadequate or excessive air pressure conditions exist, refer to Section 6 *Tmubleshooting.

Observe compressor operation closely for the first hour of operation and then frequently for the next seven hours. ARer the first eight hours, monitor the compressor a t least once every eight hours. If any abnormal conditions are witnessed, stop the compressor and correct the problem. After two days of operation check belt tension, oil level, and inspect the system for leaks.

Do not proceed until the *Pre-sfcrrfing Checklist and * I n i . Z Starting & Operating sub-sections -have been read and are thoroughly understood.

Sbep 1) Check oil level in crankcase.

Sbep2) Drain liquid from the air receiver and moisture trap (if so equipped).

Step31 Turn on cooling water (watercooled units)

Step4 Jog the starter button and check compressor rotation. Note: Continuous Run Units - Prior to starting a continuous run unit, pull the ring attached to the pilot valve out and turn the finger nut in (clockwise) until it seats against the pilot housing. Now the compressor can be started unlollded. Once the compressor is running at full speed, the finger nut on the pilot valve can be turned out (counterclockwise) until it seats against the pull ring.

QR-25 Series QIJlNCY COMPRESSOR

52291-104 21 August 1992

SbepCi) Start compressor per factory instructions. (Refer to SECTION 4, . ~ S ~ C ~ W c u t d ~ I ~ S t a r f i n g & Operatin.)

Step61 Check system pressure.

-7) Check cooling fan.

-8) Check all pressure relief valves for proper operation.

Step91 Check control system for proper operation.

817-25 Serles QUINCY COMPRESSOR

52201-104 P Aum 1992

SECTION MAINTENANCE & LUBRICATION

'Stopping fir Mainfenance 23

'Maintenance Schedule 24

.Stopping fbr Mai-

The following procedures should be followed when stopping the compressor for maintenance or semce:

Step11 Per 0.S.H.A regulation 1910.147: The Control of Hazardous Energy Source (LockoutA'agout), disconnect and lockout the main power source. Display a sign in clear view a t the main power switch stating that the compressor is being serviced.

WARNING ! Never assume a ccmpwmr is safe to w o d ~ an just because it is not " g .I tcodd~atanythne . *

SbepB Isolate the compressor from the compressed air supply by closing a manual shutoff valve upstream and downstream from the compressor. Display a sign in clear view at the shutoff valve stating that the compressor is being serviced.

step31 Lock open a pressure relief valve within the pressurized system to allow the system to be completely depressurized. NEVER remove a plug to relieve the pressure!

Sbep4) Shut off the water cooling supply (watercooled versions).

QR-25 Serles QUlNCY COMPRESSOR

52601-104 P August 1992

SbepS) Open all manual drain valves within the area to be serviced.

SbepG) Wait for the unit to cool before starting to service. (Temperatures of 125°F can burn skin. Some surface temperatures exceed 350°F when the compressor is operating.)

To assure maximum performance and service life of your compressor, a routine maintenance schedule should be developed. A sample schedule has been included here to help you to develop a maintenance schedule designed for your particular application. Time frames may need to be shortened in harsher environments.

The envelope shipped with the compressor contains a Maintenance Schedule Checklist. Make copies of this checklist and retain the master to make more copies as needed. On a copy of the checklist, enter dates and initials in the appropriate spaces. Keep the checklist and this Instruction Manual readily available near the compressor.

Naintemmce Schedule Cbedklist Sample

Every 8 Hours (or Daily)

Maintain oil level between high and low level marks on bayonet gauge. (Discoloration or a higher oil level reading may indicate the presence of condensed liquids.) If oil is contaminated, drain and replace.

Drain receiver tank, drop legs and traps in air distribution system.

Give compressor an overall visual inspection and be sure safety guards are in place.

Check for any unusual noise or vibration.

Check oil pressure (hot). Maintain 18 to 20 p.s.i.g.*

Check for oil leaks.

Every 40 Hours (or Weekly)

Manually operate the pressure relief valves to be certain they- are working..

Clean the cooling surfaces of the intercooler and compressor.

* ~ i ~ h pressure mkd compELBors should maintoin 22 to 25 p.ri.g. of oil pmauurc. QR-25 Series QUlNCY COMPRESSOR 52201-1M 2l August 1992

Check the compressor for air leaks.

Check the compressed air distribution system for leaks.

Inspect oil for contamination & change if necessary. Change more often under humid or dirty conditions.

Clean or replace the air intake filter. Check more often under humid or dirty conditions.

Every 160 Hours (or Monthly)

Check belt tension

Inspect filters in pilot valve, hydraulic unloader and three valve.

Every 500 Hours (or Every 3 Monihd

Change oil & filter (more frequently in harsher environments).

Torque pulley clamp screws or jamnut.

Every 1000 Hours (or Every 6 Month)

When Quin-Cip oil is used, oil change intervals may be extended to every 1000 hours or every 6 months, whichever occurs first (change more frequently in harsher conditions).

Inspect compressor valves for leakage andlor carbon build-up.

The oil sump strainer screen inside the crankcase of pressure lubricated models should be thoroughly cleaned with a safety solvent during every oil change. If excessive sludge build-up exists inside the crankcase, clean the inside of the crankcase as well as the screen.

Never use a flammable or toxic solvent fir cleaning. Always use WARNING ! a e h k , - w , - w

Every 2000 Hours (or Every 12 Month)

Inspect the pressure switch diaphragm and contacts. Inspect the contact points in the motor 1 starter.

QR-25 Serles QlJlNCY COMPRESSOR

52aD1-1W a5 AUQ& 1992

Quincy compressors are normally shipped without lubricant in the crankcase. Before starting this compressor, add enough lubricant to the crankcase to register between the high and low marks on the dipstick. Use a Quin-Cip oil or consult the Quincy Compressor factory for ~xxx~mmendationsl

Quin-Cip lubricant has proven under extensive testing to minimize friction and wear, limit oil carryover, and reduce carbon and varnish deposits. It will support the performance characteristics and life designed into all Quincy compressors and is highly recommended. Refer to the charts below to determine the correct amount of lubricant and viscosity to use for your model and application.

4 oz. (118 ml.) 10 oz. (296 ml.) 24 oz. (710 ml.) 20 oz. (591 ml.)

- - - - -

206 &210 20 oz. (591 ml.) 216,240*, 310 & 325 lqt. - 16 02. (1.42 lit.) 27W, 340,350 & 370 4 qts. - 24 oz. (4.5 lit.)

390 9 qts. - 16 oz. (9 lit.) 4125*, 5120 & m120 9 qts. - 24 OZ. (9.22 lit.)

*Includes vacuum pump versions.

**These mwlcls may be quipped with oil filtem Add 10 az. of oil if so equipped

Lutnicantspecifid0118 (Use Quin-Cip oil or consult factory.)

Ambient Tempexxitame SAE V i i t y IS0 V i i t y

Below O°F SAE 5W Is0 22 032" F SAE 10W IS0 32 3280°F SAE-20W IS0 68 60-104°F SAT3 30 IS0 100

The lubricant selected must have a pour point at least 15' F CAUTION ! - - ,~-~-* tm-.


522[11-104 aS August 1992

Do not operate this compressor in ambient tempenxtums lower CAUTION ! than -Is0 F. A clanLcase heater is recommended %r eomp~ssmm aperatiagin -underWF.

A new or rebuilt reciprocating compressor should be run for a total of 100 hours at full discharge operating pressure to break-in the new piston rings. Until the rings are seated, the compressor will discharge higher than normal amounts of oil. In light of this fact, the oil level should be checked more frequently during the 100 hour break-in period.

*AcUey / Sheave Aligrunent & Belt Tension

Improper pulleylsheave alignment and belt tension are causes for motor overloading, excessive vibration, and premature belt andlor bearing failure. To prevent this from happening, check the pulleylsheave alignment and belt tension on a regular basis (refer to SECTION 6, *Maintenance Schedule).

Periodically inspect the motor pulley(s) and compressor sheave(s) for oil, grease, nicks or burrs. Clean or replace if necessary. Make sure they are securely fastened. Align the compressor sheave with the motor or engine pulley. Drive belt grooves of the pulley(s) and sheave(s) should be in line with each other. The compressor crankshaft must be parallel to the motor or engine drive shaft.

Belt tension should be measured and a4justed to provide smooth operation. Step-by-step procedures are provided here to correctly measure and set the drive belt tension:

Step 1) Measure the span length of the drive. (Refer to Fig. 5-1, Setting Belt Tension.)

D ' R E C T I ~ OF COMPRESSOR F O R ~ ~ 4ppUm

SHEAVE I m

MOTOR PULLEY

Fig. 5-1 Setting Belt Tep8ion


52201-1W 27 AuW 1992

Belt -PuIlqr Recommended Cross Dia. Range Deaection Fom (Ibs.1 Sectim (inches) M .

Sq2) Determine the amount of deflection ( in inches) required to measure deflection force (in pounds) by multi- plying the span length x LO161 (i.e. 32" span length x [.016l= 1/z"1601 of deflection required to measure deflection force).

Lay a straightedge across the top outer surface of a drive belt from pulley to sheave.

-4) At the center of the span, perpendicu- lar to the belt, apply pressure to the outer surface of the belt with a belt tension gauge (refer to Fig. 5-2, Belt Tension Gauge). Force the belt to the predetermined deflection (refer to Step 2 above). Record the reading on the belt tension gauge and compare to the chart following Fig 5-1. The deflection force reading should be within the minimum and maximum values shown. Adjust belt($ accord-

Fig. 5-2 ~r lm ingly. New belts should be initially Belt Tension Gauge tensioned to the maximum value plus

33% (multiply by 1.33).

SbepS) Recheck the tension of the new belts several times in the first 50 hours of operation- and- a@ust if -necessary,-Thereafter, check belt tension on a regular basis (refer to SECTION 6, *Mcu'ntenunce Schedule).


52231-1W 2B August 1992

Pressure switches provided by Quincy Compressor are pre-set a t the factory and usually do not require adjustment. However, the following procedures can be performed by a qualified electrician to adjust the pressure switch.

Sbep 1) Remove the pressure switch cover.

Step21 While the compressor is running, screw the spring loaded adjustment screw ip (clockwise) to increase the amount of air pressure required to open the switch and stop the unit.

&wtch Screw the spring loaded adjustment

screw Pllfr (counterclockwise) to decrease the amount of air pressure required to open the switch and stop the unit.

Standard pressure switches supplied by Quincy Compressor are equipped with a fixed 20 p.s.i.g.. (approx.) differential. Optional switches include both pressure and differential adjustment capabilities.

Electric power al- exists inside the pmssure switch whenever WARNING ! f i e a m p e s m r ~ i s a m - ~ a - s u p p ~ . ~ ~ nottotouchanyelecbricalleadswhensettingthe~switch.

FULL Lwd Amps 61 Service Foctar can normally be found on thc motor nameplate.

Never assume a amqmsor is s& to work on just because it is not WARNING ! operating. It may be in the automatic stand-by mode and may restart any time. Follow all safety precautions outlined in -ON ii,*StoppingE"or M ' .-

QR-25 Serles WINCY COMPRESSOR

5Zd01-104 29 August 1992

Pressure lubricated QR-25 series compressors can be modified to operate in reverse rotation with exception to the Models 206 & 210. These two models operate in the counterclockwise direction only.

To reverse the operating direction of a -.pressure lubricated compressor, perform the following steps:

Sbepl) Remove: - the control tubing from the hydraulic

unloader and pilot valve (if so J

Fig. 5-4 Phl068 equipped).

C o ~ D i r e c t i d A r r p w s - the oil pressure gauge and hydraulic unloader.

- the pilot mounting stud set screw and pilot valve assembly. - the oil filter* (turn counterclockwise). - six (6) oil pump housing bolts.

Sbep2) Rotate the oil pump housing turn (180"). (Note: The rotational arrow a t the top of the pump housing should now reference the direction you wish the compressor to rotate. (See Fig. 54, *Compre~80r r n t i 0 n . d h)

SbepS) Re-install the six (6) housing bolts and torque them in a star or cross pattern to six (6) ft.-lbs.

Sbep4) Remove the countersunk pipe plug* from the oil pump housing and relocate i t in the opposite (bottom) hole. (See Fig. 5-5, *Relocating Countemunk P i p Plug)

t

PORTS FILTER

. -. .-

Failure to relocate this pipe plug will result in complete loss of oil flow throughout the compressor. Compressor seizure will result and warranty will be void. The countersunk pipe plug must always be relocated in the bottom port position.

9bepS) Install a new oil filter*. Tighten the filter turn after initial gasket contact.

-6) Re-assemble the control components in reverse order.

Stq~?) Double check the directional arrows. Fig. 5-5 H. IIM

Relocating C o u n ~ Pipe Plug Skp8) For aircooled models only, remove the

* ~ o t applicable to models withwt oil pumps QR-25 Series QUlNCY COMPRESSOR

52601-104 33 A u w 1992

standard compressor sheave and replace with a reverse rotation sheave available &om your local Quincy Compressor Distributor.

Sbep9) Start the compressor and adjust the oil pressure.

@Toque Speci@aiions (in ft. llbs., dry threads)

EXand Ccase Cyl. Valve Valve Valve Unldr* In- Rod Brng. Adj. Hole b ~~~~ W'= *

Model Bdt Cam. Plate Plate Cyl. Head Bob Plate Smw L'nut - Bolts

6 7 N/A 33 30 N/A 70 N/A N/A 6 7 N/A 17 30 NIA 70 N/A N/A 30 15 30 30 40 NIA N/A N/A N/A 30 15 30 20 75 N/A 70 86 8

N/A U) 17 17 30 N/A 70 86 3 30 5 30 30 30 NIA 60 75 8 30 12 50 50 90 50 60 50 8 30 12 75 50 90 50 60 75 8 30 5 30 30 30 NIA 60 75 8 30 12 50 50 90 50 60 50 8 30 12 75 65 90 50 60 50 8 30 12 75 66 90 50 60 75 8 30 12 75 65 90 50 60 75 8 75 12 ll0 ail 1 5 0 7 5 7 5 100 8 75 12 75 50 1 5 0 5 0 6 0 75 8 75 12 75 65 1 5 0 5 0 6 0 75 8 75 12 75 40 1 5 0 5 0 6 0 75 8

Torquing Cylinder to FTPad

Torque cylinder to head capscrews to specifications during assembly. Then, run the compressor for at least 30 minutes. Shut the unit off and follow precautions outlined in SECTION 5, Stopping for Maintenance. Retorque the head capscrews to same specitications while the unit is still hot.

QR-25 Serle~ WINO/ COMPRESSOR

5zU1-1W 31 A u ~ 1992

SECTION TROUBLESHOOTING

*Restricted inlet *Defective compressor valves or valve

unloading mechanism *Leaks in the compressed air distribution

system a t fittings, connections, etc. *Unloader pilot defective or set wrong *Pressure switch defective or set wrong *Drive belt slipping 03-way valve defective (Model 108) 'Flyweight assembly on crankshaft .not

functioning properly *Incorrect speed *Worn piston rings or loose piston *Faulty hydraulic unloader *Leaking head gasket *Low oil pressure *Drain valve open *Defective pressure gauge *Excessive running clearances (refer to

SECTION !4 *&xi-) *Ressure relief valve leaking *Clogged intercooler *Loose compressor valves or leaking a t

valve gaskets *Compressor incorrectly sized for the alti-

tude it is operating at *Piston rings not seated; allow 100 hours at

full pressure

QR-25 Series eLllNCY COMPRESSOR

SZdOl-1W 8 August 1992

Water in the <Tankcase (lubricant appears milky)

Rusty valves andlor cy2in- ders

*Compressor does not run long enough to get hot and vaporize the liquids squeezed out of

I the air during compression ' *Leaking water jacket or cylinder head *Incorrect or inferior grade of lubricant *Cooling water circulating in compressor too

cold *System pressure leaking back through dis-

charge valve

*Compressor operated too infrequently *Compressor does not run long enough to get

hot and vaporize the liquids squeezed out of the air during compression (compressor may be too large for application)

*Leaking water jacket or cylinder head *Cooling water circulating in compressor too

cold *Compressor not properly prepared for stor-

age *Discharge line from compressor head is

pointed upward allowing condensation to drain back at shutdown

Excessive vihmtion *Incorrect speed *Compressor valves not functioning prop-

erly *Loose pulleylsheave *Motor or engine out of balance *Compressor, motor or engine not secured

tightly, or tightened into a bind *Foundation or frame inadequate *Piping inadequately supported or tightened

into a bind *Excessive discharge pressure *Compressor feet may need to be leveled with

shims

E.cessive dFive belt wear- *Pulley/sfieave out of alignment- *Belt too loose or too tight *Belt slipping *Pulley/sheave wobbling *Pdley/sheave groove damaged or rough *Incorrect belts

Trouble PrdbahleCause

*Oil pump direction reversed *Oil sump strainer plugged *Excessive leakage a t crankshaft seals *Low oil level *Oil pump incorrectly assembled to the bear- - ing carrier ("owring not properly located between oil pump body & bearing carrier)

*Oil pressure adjusting screw not set properly

*Defective oil pressure gauge *Plugged oil filter

*Air receiver too small *Compressor valves or unloaders defective *Excessive system leakage *Compressor operating at incorrect speed *Unloader pilot differential set too close *Pressure switch defective

C o ~ r l a a d s & l m Z o s d s excessively

*Moisture &/or oil buildup on the pressure switch diaphragm

*Ruptured diaphragm *Burned contact points *Plugged air passage from the receiver to the

pressure switch *Loose electrical connection

*Air receiver too small *Compressor valves or unloaders defective *Excessive leaks in the distribution system *Compressor operating at incorrect speed *Pilot valve differential set too close *Pressure switch defective

*Air pressure gauge inaccurate *Leaks in unloader piping system *Defective compressor valve unloader *Pilot valve or pressure switch set incor-

rectly or defective *Pressure switch wired incorrectly *Hydraulic valve or three way valve not

functioning properly *Tube to compressor unloader valve plugged

QR-25 Series GUlNCY COMPRESSOR 52a0l-104 34 Auglst 1992

Excessive intawoler p=ss- ( T I L u o s f a g e ~ ~

only)

In-P==== abnormally low^ sfage mode& only)

PJmbhleCause

*Intercooler restricted or plugged .Compressor valves in second stage broken

or not functioning properly *Pilot valve or pressure switch set incor-

rectly or defective *Pressure gauge defective

*Compressor valves or valve unloaders in first stage not functioning properly or defective

*Restricted air inlet filter or suction line *Pilot valve or pressure switch set incor-

rectly or defective *Pressurized air at valve unloader not vent-

ing properly when demand for air is required; vent passage a t hydraulic unloader or three valve could be plugged

.Compressor valve or head gasket leaking

.Worn piston rings *Defective pressure gauge *Leaking air a t intercooler or intercooler

connections

*Clogged intake system *Defective compressor valves *Pressure setting too high *Clogged intercooler, internally or exter-

nally *Clogged water passages in cylinder head

Wor cylinders *Defective water temperature regulator

valve .Inadequate cooling water flow, ventilation,

or recirculation of hot air *Pulley/sheave rotation wrong .Incorrect speed *Running clearances insufficient (piston to

cylinder wall or running gear) *Lubrication inadequate *Compressor incorrectly sized

QR-25 Serles QlJINCY COMPRESSOR

52pl-104 35 AugW 1992

l = l d m b k w

*Defective water temperature regulating valve

'Inadequate cooling water flow *Compressor valve assemblies defective *Discharge pressure too high *Inadequate ventilation or hot air recirculat-

i ng *Cooling surfaces of compressor or inter-

cooler excessively dirty *Internd surface of heat exchanger fouled *Ambient temperature too high *Scored or excessively worn cylinder walls *Cooling water temperature too hot

*Head clearance insdlicient *Piston loose in cylinder bore, cylinder bore

worn, piston or piston rings worn *Worn rods or main bearing *Wrong pressure setting, discharge pressure

excessive *Crankcase lubrication inadequate *Loose pulley/sheave *Compressor valve assemblies loose

*Compressor runs unloaded too long *Worn piston rings *Restricted intake system *Compressor running too hot *Breather valve not functioning properly *Oil level in crankcase too high *Oil viscosity wrong for the application *Connecting rod out of alignment, bent or

twisted *Leaking oil seal *Piston rings not seated (allow 100 hours for

seating) *Wrong oil (may be a detergent oil with a

tendency to focrm) *Inferior grade of 'oil

817-25 Serles QUINCY COMPRESSOR

52201-l(34 35 AugLlrt 1992

Tmuble

Excessive cwmnt draw (To determine maximum amper- age allowed, multiply the FLA on the motor nameplate by the service factor.) CAUTION I .--- normally exceeds 170" F.

*Low voltage (must be within 10% of nameplate voltage)

*Loose electrical connection *Wire size too small *Incorrect oil *Discharge pressure too high *Intercooler plugging *Bearings tight or seizing *No crankshaft endplay *Motor sized incorrectly *Motor defective *Drive belts too tight

*Power not on *Blown circuit fuse *Thermal overload fuses tripped *Low voltage *Faulty start switch *Power failure *Pressure switch incorrectly adjusted or

faulty *Loose or broken wire *Motor defective *Compressor seized

*Motor overloaded (refer to Excessive curmnt draw)

QR-25 Series WINCY COMPRESSOR

52201-104 37 Aueurt 1992

SECTION 7 REFERENCE INFORMATION

Notes: 1.) Correction factors are approximate and shown for single stage

COmp~8018 .

A1titudeI (fi) 25- 40- loo*

2.) For two stage compressors use the interstage pressure to find the correction factor.

SeaLevel lo00 aOa,

9000 4UXl

Wm eOOO 'MK)

a m goo0

loo00 11OOO 12000 14000 15000

3.) This chart does not allow for air tools which require more free air at altitiudes above sea level.

LOO 1.00 Loo 1.00 1.00 1.00 1.00

0.996 0.993 0.992 0.992 0.998 0.987 0.982

0.992 0.987 0.984 0.977 0.972 0.969 0.962

0.987 0.98 1 0.974 0.967 0.959 0.954 0.942

0.982 0.974 0.963 0.953 0.944 0.940 0.923

0.977 0.967 0.953 0.940 0.931 0.925

0.972 0.961 0.945 0.928 0.9 17 0.908

0.967 0.953 0.936 0.915 0.902 0.890

0.962 0.945 0.925 0.900 0.886 0.873

0.957 0.938 0.915 0.887 0.868 0.857

0.951 0.931 0.902 0.872 0.853 0.840

0.945 0.923 0.891 0.858 0.837

0.938 0.9 14 0.878 0.839 0.818

0.927 0.897 0.852 0.805

0.918 0.887 0.836 0.784

4.) To find the capacity of a compressor a t a given altitude, multiply the rated capacity of the compressor by the factor corresponding to the altitude and discharge pressure. The result will be the actual capacity (din) of the compressor at the given altitude.

QR-25 Serle~ aUlNCY COMPRESSOR

*Average Intercooler Pressures

QR25SeriesModels


5m)l-1W S Au~ust 1992

Final

l?lw#um (psig)

100

125 150

175

a00

5

250

215 900

325

3ti0 315 400 4;25

450 475

SOD

310 525 340 350 So 990 6120 W6120

35.0 35.5 32.0 34.0 41.0 410 41.0 40.0 36.5 37.0 33.0 35.0 43.5 43.5 43.5 42.5

38.0 38.5 34.0 36.5 46.0 45.5 46.0 45.0 39.5 40.0 35.0 38.0 48.5 47.5 48.5 47.5 410 41.5 36.0 39.0 515 49.0 51.5 50.5 4!2.0 43.0 37.0 40.5 53.5 510 53.5 52.5 43.5 44.5 38.0 42.0 56.0 53.0 56.0 55.0

45.0 46.0 39.0 43.0 47.0 47.5 40.0 44.5 48.5. 49.0 41.0 46.0 50.0 50.5 42.0 47.0 51.5. 52.0 43.0

53.0 53.5 44.0 54.0 55.0 45.0

55.5 57.0 46.0 57.0 58.5 47.0

58.5 60.0 48.0

127902-J A M I S T BE PLACED ON UNlT WHEN ORDERED WlTHOLn PANEL

U

127902-K

1 WITH ~9- LITERATURE

125324-002 FOR 3 0 AND 6 0 GALLON 125324-00 1 FOR 8 0 THRU 2 4 0 GALLON 127902-D

POSITION NEAR MUST BE PLACED K X T TO MAINTENANCE

DISCHARGE TUBE DECAL W ~ L N WRED WITHOUT PANEL

127902-H ON OUTSIDE OF

PACKAGE OR UNlT

I I 0 P U. 0, z P- 4 N hl

0 - Y? ul \

lc T m0, ma, !l' N

ma, 0 IcF 0

r- EN N

\

9 N 0 0)

Qpical Q R S Unit with Vertical Receiver


52601-104 41 AuW 1992

127902-A AND 127902-B TO BE SENT WITH LITERATURE

127902-H ON OUTSIDE OF PACKAGE OR UNIT

1 1 13 17-A ON TOP PLATE IN FRONT OF ENGINE

127902-G/ 127902-D/ 127902-J/ 127902-K ON TOP PLATE BETWEEN ENGINE AND BASlC

#8773 Flexible Hoses for gas, oil, steam, and compressed air are ideal for applications requiring a high degree of flexibility with absolute tightness and protection against bursting.

North American ' 7 \

The overall length of each hose is sufficient for about '/4 "maximum vibration. It is suggested that an 8775 Quick Disconnect Coupling be used between the hose and a burner.

Hose designation

8773-03 8773-02 8773-01

BULLETIN 8770 ~ f g . Co. FLEXIBLE CONNECTIONS

- 450 330 2 % - 450 330 3'/2 bronze hose,

- bronze braid.

- 330 5' brass connections 280 4%

\

dimensions in inches overall minimum min. inside max. static

pipe size (mpt l length bend radius dia. of bend offset of pipes

'/4 24 2 - 7 '18 24 4 - 5 % % 24 5.2 - 4 %

Figure 1. Flexible hose wi th male pipe threads brazed on each end, normally connected t o a supply pipe on one end and an 8775 Quick Disconnect Coupling on a burner at the other end.

Cleveland, OH 44105 USA

max. pressure, psi wt, at 70 F at 400 F Ib construction

3000 2250 1 Teflon hose 2500 1870 1 % stainless steel braid, 2000 1500 2 brass connections

#8775 Quick Disconnect Coupling for oil, compressed air, gas

4-90

Quick Disconnect Couplings for 8773 Flexible Hoses permit instant coupling or uncoupling of the hose by pulling back a knurled sleeve. An automatic shutoff in each half eliminates leakage when disconnected.

L J /'

The coupling consists of a cadmium plated steel socket with female pipe threads and a cadmium plated steel plug with male pipe threads.

The seal is Viton A. The coupling is suitable up to 280 F with 50 psi gas or 500 psi oil or air.

AP f l o w o f 35 SSU #2 oi l i n gph weight, 240 360 Ib

8775-02 0.49 2.30 5.50 0.5 8775-01 0.99 2.20 0.8 8775-0 0.08 0.28 0.64 1.3 8775-1 0.02 0.22 2.0

Figure 2. 8775 Socket and plug.

This model has a two-stage poppet valve to allow connection against static pressure.

INDEX NO. 9

PRESSURE CONTROL VALVE

P R V - 0 0 1 - A , P R V - 0 0 1 - B

n u ACROSS RATS

For ASME code valve currently ovoiiable

in % inch sire in either aluminum or brass,

add ASME after valve number.

' Springs lor each valve ,ire are inter. changeable The Crocking Prerrure range can be changed by replacing the spring with one covering the desired range.

Printed in U S A.

.- ... . - -

INDEX NO. 10

HIGH GAS PRESSURE CUTOFF

P S H - 0 0 3 - A , P S H - 0 0 3 - B

LOW GAS PRESSURE CUTOFF

P S L - 0 0 4 - A , P S L - 0 0 4 - B

LOW O I L PRESSURE CUTOFF

P S L - 0 0 2 - A , P S L - 0 0 2 - B

HIGH GAS PRESSURE CUTOFF

P S H - 0 0 6 - A , P S H - 0 0 6 - B

LOW GAS PRESSURE CUTOFF

P S L - 0 0 6 - A , P S L - 0 0 6 - B

LOW ATOMIZING A I R CUTOUT

P L S - 0 0 7 - A , P S L - 0 0 7 - 8

PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES

8-Series pressure, differential pressure available in AlSl316 or Monel. Differen- All standard models feature rt 1 percent and vacuum switches utilize two different tial pressure models utilize a unique of range set point repeatability and a actuators, depending on set point require- dual diaphragm sealed piston design minimum of 400 percent of range proof ments. For set points between 2 and 3000 that features very hiqh static operating pressures. psi, the simple,' rugged diaphragm sealed pressures and smalisize.

-

piston actuator is used. This design These standard designs perform well in

features high reliability and choice of For set points between 4.5 and 150 applications where shock and vibration inches of H20 a large diaphragm is used could be a problem and may be used in

actuator sea' materials for every for increased sensitivity in both pressure conjunction with Ashcroft diaphragm application. An optional welded design is and differential pressure designs with seals in extreme services such as slurries also for set points up '0° psi* good choice of materials of construction. or abrasive process fluids. for maximum reliability. This design is 'Consult factory for special models up to 1000 PSI.

PRESSURE/ VACUUM SWITCHES

DIFFERENTIAL PRESSURE SWITCHES

Vacuum -30" Hg

Compound -15" HzO/

15" Hz0 -30" Hz01 30" H20

-30" Hg/ 15 psi

-30" Hg/ 30 pa

-30" Hg/ 60 PSI

Pressure 10" Hz0 30" Hz0 60" Hz0

100" H20 150" H20

15 PSI 30 PSI 60 psi

100 psl 200 psi 400 PSI 600 PSI

1000 psi 3000 psi

Overpressure

Proof psi

250

20

20

250

250

250

20 20 20 20 20

500 500 500

1000 1000 2400 2400

12000 12000

Nominal Flangei1'

-760rnm Hg

-375rnm H20/ 375mrn Hz0

-760rnrn H201 760rnrn H20

-760mm Hg/ 1.0 kglcrn2

-760rnm Hg/ 2.0 kg/crn2

-760rnrn Hg/ 4.0 kg/crnz

250mrn Hz0 750mm Hz0

1500rnm H20 2500rnrn H A 3750rnrn H20

1.0 kg/crn2 2.0 kg/crn2 4.0 kg/crn2 7.0 kg/cm2 14 kglcrnz 28 kg/crn2 42 kglcrnz 70 kg/crnz

210 kglcrnz

Nominal ~ange"'

20,26,27

3-.7

.15-.75/

.15-.75

.30-.60/

.30-.60 .5-1.0/ .3-.7

1.0-1.5/ .3-.8

2.0-3.0/ .7-1.5

.2-.5

.3-.6 5-1.3 .6-1.6

1.0-2.5

.l-.35

.l-.50

.3-1 .O 51.7 1-3 4-7.5 4-1 1 7-30

15-60

Ratings Burst psi

400

35

35

400

400

400

35 35 35 35 35

1500 1500 1500 3000 3000 3000 3000

18000 18000

-100 kPa

-3.7 kPa/ 3.7 kPa

-7.5 kPa/ 7.5 kPa

-100 kPa/ 100 kPa

-100 kPa/ 200 kPa

-100 kPa/ 400 kPa

2.5 kPa 7.5 kPa 15 kPa 25 kPa 37 kPa

100 kPa 200 kPa 400 kPa 700 kPa

1400 kPa 2800 kPa 4200 kPa 7000 kPa

21000 kPa

lalues shown are for zero static working pressure.

NOTES: Switches may generally be set between 15% 2 All deadbands are given in English units as Viton: Multiply Buna N value by 1.4 and 100% of nominal range on increasing shown in the nominal range column. Teflon: Multiply Buna N value by 1.2 pressure. Consult factory for applications Deadbands shown are for switches with Stainless Steel: Multiply Buna N value by 1.7 where set points must be lower. Buna N diaphragm. Approximate Monel: Multiply Buna N value by 1.7

deadbands for optional diaphragms:

30" Hz0 , 60" Hz0

100" HzO 150" Hz0

15 psid 30 psid 60 psid

100 psid 200 psid I 400 psid

, 600 psid

Pressure Ratings

Approximate 21,24,31

1.5-3.0

1.5-2.5/ 1.5-2.5 1.5-2.51 1.5-2.5 2.0-3.0/ .5-1.5

3.0-6.01 1 .O-2.0 5.0-9.01 3.0-5.0

1.0-2.0 1.5-2.5 1.5-3.5 2.5-5.5 4.5-8.5

.5-1.5 5-1.5

1 .O-3.5 1.5-5.0

5-13 5-24 9-30

30-110 80-235

Approximate Deadband Buna-N ~ia~hragm"'

Static Work- ing Pressure

5.4 5.4 5.4 5.4

500 500 500

1000 1000 1000 2000

750mm Hz0 1500rnm Hz0 2500mrn Hz0 3750rnrn H20

1.0 kg /cm2 2.0 kg/cm2 4.0 kg/cmZ 7.0 kg/crnz

14.0 kgIcm2 28.0 kg/cm2 42.0 kg/crn2

20,26,27

.3-.6 51.3 -6-1.6

1.0-2.5

.5-1 .O 1.0-2.0 2.0-4.0 4.0-10.0 5.0-15.0

10.0-20.0 20.0-40.0

Proof psi

21.6 21.6 21.6 21.6

2000 2000 2000 4000 4000 8000 8000

7.5 kPa 15 kPa 25 kPa 37 k Pa

100 kPa 200 kPa 400 kPa 700 kPa

1400 kPa 2800 kPa 4200 kPa

~eadband'~ '

50

.5-2.2

.45-2.0/

.45-2.0

.45-2.01

.45-2.0

.75-2.5/ .5-1.0

1.2-4.51 .7-1.5

2.5-7.0/ 1.1-4.0

.35-1.5

.45-2.0 .9-2.5

1.1-4.0 1.7-6.5

.2-1.0

.3-1 .O

.7-2.5 1.1 -3.5

2-9 5.5-1 5

7-20 18-70 37-1 60

21,24,31

1.5-2.5 1.5-3.5 2.5-5.5 4.5-8.5

2.0-5.0 -2.0-5.0 3.0-6.0

11.0-20.0 12.0-40.0 20.0-60.0 80.0-150.0

Switch Element

22

4-1.0

.2-1.0/

.2-1.0 .40-.85/ .40- 85 .7-1.4/ .4-1.0

1.4-2.1/ .4-1 .I

2.8-4.2/ 1.0-2.1

.3-.7

.4-.85

.7-1.8 ..8-2.3

1.4-3.5

.14-.50

.14-.70 .4-1.4 .7-2.5

1.4-4.5 5.6-10.5 5.6-15.4 10-42 21 -84

32

2.1 -4.2

2.1-3.5/ 2.1 -3.5 2.1-3.5/ 2.1-3.5 2.8-4.2/ .7-2.1

4.2-8.4/ 1.4-2.8 7.0-12.01 4.2-7.0

1.4-2.8 2.1 -3.5 2.1 -5.0 3.5-7.7 6.0-12.0

.7-2.1

.7-2.1 1.4-5.0 2.1 -7.0 7.0-18.2 7.0-33.6

12.6-42 42-1 54

11 2-329

50

.45-2.0 .9-2.5

1 .I -4.0 1.8-6.5 .7-3.5

1.5-3.5 3.0-4.5 7.0-15.0

10.0-26.0 15.0-40.0 30.0-1 15.0

22

.4-.8 .7-1.8 .8-2.2

1.4-3.5 .7-1.4

1.4-2.8 2.8-5.6 7.0-15.0 7.0-21.0

14.0-28.0 27.0-56.0

32

2.1 -3.5 2.1 -5.0 3.5-7.7 6.3-12.0

2.8-7.0 2.8-7.0 4.2-8.5

16.0-28.0 17.0-56.0 28.0-84.0

11 2.0-21 0.0

INDEX NO. 11

HIGH PRESSURE REGULATOR

P C V - 0 3 3 - A , P C V - 0 3 3 - B

?I001 - FEATURES PICTORIALLY TYPICAL-ORIENTATION MAY OIFFEH

L MAX -4

-P

ENVELOPE DIMENSIONS ARE + .25

I CUSTOMER ( P.O. NO. ( TAG NO.

AMERICAN HYDROTHERM C O R P O R A T I O N I 2579-26106 AM2579-PCV-033-A.AM2579-PCV-033-R SERIAL NO. 1 ORDER NO. 1 &4FORMITION CERTIFIED CORRECT ,

001-A0201598A ( DATE 3 - /d *9? B V ~ M

OWN. I R.M. 1 4-28-41 630 I

CHKD.~ UC& 1 4-28-41 -- B I G JOE@ F I ELD REGULATOR IN APIID. 1 h L S 16- 2 3 - 7 3 4 I

COO(E 22600 SCALE-N~ME -E[m[3-ze-es F a 1 0 - 2 9 - 8 6 OWGm). REV

l i .h.rCc YOIS r

Marshallto. . Iowa. USA liaher Cmntro8m 1 9 8 2.1 9 87 n€vmmMs G MMS 9-21-87 Y54 1 G

630 Series

Fisher Controls Instruction Manual

630 Series Regulators and Relief Valves

December 1990 Form 1243

Introduction

Scope of Manual This instruction manual provides operating, installation, maintenance, and parts information for the 630 Series regulators and relief valves.

Description The 630 Series cogsists of self-operated, spring loaded Type 630 Big Joe pressure regulators and Type 630R relief valves which are designed for maximum inlet pressures to 1500 psig (1 03.4 bar) and outlet pressures from 3 to 500 psig (.21 to 34.5 bar).

Specifications Table 1 lists the specifications for the 630 Series constructions. Figure 1. Spring-Loaded Type 630 Regulator

Installation

Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of pressure-containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given in tables 1 through 4 or where conditions exceed any ratings of the adjacent piping or piping connections.

To avoid such injury or damage, provide pressure-relieving or pressure-limiting de-

vices (as required by the appropriate code, regulation, or standard) to prevent service conditions from exceeding those limits.

Additionally, physical damage to the regulator could cause personal injury or property damage due to escaping gas. To avoid such injury or damage, install the regulator in a safe location.

Before installing, inspect the unit for any damage and any foreign material. The regulator or relief valve may be mounted in any position, however ensure that the flow direction corresponds with the direction of the arrow on N

0

the nameplate. Apply a good grade of pipe compound to 8 :: the male threads of the pipeline. 0

0 0

@Fisher Controls International Inc. 1955, 1990; All Rights Reserved

630 Series

Table 1. Specifications

BIG JOE TYPE 630 -1 DATE 1-1 S'RINQ RANa951 PORT SIP-IN MAX RE99 DAOPPSI

Available Configurations Material Temperature Capabilities(1) Type 630: Spring-loaded reducing regulators Standard: - 20 to 1 50°F ( - 29 to 66OC) Type 630R: Spring-loaded relief valves Optional: - 20 to 300°F ( - 29 to 14g°C)

End Connection Sizes And Style Orifice Sizes 1 or 2-inch, screwed 118 (3.2 mm), W 3/16 (4.8 mm), W 114 (6.4 mm),

318 (9.5 mm), or 112-inch (1 2.7 mm) Maximum Allowable inlet Pressures(1)

Type 630 Regulators: See table 2 Coefficients For Relief Valve Sizing Type 630R Relief Valves: See table 4

m l w ~ a a TOTAL m T

2 MAX OPERATINO OVTllT FESSRE

INSIAUCTIW W A L

MAY D W G € Ihl€FNM

ORIFICE SIZE,

Outlet Pressure Rangescl) INCH (mm)

3 to 500 psig (0.2 to 34.5 bar) with intermediate 1/8-inch (3.2 mm) orifice:

values shown in table 3 3/ 16-inch (4.8 mm) orifice: 1/4-inch (6.4 mm) orifice: 3/8-inch (9.5 mm) orifice:

Maximum Allowable Outlet Pressures(1) 1/2-inch (1 2.7 mm) orifice:

l F7496 K SHT 1

TYPE 630

Vents

See table 3 Approximate Weights

Maximum Allowable Pressure Drops(1) 1-inch End Connection: 25 Ib (1 1.3 kg) See table 2 2-inch End Connection: 30 Ib (13.5 kg)

1. The pressure/temperature limits in this manual and any applicable code or standard limitations should not be exceeded.

WIDE OPEN

r w P E 63oR I I DATE I 17

Cg 13.9 31.3 55.1 122.5 21 6.0

- - RELIEF VALVE [= 1 1

RELIEF PRESSURE RANGE

C1

28.4 28.2 27.2 26.6 26.4

I I L J - WARNING I I

I. MAX ALLOWABLE INLET PRESSURE BUILD-UP ABOVE SPRING SETTING 11 PSlG

2. MAX EMERGENCY INLET (CASING) PRESS. -1 PSlG 1 1 3 INSTALL, OPERATE 8 MAINTAIN ONLY IN ACCORDANCE WITH

INSTRUCTION MANUAL.

21A5495 G SHT 1

TYPE 630R

Figure 2. 630 Series Nameplates

When the unit is installed in an enclosed area or indoors, escaping gas may accumulate and be an explosion hazard. Under these conditions the vent should be piped away from the unit to a freely ventilated

outdoor location away from air intakes, windows, etc. Protect all vent openings against weather or the entrance of any foreign material that may plug the vent or affect operation of the regulator or relief valve. Inspect all vent openings periodically to be sure they are not plugged. If the vent is in an environment where freezing rain, ice, or snow could clog the vent, it is recommended that a weatherproof vent be used.

630 Series

Table 2. Maximum lnlet Pressures and Pressure Drops for Type 630 Regulators

Table 3. Spring-Loaded Type 630 Regulator Outlet Pressure Limits

Description

Maximum Allowable lnlet Pressure, Psig (Bar)

Maximum Allowable Pressure Drop(2) Psi (Bar, Differential)

I I I pressure I

1. lnlet pressure must not exceed the sum of the actual outlet pressure sening and Me differential). For better erosion resistance, nylon valve disks are normally furnished for maximum allowable pressure drop. For example, with an outlet pressure setting of higher pressure drops. Some erosion of valve disks occurs at all pressure drops due to 200 psig (13.7 bar) and a 318-inch (9.5 mm) orifice with a maximum allowable pressure solid particles in the flow stream. The rate of erosion is higher with large amounts of drop of 500 psi (34.5 bar, differential), the maxmum allowable inlet pressure is 700 impurities in the flow stream and with high pressure drops. Valve disks and other pslg (48.3 bar). regulator parts must be inspected periodically for erosion and damage and must be

2. Nitr~le valve disks are normally furnished for pressure drops to 200 psi (13.7 bar. replaced as necessary.

l/a-inch (3-2 mm) and 3116-inch (4.8 mm)

Orifice Size

1500 (103.5)(')

1500 (1 03.5)

Description

Outlet Pressure Range, Psig (Bar) and Spring Part Number

Maximum Allowable Operating Outlet Pressure, Psig (Bar)

1. Damage to internal parts of the regulator may occur if outlet pressure exceeds the 3. For outlet pressure settings to 350 psig (24.1 bar) only. For pressure settings over 350 actual pressure setting by amounts Preater than those shown in this row. psi (24.1 bar , outlet pressure is limited by maximum emergency outlet pressure of

2. For outlet pressure settings to 25 psl (1 7 bar) only. For pressure settings over 25 %?psig (38.b bar). psig (1.7 bar), outlet pressure is limite$bymaximum emergency outlet pressure of 45 4. Leakage or bursting of pressure containing pans may occur if outlet pressure psig (3.1 bar). exceeds these values.

l/4-inch (6.4 mm) Oritice Size

1500 (1 03.5)(1)

1000 (69)

Maximum Emergency Outlet (Casing) Pressure(4) Psig (Bar)

Spring-loaded constructions have a screened vent as- Refer to the following tables to determine pressure sembly (key 27, figures 5, 6 and 7) installed in the 114- ratings: inch NPT spring case vent opening. If a remote vent is required, remove the vent assembly and install a remote 1. Spring-loaded Type 630 regulators. vent line. a. Inlet pressure and pressure drop-table 2.

b. Outlet pressure-table 3.

Low-Pressure Regulator

2. Spring-loaded Type 630R relief valve pressure- table 4.

318-inch (9.5 mm) Orifice Size

1000 (69)(l)

500 (34.5)

3 to 10 (0.2 to 0.7)

OW01 92 27022

10 (0.7)

High-pressure Regulator

45 (3.1)

Overpressure Protection

112-inch (12.7 pm) Orifice Size

750 (51

250 (17.3)

550 (38.0)

As is the case with most regulators, the Type 630 spring-loaded regulators have outlet pressure ratings that are lower than the inlet pressure ratings. Overpres- sure protection must be provided if the actual inlet pressure can exceed the outlet pressure rating. Over- pressure protection is also required for the loading regulator and main regulator spring case of relief valves.

8 to 20 (0.5 to 1.4)

OW01 91 27022

20 (1.4)

27 to 50 (1.9 to 3.5)

OW0192 27022

50 (3.5)

Overpressuring any portion of this equipment may cause damage to regulator parts, leaks in the regulator, or personal injury due to bursting of pressure-containing parts or explosion of accumulated gas.

90 to 150 (6.2 to 10.3)

OW0190 27022

150 (10.3)

46 to 95 (3.2 to 6.6)

OW0190 27022

95 (6.6)

17 to 30 (1.2 to 2.0)

OW0190 27022

30 (2.0)

150 to 200 (10.3 to 13.8)

OY0664 000A2

200 (13.8)

27 to 40 (1.9 to 2.8)

OY0664 000A2

40 (2.8)

200 to 275 (13.8 to 18.9)

1J1469 271 42

275 (18.9)

275 to 500 (18.9 to 34.5)

1 K3709 27082

500 (34.5)

630 Series

1. Leakage or bursting of pressure-containing parts may occur if inlet pressure exceeds these values.

Table 4. Spring-Loaded Type 63013 Relief Valve Pressure Limits

To avoid overpressure, provide an appropriate overpressure protection device to ensure that none of the limits listed in tables 1 through 4 will be exceeded.

Description Maximum Allowable Relief (Inlet) Pressure, Psig (Bar)

Maximum Emergency Inlet (Casing) Pressure('), Psig (Bar)

Relief (Inlet) Pressure Settings' Psig (Bar) and Spring Part Number

Regulator or relief valve operation below the limits specified in tables 1 through 4 does not preclude the possibility of damage from external sources or from debris in the gas line. Inspect the regulator for damage after any overpressure condition.

Startup

Starting up the unit consists of opening the upstream block valve, introducing gas pressure. Use gauges to monitor pressures during startup.

Low-Pressure Relief Valve

Relief Pressure Setting Plus Maximum Allowable Buildup of 25 psig (1.7 bar)

75 (5.2)

setting by more than 20 psig (1.4 bar) for low pressure constructions or 200 psig (14 bar) for high pressure constructions, or damage to internal regulator parts may occur. However, with some higher pressure ranges, the setting plus 20 psig (1.4 bar) or 200 psig (14 bar) exceeds the maximum emergency outlet (casing) pressure. Before increasing the setting, refer to tables 3 and 4 (as appropriate). Review the pressure limits for the spring range being used, and be certain that the new pressure setting will not result in an overpressure condition. Always use a pressure gauge to monitor pressure when making adjustments.

3 t o 8 (0.2 to 0.5)

OW0192 27022

High-pressure Relief Valve Relief Pressure Setting Plus Maximum Allowable Buildup of 250 psig (17 bar)

550 (38.0)

Adjusting Spring-Loaded Regulators and Relief Valves

30to70 (2.0 to 4.8)

OW0191 27022

Loosen the locknut (key 2, figures 5, 6 and 7) atop the spring case. While monitoring the pressure, rotate the adjusting screw (key 1, figures 5, 6 and 7) clockwise to increase set pressure or counterclockwise to decrease it. When the unit is regulating or relieving pressure at the desired value, tighten the locknut.

6 t o 1 7 (0.4 to 1 . l )

OW0191 27022

The range of allowable pressure settings is marked on the nameplate. If a pressure setting beyond the nameplate range is required, substitute an appropriate spring selected from table 6. Be sure to change the nameplate to indicate the new pressure range.

50 to95 (3.5 to 6.5)

OW0190 27022

Shutdown

1 5 t o 2 2 (1.0 to 1.5)

OW0190 27022

Slowly close the upstream block valve.

75to175 (5.2 to 12.1)

010664 000A2

To avoid the consequences of over~tightening the spring in spring-loaded regulators

20to35 (1.4 to 2.4)

OY0664 000A2

150to250 (10.4 to 17.3)

1J1469 27142

or relief valves, consult table 5 and replace the adjusting screw with one of the correct

27to50 (1.9 to 3.5)

1 J1469 27142

Principle Of Operation length- whe" replacing the spring.

This section describes the operation of the Type 630 regulator and the Type 630R relief valve with spring

Some pressure ratings are dependent upon the actual loading. Set pressure is changed with the adjusting outlet pressure settings being used. For example, with a screw on the regulator or relief valve. The Type 630R Type 630 regulator, outlet pressure must not exceed the relief valve uses a light spring for added stability.

630 Series

INLET PRESSURE

OUTLET PRESSURE

4812978-A A2525-1

VALVE PLUG u

48AZ977 ~2826.1 VALVE PLUG

Figure 3. Type 630 Regulator Sectional View Figure 4. Type 630R Relief Valve Sectional View

Type 630 Regulators from the pressure system and release all pressure from the regulator or relief valve

Refer to figure 3. In the regulator construction, outlet before performing maintenance. pressure registers beneath the diaphragm. As long as the outlet Pressure is less than the set Pressure, spring Except where indicated, key numbers in the following force on the diaphragm causes the lever to hold the procedures are shown in figures 5 and 6 for the Type valve open. When the outlet Pressure ~xceeds the set 630 regulator, in figure 7 for the Type 630R relief valve. pressure, the diaphragm moves to compress the spring and the lever closes the valve until the outlet pressure returns to set pressure. Replacing Orifice, Valve Disk, and Lever

Type 630R Relief Valves Refer to figure 4. In the relief valve construction, inlet pressure registers beneath the diaphragm. As long as the inlet pressure is less than the set pressure, spring force causes the lever to hold the valve closed. When the inlet pressure exceeds the set pressure, the diaphragm moves to compress the spring and the lever opens the valve allowing inlet pressure to bleed into the downstream line or to atmosphere until the inlet pressure returns to set pressure.

Maintenance

Note

With some piping systems it may be possible to omit step 1 below by removing four cap screws (key 17) and spreading the body (key 23) and inlet adaptor (key 18) far enough apart to allow removal of the orifice (key 20) and Type 630 valve disk (key 21, figures 5 and 6) or the orifice (key 20) and the Type 630R valve seat O-ring (key 37, figure 7).

Parts are subject to normal wear and must be inspected If step 1 is omitted and the body and inlet and replaced as necessary. Frequency of inspection adaptor are separated, take care to avoid depends upon severity of service conditions. pinching fingers between the body and the

inlet adaptor.

1. Disconnect piping from inlet adaptor (key 18). Re- move four cap screws (key 17) and adaptor.

To avoid personal injury or equipment damage, isolate the regulator or relief valve 2. Remove orifice (key 20) and gaskets (key 19).

630 Series

3. To remove Type 630 valve disk (key 21, figures 5 and 6) or Type 630R valve seat O-ring (key 37, figure 7), first disconnect remote vent pipe (if one is used).

4. Unscrew the two cap screws (key 31, not shown) that secure diaphragm adaptor (key 13) to body (key 23); remove diaphragm adaptor and attached spring case (key 3).

5. If it is necessary to replace the lever (key 14), drive out the pin (key 15) and slide the lever out of the diaphragm adaptor. When replacing the lever, make sure the slot engages the connector assembly (key 12) and replace the pin.

6. Remove valve carrier assembly (key 22) from body.

7. To replace seating surface: a. For Type 630, use a 314-inch socket wrench to

remove and re-install valve disk and holder assembly (key 21, figures 5 and 6).

b. For Type 630R, unscrew machine screw (key 36, figure 7) and remove O-ring washer and O-ring (keys 32 and 37, figure 7) from O-ring holder (key 21, figure 7). When reassembling, apply a good-quality gasket shel- lac to the machine screw thread.

8. Use new orifice gaskets (key 19) and body gasket (key 16) when reassembling. Insert valve carrier assembly (key 22) into the body before re-installing the diaphragm adaptor.

Note The spring case (key 3) must point away from the inlet adaptor (key 18) on Type 630 regulators as shown in figures 5 and 6. On Type 630R relief valves, the spring case must face the same direction as the inlet adaptor (key 18) as shown in figure 7.

9. Be certain the lever (key 14) engages the valve carrier.

10. Secure the diaphragm adaptor (key 13) to the body (key 23). Fit the inlet adaptor (key 18) to the body (key 23) and install and tighten the four cap screws (key 17).

Replacing the Diaphragm 1. To relieve spring compression, loosen locknut (key 2, figures 5, 6, and 7). Turn the adjusting screw (key 1, figures 5, 6, and 7) counterclockcwise until spring compression is relieved.

2. Disconnect remote vent line (if one is present).

3. Remove spring case (key 3) by unscrewing cap screws and nuts (keys 9, 10 and 30)

4. Remove diaphragm (key 11) and attached parts from the lever (key 14).

5. Unscrew cap screw (key 6) from connector head assembly (key 12) and disassemble the diaphragm assembly.

6. Install new diaphragm being certain that the diaphragm is centered. Note that low-pressure constructions use a diaphragm plate (key 8, figure 5) on the spring case side of the diaphragm. Install new gaskets when replacing diaphragm.

7. When reassembling, be certain that the diaphragm connector is engaged in the lever.

Note

Be careful not to twist the diaphragm to lever attachment during assembly. Twisting will cause sufficient friction to interfere with the proper operation of the regulator.

8. To ensure proper slack in the diaphragm, tighten the spring case cap screws finger-tight only. Compress the spring slightly with the adjusting screw then complete the tightening of the spring case cap screws and nuts.

Parts Ordering

When corresponding with your Fisher sales office or sales representative concerning this unit, state the type number and all other pertinent information on the nameplate (key 34, figures 5, 6 and 7).

When ordering replacement parts, reference the key number and the eleven character part number as found in the following parts list.

630 Series

Parts List

OX0119 F

Figure 5. Spring-Loaded Type 630 Regulator-Low-Pressure Construction

Note

In this parts list, parts marked NACE are intended for corrosion-resistant service as detailed in the National Association of Cor- rosion Engineers (NACE) standard MR-01- 75.

Parts Kits Type 630 regulator kits are for low or high pressure spring-loaded construction. Kits include neoprene diaphragm, copper inlet gasket material (for brass trim) or composition material (for stainless trim), and valve disk assembly material as noted. Orifice included only where indicated. If separate orifice is required, must be ordered separately by appropriate part number based on orifice size and material. (Included are keys 11, 16, 19, 21 and 20)

Key Description Part Number

Low Pressure Without orifice

Brasslnitrile Brasslnylon BrassITFE Stainless steellnitrile Stainless steel/nylon (standard & NACE) Stainless steel1TFE

With orifice (key 20) 112-inch (1 2.7 rnrn) brasslnylon 112-inch (12.7 rnrn) stainless steel/nylon


High Pressure Without orifice

Brasslnitrile Brasslnylon BrassITFE Stainless steellnitrile Stainless steellnylon (standard & NACE) Stainless steel/TFE

With orifice (key 20) 118-inch (3.2 rnrn) brasslnylon 118-inch (3.2 rnrn) stainless steel/nylon (standard)

118-inch (3.2 rnrn) stainless steel/nylon (NACE)

114-inch (6.4 rnrn) brasslnylon 114-inch (6.4 rnm) stainless steellnylon (standard)

114-inch (6.4 rnrn) stainless steel/nylon (NACE)

Type 630R Relief Valve retrofit kit converts Type 630 to a Type 630R. (Included are keys 20, 21, 32, 34, 36 and 37)

112-inch (12.7rnrn) brasslnitrile R630R XOOB12 1 12-inch (1 2.7rnrn) stainless steellnitrile R630R XOOS12

1 Adjusting Screw, steel 2 Hex Nut, zinc pl steel 3 Spring Case

Low-pressure Cast iron Steel

High-pressure Cast iron Steel

4 Upper Spring Seat, zinc Pressure range to 275 psig (19 bar) Pressure range over 275 psig (19 bar)

See table 5 1 A3524 241 22

630 Series

Figure 6. Spring-Loaded Type 630 Regulator-High-pressure Construction

Description Part Number Key Description Part Number

Spring, steel Cap Screw, plated steel Lower Spring Seat Low-pressure, steel High-pressure, zinc Pressure range to 275 psig (1 9 bar)

Pressure range over 275 psig (19 bar)

Diaphragm Plate, zinc plated steel Low-Pressure only, (1 req'd)

Cap Screw, zinc plated steel For use with steel diaphragm adaptor For low-pressure regulator (10 req'd) For high-pressure regulator (4 req'd)

Cap Screw, plated steel (for use with cast iron diaphragm adaptor)

Low-pressure (1 0 req'd) High-pressure (4 req'd)

Diaphragm Neoprene For low-pressure regulator For high-pressure regulator

Fluoroelastomer For low-pressure regulator For high-pressure regulator

Connector Head Assembly Aluminum trim Aluminum trim (NACE) Stainless steel trim Stainless steel trim (NACE)

Diaphragm Adaptor Low-pressure Cast iron Steel Steel (NACE)

High-pressure Cast iron Steel Steel (NACE)

See table 6 1 R81 76 9901 2

14 Lever Assembly, stainless steel Low-pressure Low-pressure (NACE) High-pressure High-pressure (NACE)

15 Pin, stainless steel Stainless steel (NACE)

16" Gasket, composition

17 Cap Screw, steel (4 req'd) 1 -inch body 2-inch body

18 lnlet Adaptor, steel 1-inch NPT 1-inch NPT (NACE) 2-inch NPT 2-inch NPT (NACE)

19' lnlet Body Gasket (2 req'd) Copper, for brass trim Composition, for stainless steel trim

20' Orifice Type 630

Brass 118-inch (3.2 mm) 3116-inch (4.8 mm) 114-inch (6.4 mm) 318-inch (9.5 mm) 112-inch (1 2.7 mm)

Stainless steel 118-inch (3.2 mm) 3116-inch (4.8 mm) 114-inch (6.4 mm) 318-inch (9.5 mm) 112-inch (12.7 mm)

Type 630R Brass 112-inch (12.7 mm)

Stainless steel 112-inch (12.7 mm)

'Recommended spare part. 8

630 Series

Figure 7. Spring-Loaded Type 630R Relief Valve-High-pressure Construction

Key Description

20' Orifice (Continued) Stainless steel (NACE)

118-inch (3.2 mm) 3116-inch (4.8 mm) 114-inch (6.4 mm) 318-inch (9.5 mm) 112-inch (12.7 mm)

Part Number Key Description

23 Body I-inch NPT, cast iron

1 K4166 XOOI 2 1-inch NPT, steel 1 K4165 X0012 1-inch steel (NACE) 1 K4164 X0012 2-inch NPT, cast iron 1 K4163 XOOI 2 2-inch NPT, steel 1 K4162 XOOI 2 2-inch steel (NACE)

21' Valve Disk Assembly Type 630 only

For pressure ranges to 200 psig (13.8 bar) Brass holder, nitrile disk 184500 000A2 Stainless steel holder, nitrile disk 184500 00082 Brass holder, polyurethane disk 1P7351 X0012 Stainless steel holder, polyurethane disk 1P7351 000A2

Brass holder, fluoroelastomer disk 184500 X0042 Stainless steel holder, fluoroelastomer disk 1 84500 X0012

For pressure ranges over 200 psig (13.8 bar) Brass holder, nylon disk 1 C1860 000A2 Stainless steel holder, nylon disk 1C1860 00082 Brass holder, TFE disk 1 C1860 OOOC2 Stainless steel holder, TFE disk 1 C1860 000D2

NACE construction For pressure ranges to 200 psig (13.8 bar) Stainless steel holder, nitrile disk 184500 X0072 Stainless steel holder, fluoroelastomer disk 184500 X0082

For pressure ranges above 200 psig (13.8 bar) Stainless steel holder, nylon disk 1 C1860 000B2 Stainless steel holder, TFE disk 1 C1860 000D2

21 0-Ring Holder Type 630R

Brass 1 D3360 1401 2 Stainless steel 1 D3360 35032

22 Valve Carrier Brass OW01 86 14022 Stainless steel OW01 86 35032 Stainless steel (NACE) OW01 86 X0022

Part Number

OW0209 000A2 2N6990 000A2 2N6990 X0092 OW0215 19012 2N6991 22012 2N6991 X0032

27 Vent Assembly, Y602-12 27A551 6x012 30 Hex Nut, zinc plated steel, (used only

with cast iron diaphragm adaptor, key 13) Low-pressure (1 0 req'd) 1A3527 24122 High-pressure (4 req'd) 1 A3527 241 22

31 Cap Screw, plated steel (2 req'd) (not shown) 1 A341 8 24052

32 0-Ring Washer (For 630R only) Brass Stainless steel

33 Plug, plated steel (not shown) For 2-inch NPT bodies only

34 Nameplate, aluminum Type 630 Type 630R

35 Drive Screw, stainless steel (4 req'd)

36 Machine Screw Type 630R only

Brass Stainless steel

37' 0-Ring Type 630R only

Nitrile TFE

52 NACE Tag (not shown), 18-8 stainless steel 19A603 4x012 53 Tag Wire (not shown), 303 stainless steel 1U7581 X0022

'Recommended spare part. 9

630 Series

Table 5. Key 1, Adjusting Screw, Steel

Table 6. Key 5, Regulator Spring, Steel

TYPE

630

630R

While this information is presented in good faith and believed to be accurate, or any other matter with respect to the products, nor as a recommendation to Fisher Controls does not guarantee satisfactory results from reliance upon such use any product or process in conflict with any patent. Fisher Controls reserves information. Nothing contained herein is to be construed as a warranty or the right, without notice, to alter or improve the designs or specifications of guarantee, express or implied, regarding the performance, merchantability, fitness the products described herein.

SPRING PART NUMBER

OW01 92 27022 OW0191 27022 OW01 90 27022 OY0664 27022 1 J1469 27142 1 K3709 27082

OW01 92 27022 OW0191 27022 OW0190 27022 OY0664 27022 1 J1469 27142

[FISHER] Fisher Controls For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Sao Paulo 05124 Brazil Cernay 68700 France Singapore 2158

ADJUSTING SCREW PART NUMBER

1A2791 28982 182120 28982 1A5005 28982 1A5005 28982 1A5005 28982 1 A5005 28982

1A2791 28982 1821 20 28982 1 A5005 28982 1 D3366 28982 1 D3366 28982

Spring Part Number

OW01 92 27022 OW0191 27022 OW01 90 27022 OY0664 27022

OW0192 27022 OW0191 27022 OW0190 27022 OY0664 27022 1J1469 27142 1 K3709 27082

OW0192 27022 OW0191 27022 OW01 90 27022 OY0664 27022 1 J1469 271 42

OW0191 27022 OW0190 27022 OY0664 27022 1 J1469 27142

Outlet (or Relief) Pressure Setting, Psig (Bar)

3 to 10 (0.2 to 0.7) 8 to 20 (0.8 to 1.4) 17 to 30 (1.2 to 2.0) 27 to 40 (1.9 to 2.8)

27 to 50 (1.9 to 3.5) 46 to 95 (3.2 to 6.6) 90 to 150 (6.2 to 10.3) 150 to 200 (10.3 to 13.8) 200 to 275 (13.8 to 18.9) 275 to 500 (18.9 to 34.5)

3 to 8 (0.2 to 0.5) 6 to 17 (0.4 to 1.1) 15 to 22 (1 .O to 1.5) 20 to 35 (1.4 to 2.4) 35 to 50 (2.4 to 3.5)

30 to 70 (2.0 to 4.8) 50 to 95 (3.5 to 6.5) 75 to 175 (5.2 to 12.1) 150 to 250 (10.4 to 17.3)

Type Spring Color

Code

Red Stripe Olive Drab Silver Green Stripe

Red Stripe Olive Drab Silver Green Stripe Blue Stripe Yellow Stripe

Red Stripe Olive Stripe Silver Green Stripe Blue Stripe

Olive Drab Silver Green Stripe Blue Stripe

Spring-Loaded Type 630

Spring-Loaded Type 630R

ADJUSTING SCREW PART NUMBER (WIRE SEAL)

1 R8299 28992 1 R8300 28992 1 R8085 28992 1 R8085 28992 1 R8085 28992 1 R8085 28992

1 R8299 28992 1 R8300 28992 1 R8085 28992 1R8301 28992 1R8301 28992

Low-Pressure

High-Pressure

Low-Pressure

High-Pressure

LENGTH OF THREADED PORTION

Inches

4 3-112

3 3 3 3

4 3-112

3 3-114 3-1 14

mm 102 89 76 76 76 76

102 89 76 83 83

INDEX NO. 12

LOW GAS PRESSURE REGULATOR

PCV-026-A, PCV-026-B

- FEATURES PBCTORIAUY TYPICAL-ORIENTATION MAY DIFFER

I JL, 2-11- 2 I NPT

BODY MATERIAL

J l RON 9Em

h 127.0 _. "O0 254.0

i- 10.00

ENVELOPE DIMENSIONS ARE 2

@) Fisher Control* 1986,1988 -

AMERICAN HYDROTHERM CORPORATION I 2579-26106 2579-PCV-026A 7 5 7 ~ - P ~ V - n 7 ~ - R

CUSTOMER 1 P.O. NO. 1 TAG NO.

INFORMATION CERTIFIED CORRECT

DATE 3 y . o -F3BY dfl SERIAL NO. ORDER NO.

001-A0201598A

Fisher Controls Marshalltown, Iowa, USA

I

GAS REGULATOR ~SSH 133L

L

E mq +;Ui SCALE 1-5-88 D M ALB 9-8-71 owow. REV NONE D M i l - 7 - 8 6 WKD. R O 9-8-71

CODE22506 ,( IAPIID. RHO 1-21-76 l O A 8 0 9 4 E

Series 133

Fisher Controls Instruction Manual

Series 133 Gas Regulators

March 1991 Form 5007

Regulators should be installed, operated, and maintained in accordance with federal, state, and local codes, rules and regulations, and Fisher instructions.

If the regulator vents gas or a leak develops in the system, it indicates that service is required. Failure to take the regulator out of service immediately may create a hazardous condition.

Call a gas serviceman in case of trouble. Only a qualified person must install or service the regulator.

Introduction

Figure 1. Series 133 Gas Regulator The Series 133 self-operated gas regulator, shown in figure 1, is primarily designed for industrial and commercial applications supplying gas to furnaces, burners, and other appliances. The Series 133 balancing system enables the regulator to provide accurate control of gas pressure for maximum combustion efficiency despite varying inlet pressure conditions. The single port construction provides bubble tight shutoff. An external downstream control line is required for the operation of the regulator. A restriction collar is available to reduce the flow capacity of the regulator.

Type Number Description

Type 133L - Low pressure construction for outlet pressure range of 2-inches wc to 2 psig (5 mbar to 0.1 4 bar). The maximum operating inlet pressure is 60 psig (4.1

bar) with a maximum emergency inlet pressure of 125 psig (8.6 bar).

Type 133H - High pressure construction for outlet pressure range of 1-112 to 10 psig (0.10 to 0.69 bar). The Type 133H can also use the 2-inches wc to 2 psig (5 mbar to 0.14 bar) springs of the Type 133L. The maximum operating inlet pressure is 60 psig (4.1 bar) with a maximum emergency inlet pressure of 125 psig (8.6 bar).

Type 1332 - Zero governor construction for outlet pressure range of -1 to 4-inches wc ( - 2.5 to 10 mbar). The maximum operating inlet pressure is 20 psig (1.4 bar) with a maximum emergency inlet pressure of 125 psig (8.6 bar).

@Fisher Controls International Inc. 1972, 1991; All Rights Reserved

Series 133

INLET

BOOS1

DOWNSTREAM PRESSURE

80098 3

Figure 2. Operational Schematic of Type 133L Regulator

Principle of Operation

Refer to the operation schematic in figure 2. In the Series 133, outlet pressure is registered under the diaphragm via the external control line and is used as the operating medium. Increased demand lowers the outlet pressure and allows the spring to move the diaphragm and stem assembly down, opening the valve disk and supplying more gas to the downstream system. De- creased demand increases the outlet pressure and moves the diaphragm and stem assembly up, closing the valve disk and decreasing the gas supply to the downstream system.

Boosting System The Series 133 incorporates a balancing diaphragm and boosting system. When the regulator is locked up, inlet pressure is registered on the top of the valve disk and on

the bottom of the balancing diaphragm through registration holes in the top of the cage. Also, outlet pressure is registered on the bottom of the valve disk and on the top of the balancing diaphragm through a passage formed by grooves in the registration disk and an annular space between the stem and stem sleeve.

When the valve disk open, gas flows over the edge of the valve disk to the outlet side. Under the valv'e disk near the registration disk, there is little gas flow. The gas pressure near the registration disk is higher than it is in the flow path where gas velocity tends to lower the pressure. The higher pressure near the disk is registered on the top of the balancing diaphragm through the registration disk and the annular space between the stem and stem sleeve.

This pressure registered on the top of the balancing diaphragm aids downward disk travel and compensates for spring and diaphragm effect. This improves regulator rangeability and performance.

Series 133

Installation

Before installing the Series 133, inspect it for shipping damage and be certain that the body and orifice are clean. Blow out the pipeline to remove pipe scale and other foreign material.

The regulator may be installed in any position as long as the flow through the body is the same as indicated by the flow direction arrow on the body and the vent opening is unobstructed and protected from the entrance of rain, ice, and other foreign material.

If the regulator has threaded end connections, coat male threads with pipe compound. For flanged end connections, tighten the flange bolts evenly. Install a three- valve bypass around the Series 133 if continuous operation is necessary.

The regulator must be protected from damage by vehi- cles and other outside sources.

Overpressure Protection The Series 133 regulator, as is the case with most regulators, has an outlet pressure rating that is lower than the inlet pressure rating. Some type of overpressure protection is needed if the actual inlet pressure exceeds the outlet pressure rating.

The maximum operating inlet pressure for the Types 133L and 133H is 60 psig (4.1 bar). The maximum operating inlet pressure for the Type 1332 is 20 psig (1.4 bar). All models must be protected against inlet pressure above 125 psig (8.6 bar). Inlet pressures between 60 and 125 psig (4.1 and 8.6 bar); 20 and 125 psig (1.4 and 8.6 bar) for the Type 1332; may impair regulator performance.

The maximum operating outlet pressure for the Type 133L is 2 psig (0.14 bar), for the Type 133H it is 10 psig (0.69 bar), and for the Type 1332 it is Cinches wc (10 mbar).

The maximum casing pressure for the Series 133 is 15 psig (1 bar).

Outlet pressures more than 3 psig (0.21 bar) over the set point of the regulator may damage internal parts such as the diaphragm plate and valve disk.

Regulator operation below these emergency pressure limitations does not preclude the possibility of damage from external sources or from debris in the gas line. The regulator should be inspected for damage after any over pressure condition.

Downstream Control Line An external downstream control line must be installed before putting the Series 133 in operation. Without the

control line, the regulator will remain wide open. The downstream control line should be a pipe of at least 112- inch diameter; connect it to the downstream pipe line at least 5 to 10 pipe diameters from the regulator and in a straight section of pipe.

Vent The Series 133 vent is screened to prevent insect or foreign material from entering. On indoor installations, if a vent to atmosphere is required, remove the snap ring and screen (key 8J and 8H; figure 6,7, or 8) and pipe the vent to the outside. The vent pipe should be as short as possible with a minimum of bends and elbows. The pipe should also have as large a diameter as possible. Install a weather and bug resistant vent assembly on the outside end of the vent pipe.

For indoor installation that have been piped to the outside and for outdoor installations, the vent opening must be positioned so that water, ice, and other foreign material cannot enter the spring case. Use care not to place the vent opening below downspouts and eaves. Position the vent opening above the probable snow level. The vent opening should be checked periodically to see that the opening has not been plugged by foreign material. On some installations it may be necessary to provide additional protection from the elements.

Startup

If the downstream system is already pressured by another regulator or by a manual bypass, then extra precautions must be taken when placing the Series 133 in service. The outlet of the regulator must never be subjected to pressures higher than the inlet pressure, or the balancing diaphragm may be damaged. Also, the control line pressure must never exceed the set point dictated by the spring setting by more than 3 psig (0.21 bar), or the valve seat or diaphragm plates can be damaged. The procedure used in putting the regulator in service must be planned accordingly. Pressure gauges should always be used to monitor downstream and control line pressures during start-up.

If the downstream system is not pressured by another regulator or by a manual bypass, use the following procedure.

1. Slowly open the upstream shutoff valve.

2. Slowly open the downstream shutoff valve.

3. Check all connections for leaks.

Series 133

Table 1. Series 133 Outlet Pressure Ranges, Spring Part Numbers, and Color Codes

TYPE

1. if the 2" wc to 2 psig springs are used in the Type 133H, the pressure ranges will that the actuator is installed above the body) Increase bv aDDroximatelv 1 ' wc due to the weiaht of the TvDe 133H Darts fassumina 2. Extension sorina. I

PART COLOR NUMBER I CODE I PRESSURE RANGE

133L (Low Pressure)

133H(') (High Pressure)

1332 (Zero Governor)

Adjustment

Inches wclnsia

To increase the pressure setting, remove the closing cap (key 9; figure 6, 7 or 8) and turn the adjusting screw (key 11) clockwise; to lower the setting, turn the adjusting screw counterclockwise. A pressure gauge should always be used when adjustments are being made. Do not adjust the spring to produce an outlet pressure setting above the limit stamped on the nameplate (key 38), located on the casing flange. If the required pressure setting is not within the range of the spring in use, substitute with the correct spring. Ranges of available springs are shown in table 1. When changing the spring, also change the nameplate (key 38), located on the casing flange, to indicate the outlet pressure range.

Barlmbar

2 to 4-inches wc 3.5 to 6-inches wc

5 to 9-inches wc

8.5 to 18-inches wc 14 to 28-inches wc .75 to 2 psig

1.5 to 3 psig 2 to 5 psig 5 to 10 psig

- 1 to 1 -inch wc

0 to 4-inches wc

Shutdown Isolate the regulator from the pressure system and release pressure from the outlet and the control line. Inlet pressure will then automatically be released as the regulator opens up in response to the lowered pressure on the diaphragm.

5 to 10 mbar 8.7 to 15 mbar 12 to 22.4 rnbar

21.2 to 44.8 mbar 35 to 70 mbar

0.05 to 0.14 bar

0.10 to 0.21 bar 0.14 to 0.34 bar 0.34 to 0.69 bar

- 2.5 to 2.5 mbar

0 to 10 mbar

Maintenance

To avoid personal injury, property damage, or equipment damage caused by sudden release of pressure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure from the equipment.

1 D8925 27022 1 D8926 27022 1 D8927 2701 2

1 D8932 27032 1 D8933 27032 11-19758 27032

1 H9759 27032 10A9440 X012 1J1469 27142

1 K6634 2701 2(1)

1 K6634 2701 2(2) & 108925 27022

Due to normal wear that may occur in gas regulators, parts must be periodically inspected and replaced if necessary. The frequency of inspection depends on the

Brown Red Black

Gray Green Blue

Orange Yellow Blue Stripe

Silver

Silver Brown

severity of service conditions or state and federal laws. This section included instructions for disassembly and replacement of parts. All key numbers refer to figures 6 , 7, and 8 except where indicated.

Disassembly 1. Disconnect the downstream control line from the regulator and disconnect the remote vent pipe if one is used.

NOTE

Allowing a slight amount of compression to remain in the regulator spring will facilitate disassembly of the trim parts.

2. Unscrew the four nuts (key 34) and lift the actuator portion off the body (key 1). All of the trim parts will come out of the body with the actuator. The valve disk (key 28), orifice (key 2), and restriction collar (key 46, figure 9), if used, can now be inspected.

3. For further field disassembly and inspection, the actuator may be turned upside down and the spring case (key 8A) inserted into the body cavity (see figure 3).

Use care in performing step 4 to guard against damage to the balancing diaphragm (key 22).

4. Insert a 112" open-end wrench between the legs of the cage (key 5) and place the wrench on the stem sleeve wrench flats. Hold this wrench while unscrewing the nut (key 31) to prevent stem and stem sleeve (key 18 and 25) rotation and diaphragm damage due to twisting (see figure 3).

Series 133

Figure 4. Inspecting Guide Bushing and Stem Seal 0-Ring

Figure 3. Spring Case Inserted in Body for Disassembly. Note Proper Method of Holding Stem

and Sleeve When Loosening or Tightening Stem Nut,

5. Remove the washer, registration disk, and valve disk (keys 30, 29, and 28). To remove the restriction collar (if used), loosen the set screw (key 47, figure 9) and slip the E-ring (key 26) and collar off of the stem. Remove the orifice (key 2) by rotating it until the pins (key 5A) in the cage line up with the slots in the orifice; then, lift off the orifice. Replace the valve disk and orifice if necessary.

6. Loosen the set screws (key 39) in the cage and remove the roll pin (key 27) from the stem. Remove the cage and stem sleeve, the sealing washer under the balancing diaphragm, flat washers (key 23), balancing diaphragm, and balancing diaphragm plate (key 21). Replace sealing washer and balancing diaphragm if necessary.

7. To inspect or replace the upper stem seal O-ring or main diaphragm (key 15) on the Type 133L or 133H (figure 6 or 7), remove the closing cap (key 9), disengage the adjusting screw (key 1 I ) , and remove the spring (key 12).

For Type 1332 (figure 8), remove the closing cap (key 9) and disengage the adjusting screw (key 11). Lift the adjusting screw assembly (keys 11, 41, 42, 43, and 45) out of the spring case with pliers. Unhook the extension spring (key 44) from the spring retainer (key 42). Re- move the compression spring (key 12) if one is used.

8. Unscrew the cap screws and nuts (keys 35 and 36) and remove the spring case.

9. Pull out the diaphragm and stem as an assembly; replace diaphragm and sealing washer (key 17) if neces-

sary. When removing or replacing the diaphragm, clamp the smallest diameter portion of the stem in a vise while turning the nut (key 20).

10. If necessary, replace the guide bushing (key 6) and the upper stem seal O-ring (see figure 4). Before reassembling, coat the O-ring with Bel-Ray No. 80 or an equivalent O-ring sealant and lubricant.

Reassembly Reassemble in the reverse order of the above steps. When reassembling, observe the following steps and cautions.

1. If the spring case was disassembled, reassemble it first. To ensure proper slack in the diaphragm and to facilitate reassembly of the trim parts, tighten the casing cap screws finger-tight only. Then adjust the spring to stroke the diaphragm assembly fully. Final tightening of the casing cap screws and nuts must be done alternately in equal increments to ensure a proper seal without crushing the diaphragm.

2. During reassembly, check all O-rings to be certain they are in good condition; replace if necessary. Coat O- rings (keys 4, 19, and 32) with Dow Corning No. 3 or an equivalent elastomer sealant and lubricant.

3. When installing the balancing diaphragm, be certain the side marked PISTON SIDE is facing the spring case. Carefully tuck the slack diaphragm, material into the space between the diaphragm plate and the lower casing (key 7) until the diaphragm fits smoothly over the diaphragm plate without wrinkles and the bead fits snugly and evenly in the groove provided in the lower casing. This can be done with a small screwdriver, but be careful not to puncture the diaphragm (see figure 5).

4. When replacing the cage, insert the set screws (key 39) only far enough to retain the cage. Do not tighten.

5. The registration disk (key 29) is marked for proper placement; be certain it is positioned correctly on the stem.

Series 133


Figure 5. Installing Balancing Diaphragm. The Side of Diaphragm Marked "PISTON SIDE" Must Face Casing.

Always use the stem sleeve wrench flats when loosening or tightening the nuts (key 20 or 31) to prevent twisting of the main and balancing diaphragms (key 15 and 22).

6. Be certain the Belleville spring washer (key 3) is in good condition and is in place before placing the actuator on the body.

Parts Ordering

When corresponding with your Fisher sales office or sales representative about this equipment, be sure to include the type number and other information stamped on the nameplate.

When ordering replacement parts, reference the key number of each needed part and specify the eleven- character part number as found in the following parts list.

Parts List

Key Description Part No. Qty

Parts Kit (included are keys 2, 4, 6, 10, 15, 17, 19, 24, 28, 32 and 40. R133HX 0001 2

1 Body Cast iron

NPT screwed 30A304 4x01 2 125 Class FF 30A304 5x01 2

Steel NPT screwed 308085 5x012 150 RF 308085 4x01 2

2" Orifice, aluminum 20A304 6x01 2 3 Belleville Spring Washer, 17-4PH 10A304 7x01 2 4' 0-Ring, nitrile 10A933 9x01 2

5' Cage, aluminum (including roll pins, key 5A) 20A304 8x01 2

6' Bearing, nylon 10A304 9x012 7 Lower Casing, aluminum 40A305 OX01 2 8A Spring Case, aluminum 4L1423 08032

8B Flapper Stem, 302 stainless steel 1 H9763 35022 8C Lower Flapper, nylon 1 H9764 06992 8D Upper Flapper, polyethylene 1H9765 06992 8E Orifice, 302 stainless steel 1 H9766 3601 2

8F Screw, zinc pl steel (3 req'd) 1 H9767 28982 8G Spring, 302 stainless steel (2 req'd) 1 H9768 37022 8H Screen, monel 1 E5648 431 22 8J Snap Ring, 302 stainless steel 1 E5649 37022

9 Closing Cap, aluminum 10" Closing Cap Gasket, neoprene 11 Adjusting Screw

Type 133H, brass Type 133L, aluminum Type 1332, brass

12 Spring, steel Type 133H(')

1-1 /2 to 3 psig Orange

2 psig Yellow

5 to 10 psig Blue stripe

Type 133L 2 to 4-inches wc

Brown 3-1 /2 to &inches wc Red

5 to 9-inches wc Black

8-1 /2 to 1 Sinches wc Gray

14 to 28-inches wc Green

314 to 2 psig Blue

Type 1332 - 1 to 1 -inch wc Silver (use extension spring, key 44)

0 to 4-inches wc Brown (Extension spring, key 44, silver, also req'd)

13 Spring Seat, pl steel 10A305 2x01 2 14 Diaphragm Plate, steel

Type 133H (1 req'd) ID5557 25012 Type 133L (1 req'd) 1J8817 25072 Type 1332 (2 req'd) 1 J8817 25072

15' Diaphragm, nitrile & nylon 1 N 1508 02052 16 Sealing Diaphragm Plate, zinc pl steel 1 D4757 25062

17" Sealing Washer, steel & syn. rubber (2 req'd) 1 F9904 28982

18 Stem, 416 stainless steel Type 133H & 133L 20A305 3x01 2 Type 1332 10A306 9x01 2

19" 0-Ring, nitrile Type 133L & 133H (2 req'd) 1 E5914 X0042 Type 1332 (1 req'd) 1 E5914 X0042

20 Hex Nut, aluminum 105297 X0012

'Recommended spare part. 1. If the 2-inch wc to 2 psig (5 mbar to 0.14 bar) springs listed under Type 1331 are used

in the Type 133H, the pressure ranges will increase by approximately 1-inch W.C. due to the weight of the Type 133H parts (assuming that the actuator is Installed above the body).

Series 133

DC-DOW CORNING NO. 3

NS-Never-SEE2

4OA3066-0

Figure 6. Type 133L


NS-Never-SEEZ

40A3070-E

Figure 7. Type 133H

Series 133


NS-Never-SEEZ

Figure 8. Type 1332

Description

Diaphragm Plate, pl steel Diaphragm, nitrile & nylon Washer, p l steel (2 req'd) Guide Bushing, nylon

Stem Sleeve, 303 stainless steel E-Ring, pl steel Roll Pin, steel Valve Disk Assembly, aluminum/neoprene

Registration Disk, nylon Washer, zinc pl steel Hex Nut, zinc pl steel 0-Ring, nitrile

Stud, alloy steel (4 req'd) Locknut, pl alloy steel (4 req'd) Cap Screw, pl steel (12 req'd) Hex Nut, pl steel (12 req'd)

Nameplate, aluminum Nameplate, brass Set Screw, alloy steel (2 req'd) Thrust Washer, nylon

Type 133H only

Upper Spring Seat, brass Type 1332 only

Spring Retainer, brass Type 1332 only

Ball, 440C stainless steel (10 req'd) Type 1332 only

Part Number

10A305 4x01 2 10A305 5x01 2 10A305 6x01 2 10A305 7x01 2

10A306 1x012 1 F5994 28982 1 E9540 28992 10A305 8x012

10A306 OX01 2 1 D7162 28982 1C1219 28982 1 J1079 X0012

10A306 2x01 2 10A306 3x01 2 181 363 24052 Figure 9. Optional Restriction Collar Assembly 1 A3093 241 22

1 1 A047 OXOA2 Key Description Part Number

13A049 6XOA2 44 Extension Spring, steel

10A305 1x012 Type 1332 only 1 K6334 27012

1V9661 X0012 45 Retaining Ring, pl steel Type 1332 only

46 Restriction Collar, aluminum 1 K6335 1401 2 25% capacity

40% capacity 1 K6338 1401 2 60% capacity

47 Set Screw

B7935 46202 'Recommended spare part.


[ E j Fisher Controls For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil Cernay 68700 France Singapore 2158

INDEX NO. 1 3

MAIN GAS SOLENOID

E S V - 0 0 3 - A , E S V - 0 0 3 - B

H I 17 Fuel Gas Valve High-Flow, On-Off Hydramotor@

The normally closed H I 17 is a combination Hydramotors actuator and safety shutofflcontrol gas valve. It is used for commercial and industrial burners in applications such as furnaces, dryers, dehydrators, conversion burners, and heaters.

The cast iron valve body provides high flow and self cleaning operation. Its soft synthetic seat and integral, heavy-duty return spring close the valve tightly upon current interruption, in one second or less. The V-port valve guide ensures smooth, reliable operation.

The self-contained, hermetically sealed, electrohydrau- lic actuator provides an output force of 200 pounds. It consists of a motorlpump unit immersed in oil, reducing wear and the need for service, and a push-type piston assembly.

Specifications Service: natural, mixed, manufactured, or LP gases, including high sulfur, and scrubbed and dried coke and sewer gases Opening Time: 12-20 Seconds Closing Time: 1 second maximum Maximum Operating Pressure Differential: 20 psid Body Class: 250# Scr. Ambient Temperature : -40" to1 50" F (-40" to 66" C) Agency Approvals: UL listed; FM approved Housing: NEMA4 (watertight) and NEMA 7 (Hazardous locations, explosion-proof) available, see Factory

To Order:

HI 17 Fuel Gas Valve

Voltage: 1 10-1 20 Vl50-60 Hz and.220-240 V/50-60 Hz Current: 158 VA Auxiliary Switch: Integral auxiliary SPDT switch: 15A @ 120V, 7.5A @ 240V (1800 VA ma.) (actuates at energized, full open end of actuator stroke). Up to six adjustable, yoke-mounted switches may be added.

One cubic foot per hour = 1,000 BTUIHr, 0.64 Specific Gravity Natural Gas. FPIHr values determined at 1" W.C.P.D.

Auxiliary Switches (Adjustable)

Dimensions and Shipping Weights

Replacement Actuatorsf

+ For FM Proof of Closure add F26 to Catalog Number

Current Ratings

Dimensions -- HI 17 Fuel Gas Valve

1

R

SWITCH PLATE.

AUXILIARY AND/OR PROOF OF CLOSURE

SWITCH OPTIONAL

A Normally closed when actuator is de-energized

B Normally open when actuator is de-energized

Typical Wiring - 2-Wire with Auxiliary Switch

INDEX NO. 14

PRESSURE REDUCING GAS REGULATOR

PCV-027-A, PCV-027-B

Figure 1. Series 7349 Pressure Reducing Gas Regulator.

NORTH AMERICAN Mfg Co / \

Turbo Blower

Gas Burner

Figure 2. Piping Arrangement for 7349 and 7218 Regulators.

BULLETIN 73.49 10-75

4455 E 71 st Cleveland. OH 44105 USA

Series 7349 Pressure Reducing Gas Regulators deliver constant outlet pressure regardless of fluctuating inlet pressure. Large clearance internal guides eliminate friction that might cause time lag, yet minimize chatter. A soft valve seat provides nearly tight shutoff. Two basic models are, available: 7349, with an internal impulse tap, and 73493, with external impulse tap for maintaining pressures at remote downstream locations.

J J

PRESSURE REDUCING GAS REGULATORS

Pressures and Temperatures. Inlet pressure-5 psig (0.35 kg'/cm2) maximum Outlet pressure-Available in 4 ranges-Specify:

"Y" Spring (ye1 low). ............. for 1 to 4 osi range (44 to 176 mm H20)

"A" Spring (aluminum).,. ......... for 3 to 8 osi range (132 to 352 mm H20)

"G" Spring (green). ............ for 7 to 15 o s i range (308 to 659 mm H20)

"R" Spring (red). ........... ..,for 14 to 24 osi range (615 to 1055 mm H20)

The standard 7349 regulator i s suitable for 180 F (82C) maximum ambient temperature. For ambients up to 300 F (149C) with cool gas flowing, the 7349V regulator i s available with viton-coated dacron diaphragms. For gases corrosive to brass, specify 7349K1 incor- porating stainless steel internals in place of brass. Gas capacities of 7349K and V regulators are same as corresponding standard versions.

Installation. Mount in horizontal lines with the adjustment spring either straight up or straight down (spring down mounting allows less outlet pressure because of the weight of internals). Figure 2 shows a 7349 Regu- lator with a cross-connected 7218 Regulator. Allow a run of 15 or more pipe diameters between the regulators to avoid interaction.

Adjusting Instruct~ons. Pul l off the cap and, wlth a wrench, turn the adjusting screw clockwise for In- creased outlet pressure (counterclockw~se for less pressure). The spring, not the screw, moves up and down. To avoid exceeding the sprrng range, make adjustments only under flow conditions with a pressure gauge on the outlet tap of the regulator. Turnlng the screw down too tightly can prevent the regulator from closlng

Order Must Specify: Complete regulator designation, including spring letter and pipe size code.

Example: 7349SVY-4 (for a 2" regulator with external impulse tap, viton diaphragms, and 1 to 4 osi (44 to 176 mm &O) outlet range).


Series 7349 PRESSURE REDUCING GAS REGULATORS Capacities, Select ion

Pressure Drop Across Regulator mm H,O 3% 500 700 1000 1500 2400 3000 I 1 I I I 1 I

. . 350 sdo 70'0 lob0 1560 2400 3000

Figure 3. Capacities of 7349 and 73495 Regulators.

Selection. On Figure 3, locate the intersection of lines corresponding to maximum required gas flow- and pressure drop available across the regulator, 'move up to the diagonal line : immediately above that point, and select the regulator whose designation appears on that line.

Capacities for 7349 and 73498 models are den tical, and both hold outlet pressures with approximately the same degree of accuracy. Use the 73498 to maintam downstream gas pressure at a point remote from the regulator itself. Never locate the remote tap downstream of another regulator or control valve, however. See-Figure 5 for installation of 73498 regulators

Be sure pipe downstream of the regulator i s adequately sized. Pipe of a larger size then the regulator connection is often necessary. To determine the pipe

size needed, use Flgure 4' Starting with the maximum cfh (m3/hr) natural gas the pipe must handle, read across to the diagonal llne correspond~ng to the pipe size of the regulator and read down to the pressure drop. Phls IS the drop per 100 equ~valent feet (30 m) of pipe. For equivalent lengths of pipe fittings, see Table on Equivalent Lengths of .Pipe Fittings in Section 5, North American Combustion Handbook, or use the North American Pipe Rule.- If the actual installation wi l l have 50 equivalent feet (15m) downstream of the regulator, actual drop w i l l be half the figure shown, and so on. If this drop i s excessive, repeat the procedure for the next larger size of pipe. See selection examples for more details.

When selecting a regulator for other.than natural gas, divide required flow by the appropriate gas gravity factor (Table A) and use the resulting equivalent flow to size the regulator from Figure 3 and downstream pipe from Figure 4.

TABLE A. Gas Gravity Correction Factors. Gas Gravity 0.4 0.6 1.0 1.5 2.0

Factor 1.22 1.00 0.774 0.632 0.547

Example 1. Select a regulator and size downstream piping for 60 000 cfh natural gas with 5 psi (80 osi) inlet and ' 15 osi outlet, pressure. Maximum drop permitted in 20 equivalent feet of downstream pipe is 2 osi.

Pressure drop across the regulator i s 80 - 15 = 65 osi. From Figure 3, seleci a 7349G-7 (or 7349SG7).

The permitted 2 osi drop in 20 f t i s equivalent to 10 osi in 100 ft. From Figure 4, 100 equivalent feet of 4" pipe wi l l pass 60 000 cfh natural-gas with 14.5 osi drop, or 100 feet of 6" pipe wi l l pass 60 000 cfh with 1.8 osi drop. Use 6" pipe and the pressure drop in 20 feet wi l l be 1.8 x 20/100 = 0.36 osi.

Example 2. Select a regulator for 1950 cfh 0.4 sg coke oven gas with 15 osi inlet pressure. Assume 2 osi furnace back pressure, 3 osi drop across downstream valves and burners, and 1 osi maximum drop in 10 equivalent feet of downstream piping

Regulator outlet pressure requlred is 2 + 3 + 1 = 6 osl , so regulat~r drop IS 15 - 6 = 9 osl Natural gas flow equ~valent to 1950 cfh coke oven gas i s 1950 - 1.22 = 1600 cfh (from Table A). From F~gure 3, a 7349KA-2 or 7349SKA-2 IS required. From Figure 4, 1600 equivalent cfh of natural gas fiowlng through 10 feet of llh" plpe (same plpe slze as regulator connections) w l l l take a pressure drop of 3 3 x 10/100 = 0.33 osi, which i s well wlthln the oricllnally assumed 1 osi.

Note: Use same computations demonstrated in these examples when dealing with metric quantities.


Series 7349 PRESSURE REDUCING GAS REGULATORS Selection, Dimenslone

Pressure Drop, mm H,0130 equivalent metres of plpe

Pressure Drop, osi/100 equivalent feet of pipe

Figure 4. Pressure Drop i n Downstream Pipe.

7349-7 Flanged

fpt = female pipe thread (American Standard)

Reaulalor 1 I Deal* natlon

7349-0

Dlrnenalons In Inches C E

1'4 ( 48) 3%( 95) 2%. ( 52) 3%( 95) 2% ( 64) 5%(133) 2" ( 67) S1/r(133) 3% ( 83) 6%(171) 4'/.(111) 9%(W5) 4'4 (124) 9%(235) !?A (146) 9%(235)

(and Mllllmetrer) F a

7%(19l) 3'36 ( 83) 7%(191) 336 ( 83)

lOK(287) 3"/. ( 98) lOH(287) 3"36 ( 98) 13%(343) 4'4, (109) 18%(470) 6"& (181) 18H(470) 6"4, (161) 18%(470) 6"& (174)

Figure 5. Dimensions of Series 7349 Regulators.

2 D Minimum t o next

ptpe wall. Remove urrs from tns~de.

Items i n dot ted lines not by North American

Figure 6. Installation of Series 73495 Regulators.

NORTH AMERICAN M f g . Co. Cleveland, OH 4410 5 USA

Series 7349 PRESSURE REDUCING GAS REGULATORS

Adjusting Scraw Parts L i s t

Adjusting Screw Cap,

Body Cover

Body

Gasket

Tension Warhe

Spring Adlurhng Scraw Bsanng

Valve Haad

,Body Corer 73494.4, and-7 7

instruction Plate

Regulator Designation 7349-0 7349-1 7349-2 7349-3 7349-4 7349-5 7349.6- 7349-7

Adlusting Screw O r 23889.1 2-3889-1 2-3923-1 2-3923-1 2-3905-1 2-3899-1 2-3899-1 2-3899-1 Adlusting Screw Cap Adlusting Screw Plots

Balancing Di%phragm (Std.10 Balancing Diaphragm V (Vitan) Balancing Diaphragm Cup

Body * Body Cover Gasket Body Plus or Bodv Cover (Std.)

Body Plug (7349K) Banded Valve Facing Diaphragm Spacer

Flange Flange Gasket Gos Diaphragm (Std.10

Gas Dia~hraam V (Vitan)

Gripca Locknut 1 R-510.5090C R.5'10-5090C R-510-5098C R-510-5098C R-510-5098C R-510-5150 R-510-5150 R-510-5150

2-3893-1 2-3893-1 2-3906 1 2-3904-1 2-3904-1 2-3904-1 2-3904-1 2-3904-1 2-3890-2 2-3890-2 2-3929-3 2-3929-3 2-3929.3 2-3902-2 2-3902-2 2-3902-2

2-3912-1 2.3912-1 2-3913-1 2.3913-1 2-3914-1 2-3915-1 2.3915-1 2-3916-2 2-3912-2 2-3912-2 2-3913-2 2-3913-2 2.3914-2 2.391 5-2 2-3915-2 2.3916.3 2-1290-1 2-1290-1 2-1290.2 2.1290.2 2.1290.3 2.1290.4 2.1290-4 2.2736-1

2-1 165.3 2.1073.3 2.1 166.3 2-11 12.3 2-1169-3 2-1297-4 2.1 179-4 2-2732-2 - - - - - 2-3840-1 2.3840-1 2-2739- 1 2-2036.1 2-2036-1 2-2038-1 2-2038-1 2.2043.1 2-3839-1 2-3839-1 2.2738.1

2-2036-2 2-2036-2 - - - - - - 2-3941-2 2.3941.2 2-3942-2 2.3942-2 2-3943-2 2-3944-2 2-3944-2 2-3945.2 2-1228-1 2-1228-1 2-1228-6 2.1228-6 2-1228-3 2-1228-4 2-1228-4 2-1228-4

- - - - - - - 2-855-1 - - - - - - - 2.3522-1 2-2239-1 2-2239-1 2- 1127- 1 2-1 127-1 2-1177-1 2-4086-1 2-4086.1 2-4086- 1

2-2239.2 2.2239-2 2-1 127-2 2-1 127-2 2-1 177-2 2-4086-2 2-4086-2 2-4086-2 Gas ~ i obh rogm ~a;e Gas Diaphragm Cover

Gas Diaphragm Disc Gasket

2-2075-3 2-2075.1 2-2111-1 2.211 1-2 2-2112-1 2-21 13.3 2-2113-4 2-3939-2 2-3887.1 2.3887.1 2.3906-1 2-3906-1 2-3907-1 2.3908.1 2-3908-1 2.3908.1

2-4049-1 2-4049.1 2-4084-1 2-4084-1 2-4080-1 2-4059-1 2-4059-1 2-4059-1 2-3898-1 2-3898-1 2-3930-1 2-3930-1 2-3930-1 2-3901-1 2-3901-1 2-3901-1

Instruction Plate lnstruciian Tag (2 req'd.)

O Jam Nut E Pressure

f R e t a i n i n g k t g 2 Semi-Washer or Ba l l Socket (Std.)

Semi-washer or Bo l l Socket (7349K) Shaft (Std.)

2-3838.1 2.3838-1 2-3838-1 2-3838-1 2-3838-1 2-2800-1 2.2800-1 2-2800-1 2-3892-1 2-3892-1 2-3892- 1 2-3892-1 2-3892-1 2-3892-1 2-3892-1 2-3892-1

R-510.5090C R-510.5090C R-510-5092JC R.510.5092JC R-510.5092JC R.510-5099JC R.510-5099JC R-510-5099JC

23949.1 2-3949-2 2-3949-3 2-3949-4 2-3949-5 2-3949-6 2.3949-7 2-3949-8 R.740.7150 R-740-7150 R-740.7190 R-740.7190 R-740-7190 R.740.7231 R-740.7231 R-740.7231

2-4067-1 2-4067-1 2-4067-1 2-4067.1 2-4067-1 2.4062.1 A 2-4062-1 A 2-4062-1 A

2-4067-2 2-4067-2 2-4067-2 2-4067-2 2-4067-2 2-4062-2 2-4062-2 2-4062-2 2-4083.3 2.4083-3 2-4083-1 2-4083-1 2-4083-2 2-4068- 1 2-4068-1 2-4065-1

Shaft (734910

(4 asi Y-Yellow) as1 A-Aluminum)

spring ::6 as1 t-Graen) (24 os i R-Red)

Spring Adl. Screw Bearing Spring Housing Spring Housing Gasket

Swivel Spring 2-3314-1 2-3314-1 2-3314-1 2-3314-1 2-3314-1 - - - Tension Washer 2-4359.1 2-4359-1 2-4359-2 2-4359-2 2-4359-2 2-4359-3 2-4359-3 2-4359-3 Valve Head Guide - 2-4053-1 2-4079-1 2-4081-1 2-4085-1 2-4066-1 2-4069-1 2-4064-1

Valve Head Guide S ~ a c e r (Std.1 2-4054-1 - - - - - -

2-4083.4 2r4083-4 2-4083-5 2-4083-5 2-4083-6 2-4068-2 2-4068.2 2-4065.2

2-3756-2 2-3756-2 2-3917-1 2-3917-1 2-3919-1 2-3921-2 2-3921-2 2-3921-2 2-3757-2 2.3757-2 2-3918-1 2-3918-1 2-3920-1 2-3922-2 2-3922-2 2-3922-2 2-4318.1 2.4318-1 2-4319-1 2-4319-1 2-4320-1 2-4321-1 2-4321-1 2-4321-1 2.4944.1 2.4944.1 2-4945-1 2-4946-1 2-4947-1 2-4947.1 2.4947- 1 2-4945-1

2.3888.1 2-3888-1 2-3925- 1 2-3925-1 2-3925: 1 2-3900- 1 2-3900-1 2-3900-1 - - - - - 2-3911-1 2-3911-1 2-3911-1 - - - - - 2-39261 2-3924.1 2-3924-1

Spring Torsion Plate Swivel Swivel Nut

- . . . . . . . . . - . . . - . . - . . . . . . . . . - Washer 1 2-541.1 2.541.1 2-541-1 2.541-1 2.541-1 2.2340-1 2-2340-1 2-2340-1

2-3891-2 2-3891-2 2-3928-2 2.3928-2 2-3928-2 2.3903.2 2-3903.2 2-3903.2 2-3313.6 23313.6 2.4116-1 2-4116-1 2-4116.1 2-4060-1 2-4060.1 2.4060.1 2.3385.2 2.338512 2.3385-2 2.3385-2 2.4063-1 2-4063-1 2-3385-2 2.4063.1

'Includes Pressure Tubs and Valva.Seot. ATwa required, t lnc luded w i t h Body.and cannat.be sold saparately. ORecammended Spare Parts.

INDEX NO. 15

D I F F . PRESSURE GAGE

D P I - 0 0 4 - A , D P I - 0 0 4 - B

Manual no. 120M75

INSTALLATION. OPERATION and MAINTENANCE INSTRUCTIONS

A sealed magnetically operated reed switch is available with the Model 120 for use as an electrical alarm or control.

A maximum indicating follower pointer is available with the Model 120. e Available with a stainless steel pressure housing as Model 120-S or SS. or with an aluminum housing as Model 120-A.

Seals are available in either Buna N. Butyl, Neoprene, Viton or Teflon.

MID-WEST MODEL 120 2%'' Dial Differential Pressure Gauge

PISTON TYPE. 5000 PSI SERVICE, S.W.P.

0 - 2 t o 0 - 100 PSID DIAL (0 - 15 to 0 - 700 PASCALS)

4 Front View The Model 120 Differential Pres- sure Gauge is a rugged 2-1/2" dial

Back View

I instrument used to measure and control the pressure drop across filters, valves and equipment and for flow measurement and control, Differential pressure is measured in a sol id high pressure housing as the deflection of a spring by a free floating precision piston. The piston carries a magnet that is magnetically coupled to a magnet on the gauge pointer outside the pressure housing so that the pointer accurately tracks the position of the piston and indicates differential pressure on a calibrated dial scale.

The pressure housings are supplied with a 0.50 inch diameter piston for pressure ranges above0-10 PSiD, (0-70 Kilo p-and with a 0.70 inch diameter piston for pressure ranges below 0-10 PSID (0-70 Kilo pascals). The gauges with an 0.70 inch piston are identified as Model 120-AL. 120-SL or 120-SSL.

INSTALLATION Mid-West Model 120 Differential Pressure Gauges are carefully adjusted, calibrated and scaled according

to specifications before shipment and are ready for installation and use on receipt. The gauge as supplied may be either l ine mounted on the inlet and outlet pressure connections to the

gauge or may be flush panel mounted. An accessory to mount the gauge on a 2 inch support pipe for stanchion or wall mounting i s available.

A. Line Mounting When line mounting the gauge on the inlet (High and outlet (Low) pressure connections, use full size 1/4

inch pipe i f possible. The gauge can be solidly supported with input nipples up to 3 inches long. The nipple connections should be solidly supported a t the piping ends.

INSTALLATION - continued

0. Panel Mounting

The Model 120 gauge i s designed w i th a bui l t- in panel mounting bracket for mounting the gauge on panels-plates or enclosures. The gauge mounts i n a clearance hole 3.00 inches diameter, with 4. No. 8 mounting bolts on 3.50 inch bolt circle. To mount the gauge, insert the gauge thru the panel and hold with the 4 mounting screws.

The inlet (high pressure) and outlet (low pressure) connections to the gauge should be made with relatively flexible tubing connections, rather than with rigid pipe, to reduce the chance of mis-alignment between the panel and the piping system.

C. Piping Connections

A Differential Pressure Gauge senses the direction of the pressure difference, High - Low, plus and minus, i t i s essential that the "high" inlet side of the differential pressure gauge be connected to the high pressure side of the system and the "low" outlet side be connected to the low pressure side of the system. If on start-up, the gauge reads zero, i t may be that the high and low connections on the gauge are reversed.

(1) Very High Temperature Conditions - When the Model 120 is used in a high temperature system, the connecting tubing to the inlet and outlet of the gauge should be as long as possible to cool the fluid, so that the fluid temperature at the gauge is less than 200.F (90.C). This precaution is to reduce the chance of dis- coloring the dial or warping the dial housing of the gauge due to high temperatures. A length of tubing of 6 feet is usual ly adequate for most applications.

ASSEMBLY and CALIBRATION An exploded view of the Model 120 Differential Pressure Gauge, shows the piece parts of the gauge and

the method of assembly. CAUTION: When tightening or loosening the pressure connections at the back of the gauge, or the seal nuts at the left and right side of the gauge. hold the bar-stock body of the gauge securely with a 1 inch wrench. Do not wrench the front D ia l Chamber and bezel.

To Disassemble the Pressure housing;

(a) On the standard type, loosen the seal nuts and remove the adjustment screws. See exploded view. (b) On the low pressure 1204 ) L type, loosen the seal plugs and remove. See exploded view. (c) With a pencil or a wooden dowel, push out .the piston assembly and spring. (d) Cleaning. Thoroughly clean the housing, piston and metal parts with detergent solutions or mild

solvent. Do not use strong solvents (acetone, ether, toluene, and such) These may damage the dial and bezel assembly.

(e) Re-Assembly. Inspect al l parts, use new '0' Ring seals i f available. Coat a l l 'Ow Ring seals and al l sealing surfaces with silicone grease; also, apply a thin fi lm of silicone grease to the piston and cylinder. Check that the piston assembly is a free sliding f i t to the cylinder. On the low pressure Model 120 -( ) L, if the pointer moves in reverse as the piston is moved, reverse the pis- toke&br.end. Re-assemble seal nuts and adjustments as shown in exploded view.

( f ) Calibrati3K-The adjustment screw on the right side of the gauge is for "zero adjust" and that on the left side is for calibration.

(1) Zero adjust. Turn right hand screw in, until pointer moves off zero stop on dial; tap lightly and back off screw until pointer reads zero. Lock adjustment nut securely; recheck to see i f zero holds.

(2) Dial Calibration. Check gauge at approximately 30%. 50% and 70% of full scale pressure and adjust calibration screw at left end of gauge for proper calibration. Lock adjustment securely.

MAXIMUM INDICATION FOLLOWER POINTER The maximum indication follower pointer that is supplied with the Model 125 i s a light weight and bal-

anced 'lazy' pointer on a free pivot that moves with the main indicating pointer and remains at the highest point, that the main pointer travels. The 'maximum' pointer i s reset with a knob on the front of the gauge.

The 'maximum* pointer i s free moving and does not affect the accuracy of the gauge. The 'maximum* pointer i s affected by severe vibration and gauges equipped with 'maximum' pointers should be mounted as solidly as possible and where vibration i s not severe. The piece parts and the method of assembly of the maximum pointer i s shown on the exploded view.

DIMENSIONAL DATA

INDICATOR POINTER 7 /- FOLLOWER POINTER

ON GAUGES SO EQUIPPED' 3.5" DIA. - (4) -NO. 8 SceW I

LOW PRESSURE MODEL 1204 ) L

REED SWITCH, 1 or 2 MODEL 120E Only

ASSEMBLY and REPLACEMENT PARTS LIST A

R A N G E S P R I N G

P I S T O N (0.501

ADJ. S C R E W

11 17 Follower Pointer Assy. 703 Bezel Gasket. ITEM

237 Lens, Glass.

989 Lens, Acrylic. @) 5/16-18 Hex Jam Nut, Brass ( 2 )

1 11 8 Pointer Assy. 5/16-18 Hex Jam Nut, 316 Stainless Steel ( 2 )

1005 Bridge @ 2- 10 "0" Ring Seal - Specify Material ( 2 )

1113 Dia l @ 3-908 "0" Ring Seal - Specify Material (2)

763 Housing @ 318 Seal Nut, Brass ( 2 ) 11 19 Fastener Hardware (not i 1 lus.1 566 Seal Nut, 316 Stainless Steel ( 2 )

4 Bezel Screws @ 3-906 "0" Ring Seal - Specify Material (2 ) 4 Housing Screws 2 Pointer Stops @ 1066 Switch Assembly.

MID-WEST MODEL 120E with Alarm Control Switch Option

ALARM CONTROL SWITCH OPTION - Model 120 ( ) E The model 120 ( ) E is a single pole double throw switch

that can be adjusted to switch an alarm or control circuit at any part of the operating range of the pressure gauge. The switch is a hermetically sealed reed switch and is not affected by moisture, dust, dirt, vibration or shock. Operation of the switch does not affect the accuracy of the gauge. The switch is assembled in a protective housing and is provided with an external adjustment screw for changing the switch set point. To adjust the switch, turn the adjustment screw 'in', clockwise, for lower set point and 'out', counter clockwise, for higher set points. One-half turn on the ad- ----

4> justment screw i s approximately 1 % of fu l l scale on the gauge.

CAUTION: Do not exceed the rating of the switch, that i s : 4 watts: 200 volts AC or DC contrnuous, or 0.1 ampere maximum at lower voltages. When higher loads are required use Mid-West Power Relay 1000 TR or equivalent. The switching action of the alarm-control switch i s as follows:

I (RED) N.O. at ZERO, closes on rising Ap

t I - i S W I T C H ! ,WHITE, - Common

}HIGH ALARM

A T Z E R O I P R E S S U R E I (BLACK) N.C. at ZERO, opens on rising Ap

. )LOW ALARM . -

POWER RELAY - Model 1000 TR. Mid-West Model 1000 TR i s an isolated Power Relay that i s used with the Model 120 E Differential Gauge-

Switch for controlling high energy loads. The relay has a low voltage isolation transformer. Open runs of low voltage wiring of the type used for signalling and telephone connections can be used from the Model 120 E reed switch to the relay. The Model 1000 TR i s housed in a dust tight case on a standard 4" square junction box cover.

MODEL 1000 T R 115V - 60 Hz - A C RATING: 10Amps,continuous

1/2 Horsepower, continuous 1,000 Watts, continuous

I----- 7 f WHITE LINE (Common)

48 [ BLACK LINE

115V

i i LOAD

1/2 HP 10A YELLOW RED llsv A C

L,--J L

INDEX NO. 16

MAIN GAS PRESSURE REGULATOR

P C V - 0 2 9 - A , P C V - 0 2 9 - B

FEATURES PICTORIALLY TVPICAL-ORIENTATION MAY DIFFER

Fisher Controls April 1992 Bulletin 71. I:Y750

The Y750 Series self-contained, spring-loaded regulators (figure 1) provide economical pressure-reducing control in a variety of commercial and industrial applications. The Y750 Series design is ideally suited to control gas supply to in-plant processing equipment. The rugged casings and sliding pusher post design withstands the full 150 psig (1 0.3 bar) inlet pressure at both the inlet and outlet connections. Because the regulators can withstand the full inlet pressure a downstream relief valve is not required to protect the downstream side of the regulator.

Features High Outlet Pressure Capabilities-Full inlet pres-

sure capability on the downstream side of the regulator, eliminates the requirement for a downstream relief valve.

Corrosion Resistance-Multiple regulator constructions are available in a variety of materials for compatibility with corrosive process gases.

Ease of Inspection and Maintenance-The union nut connection between the body and the actuator permits access to the disk and orifice by only removing the diaphragm casing assembly without removing the body from the line.

Multiple Applications-Can be used for a wide variety of gases including air, nitrogen, natural gas, sour gas, butane and propane.

Sour Gas Service Capability-For sour gas applications, the Y750 Series regulators are available in materials that comply with National Association of Cor- rosion Engineers (NACE) Standard MR0175-91.

Product Description Type Y750 Self-operated Pressure Reducing Regulator

The Type Y750 regulator provides economical pressure reducing control for a variety of commercial, and industrial applications. For extra regulator protection the ex-

Figure 1. Type Y750 Self-operated Pressure Reducing Regulator

tra heavy diaphragm casing has the same pressure rating as the body. The sliding pusher post design prevents damage to internal parts if the downstream pressure exceeds the set point.

Downstream Control Line for Type Y750M Regulator

A Type Y750M regulator has a blocked throat stem seal with O-rings and a 112-inch NPT control line connection in the diaphragm case (figure 3). It is used for monitoring applications or other applications where other equipment is installed between the regulator and the pressure control point. The stem seal separates the body outlet pressure from the diaphragm case.

Internal Relief for Type Y750R Regulator

The Type Y750R regulator (figure 4) has limited capacity internal relief across the diaphragm to help minimize overpressure. Any outlet pressure above the start-to- discharge point of the nonadjustable relief valve spring moves the diaphragm off the relief valve seat, allowing excess pressure to bleed out through the spring case vent. Note that the internal relief valve has a very limited capacity.

@Fisher Controls International Inc. 1992; All Rights Reserved

Bulletin 71.1:Y750 page 2

(FISHER")

Specifications Available Configurations Maximum Operating Inlet Pressure

Type Y750: Self-operated pressure reducing See table 1 regulator equipped w~th a pitot tube for greater regulated capacities (figure 2). Outlet Operating Pressure Ranges(2) Type Y750M: Type Y750 with a stem seal See table 2 between the body outlet pressure and diaphragm case. Pressure is measured under Orifice Size and Flow Coefficients the diaphragm through the 112-inch NPT downstream control line connection (figure 3). See table 1

Type Y750R: Type Y750 with interal relief and Flow Capacities open throat (figure 4).

See table 3 Body Sizes (Inlet X Outlet)

3 1 4 x 314, . 1 x 1, or.?-114 x 1-114-inches Construction Materials See table 4

End Connection Style NPT screwed(1): 314, 1, or . 1 -114-inches Material Temperature Capabilities(2)

sizes Nitrile: - 20°F to 1 50°F ( - 29°C to 66°C) ANSI Class 150 and 300 raised face (RF) Fluoroelastomer: + 40" to 300°F ( + 5 to 149°C) flanged: 314, or II 1 inch sizes

Pressure Setting Adjustment Maximum Inlet Pressure (Body Rating)@) Adjusting screw

150 ps~g (10.3 bar) Spring Case Connection

Maximum Outlet Pressure (Casing)@) 114-inch NPT 150 psig (10.3 bar)

Pressure Connections Maximum Outlet Pressure to Avoid Internal Part See figure 5 Damage (emergency only)(2)

150 psig (1 0.3 bar) Approximate Weight 19 pounds (8.6 kg)

1 Flanged end connecttons or end connecttons for other than U S standards can 2 The pressureltemperature ltrnlts m th~s bullet~n, and any appl~cable code or usually be prov~ded, consult the Ftsher sales offlce or sales representattve standard Ilmttat~ons. must not be exceeded.

*-CLOSING CAP

ADJUSTlNG SCREW

CONTROL SPRING

Figure 2. Type Y750 Construction Features


Figure 3. Type Y750M Construction Features

Figure 4. Type Y750R Construction Features


[FISHER")

Table 1 . Additional Specifications

Table 2. Outlet (Control) Pressure Ranges

Capacity Information Table 3 gives the natural gas regulating capacities of Y750 Series regulators at selected inlet pressures and outlet pressure settings. Flows are in scfh (60°F and 14.7 psia) of 0.6 specific gravity gas at 60°F. To determine equivalent capacities for air, propane, butane, or nitrogen, multiply the table 3 capacity by the following appropriate conversion factor: 0.775 for air, 0.628 for propane, 0.548 for butane, or 0.789 for nitrogen. For gases of other specific gravities, multiply the given capacity by 0.775, and divide by the square root of the appropriate specific gravity.

Approximate Point Above Outlet Pressure Setting

at Which the Type Y750R Internal Relief Starts

to Discharge

0.5 to 2 psig (0.035 to 0.14 bar)

Type Number

Y750, Y750R, & Y750M

Then, if capacity is desired in normal cubic meters per hour at O°C and 1.01325 bar, multiply scfh by 0.0268.

1. With spring case above diaphragm as shown in Figure 1. With the spring case below the diaphragm, the sprlng rate is 1-114 inches wc (2.6 mbar) lower.

To determine wide-open flow capacities for relief sizing, use the following formula: I r- I -7

Control Spring Color

Red

Olive Drab

Yellow

Lt. Green

Lt. Blue

Black

where, Cg =gas sizing coefficient from table 1 C1 = Cg/C,, or 35 from table 1 G = gas specific gravity (air = 1 .O)

P,,,, = inlet pressure, psia (add 14.7 psi to gauge inlet pressure to obtain absolute inlet pressure)

Q =flow rate, scfh T =absolute temperature in OR of gas at inlet

Control Spring Part

Number

18653827052

18653927022

18537027052

185371 27022

18537227022

18537327052

Outlet Pressure Range(')

5-1 0 inches wc (1 2-25 mbar)

7-15 inches wc (17-37 mbar)

0.5-1.2 psig (34-83 mbar)

1.2-2.5 psig (83-172 mbar)

2.5-4.5 psig (.17-.31 bar)

4.5-7 psig (.31-.48 bar)


Table 3. Typical Y750 Series Regulator Capacities in Scfh of 0.6 Specific Gravity Natural as(')

- Continued -

Bulletin 71.1:Y750 Page 6

Table 3. Typical Y750 Series Regulator Capacities in Scfh of 0.6 Specific Gravity Natural Gas(') (Continued)

0.5 to 1.2 psig (34 to 83 rnbar)

1.2 to 2.5 psig (83 to 172 mbar)

28 inches wc (67 mbar)

1 psig (0.069 bar)

5.5 inches 1 f 1 wc (13 mbar) 30

150

1 yi20~:i bar) 14

1 See Capac~ty lnformat~on sectlon for conversion to equivalent capacltles of other -Shaded areas show where lndlcated droop would be exceeded regardless of gases and/or normal mJ/hr capaclty

2 Wlth sprlng case above d~aphragm as shown In flgure 1 Wlth sprlng case below t8ylLev -Shaded areas show where maxlmum operating Inlet pressure for a glven orlflce d~aohraam, ranae IS 1-114 ~nches wc 12 6 mbar) lower wlth heavv d~aohraam date lameter IS exceeded

Installation A Y750 Series regulator may be installed in any orientation as long as flow through it matches the direction of the arrow cast on the body. Normal installation is with the spring case vertical above or below the diaphragm case. Any possible mounting position will provide excellent performance. However, when exposed to the weather, the spring case vent should be protected by the umbrella vent or should be pointed downward to allow condensate to drain. On indoor installations, the vent should be piped outdoors if used in hazardous gas service. External dimensions and connections are shown in figure 5.

NACE Standard MR0175-91 Compliance Optional materials are available for applications handling sour gases. These constructions comply with the recommendations of National Association of Corrosive Engineers (NACE) MR0175-91.

The manufacturing processes and materials used by Fisher Controls assure that all products specified for sour gas service comply with the chemical and physical requirements of NACE standard MRO-175-90.


Table 4. Y750 Series Regulator Construction Materials

PART

Body I For standard and sour gas service(1)

Body Gasket

Union Nut

Diaphragm and spring cases

Spring case vent

Closing cap

Closing cap gasket

Adjusting screw I

Standard

CFBM (316 stainless steel)

Organic aramidlinorganic filler/nitrile elastomeric binder

Malleable iron

31 6 stainless steel


Thermoplastic

Thermoplastic

Neoprene rubber

Zinc

303 stainless steel


Plated steel

Nitrile rubber

303 stainless steel

302 stainless steel

304 stainless steel

3021304 stainless steel

303 stainless steel

302 stainless steel

MROl75-91.

Seat ring and disk holder

MATERIAL

Optional . Ductile iron or . WCB steel

- - -

WCB steel

Ductile iron or . CFBM (316 stainless steel) - - - . Steel or 316 stainless steel - - - - - -

Aluminum

- - -

Fluoroelastomer, PTFE

316 stainless steel

Stainless steel

Plated steel

Zinc - - - - - -

For other than sour gas service

For sour gas service

Diaphragm plate, control spring, control spring seat, split ring, and bolting

Diaphragm and disk

Pusher post

Lever and support

Lever and pitot tube screws

Pitot tube assembly

Stem

Cotter pin 1. As detailed in National Association of Corrosion Engineers (NACE) Standard


1/4-14 NPT VENT CONNECTION WITH REMOVABLE V E N T 7

NPT SWE 7

TYPE Y750M

ANSI FLANGED BODY NPT BODY (OPTIONAL) (mm)

Figure 5. Dimensions

Ordering Information 3. Control spring range in psig (bar) 4. Orifice size

When ordering, specify: Construction

Application Refer to the page 2 specifications and to each refer-

1. Type of regulator enced table. Specify the desired selection whenever 2. Body, spring case, diaphragm case, and trim there is a choice to be made. Always be sure to specify materials the regulator type number.


[-) Fisher Controls For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Sao Paulo 05424 Brazil Cernay 68700 France Singapore 2158

INDEX NO. 17

MAIN GAS SOLENOID

ESV-004-A, ESV-004-8

Honeywell

THE V4055 GAS VALVE ACTUATOR CONTROLS THE GAS SUPPLY TO COMMERCIAL AND IN- DUSTRIAL BURNERS.

The V4055 actuator, when used with the V5034 or V5055 valve, is rated for final safety shutoff service.

In installations where smooth lightoff is important, the V4055 may be used withe the V5055B valve, which has a characterized guide.

The standard model has an opening time of 26 sec at 60 Hz, or 32 sec at 50 Hz. A fast-opening model is available, with timings of 13 sec at 60 Hz, or 16 sec at 50 Hz.

Maximum closing time is 1 sec, which meets approval body requirements.

Optional damper shaft available, with or without spring return; shaft extends out both sides and rides in Teflon-like, Delrin bushings; used with standard 761 6BR Damper Crank Arm.

Red "OPEN" indicator attached to the actuator piston will show if the valve is even slightly open; yellow "SHUT" indicator on the valve stem will show only when the gas valve is fully closed.

Ambient temperature rating is -40 F to +I50 F [-40 C to +66 C] for 66 Hz models; -10 F to +I58 F [-23 C to +70 C] for 50 Hz and 50/60 Hz models.

Valve and actuator may be mounted in any position.

Optional, field-adjustable, spdt auxiliary switch, rated at 1 /2 hp [0.37 kW], may be added in the field.

Standard enclosure meets NEMA 1 general purpose requirements; optional enclosure meets NEMA 4 weatherproof requirements.

V4055D/V5055C and V4055E/V5055E combinations available to meet Factory Mutual valve-closed indication requirements for firing more than 250 Bohp (12.5 million Btuh input, or 10,000 Ib. of steam per hr [2.5 MW] output) and Underwriters Labora- tories Inc. 795 requirements for a valve seal overtravel interlock.

F.P. REV. 3-86.

Form Number 60-2309-7 @Honeywell Inc. 1986

MODELS: NOMINAL OPENING TIME (sec): V4055A Fluid Power Gas Valve Actuator for use with

V5055 or to replace the V4034 actuator on a V5034 valve (with the proper adapter). Provides on-off control.

V4055B-Same as V4055A, but high pressure rated. V4055D-Same as V4055A, but with valve-closed

indication switch. V4055E-Same as V4055B,

indication switch. but with valve-closed

Full Load 1 9.8 A 1 4.9 A

AUXILIARY SWITCH AND VALVE-CLOSED INDICA- TION SWITCH RATINGS: 1 /2 hp [0.37 kwa .

Locked Rotor 1 58.8 A 1 29.4 A

LOAD 1 120V

CLOSING TIME: 1 sec maximum when de-energized. DAMPER SHAFT: Models available with or without

integral damper shaft. Shaft is 3 /8 in. [9.5 mm] square, for use with 7616BR Damper Crank Arm (not included). Models available with or without damper shaft return spring.

MAXIMUM DAMPER SHAFT ROTATION: 52 angular degrees.

240 V

a ~ a x i m u m total connected power to both switches (if used) is 1800 VA.

ELECTRICAL RATINGS: V4055A,D-

HOLDING

0.1 4

VOLTAGE AND FREQUENCY

b ~ n 60 Hz power supply. (continued on page 3)

OPENING (STANDARD)

INRUSH I W I A I VA

220/50

240/50

240/60

I. Order number. 4. Damper shaft, with or without return spring, 2. Voltage and frequency. if required. 3. Standard or fast opening time. 5. NEMA 4 enclosure, if required.

6. Accessories, if desired.


1. YOUR LOCAL HONEYWELL RESIDENTIAL SALES OFFICE (CHECK WHITE PAGES OF YOUR PHONE DIRECTORY).

2. RESIDENTIAL DIVISION CUSTOMER SERVICE HONEYWELL INC., 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS, MINNESOTA 55422-4386 (612)542-7500

(IN CANADA-HONEYWELL LIMITEDfHONEYWELL LIMITEE, 740 ELLESMERE ROAD, SCARBOROUGH, ONTARIO M1P 2V9) INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.

OPENING (FAST)

INRUSH I W I A I VA

a ~ n 50 Hz power supply.

1.6

-

2.6

55.5

81.5

51.0

0.55

0.79

0.45

121

190

115

3.0

-

4.0

76.0

95.0

71.5

0.80

1.00

0.68

176

240

160

9.0

9.1

9.2

0.06

0.06

0.06

14

14

14

V4055B,E-120 V, 60 HZ. Opening-60 W 0.94 A (5.4 A inrush), 115 VA. Holding-9.5 W, 0.1 6 A, 19 VA.

PRESSURE RATINGS OF VALVE-ACTUATOR COMBINATIONS:

a~aximum operating pressure differential.

b~ax imum close-off pressure without seat leakage. This is the maximum allowable pressure drop to which a valve may be subjected while fully closed, and is independent of the valve body rating.

'use a V4055D or V4055 E (with valve-closed indication switch) with a V5055C or E (with double seal) for a Valve Seal Overtravel Interlock.

VALVE

V5055A,C 3/4 to 3 in.

V5055A,C 4 in.

V5055B 3/4 to 3 in.

V5055B 4 in.

V5055D,E 314, 1-114, 1-1 12 in.

V5055D,E 2, 2-1 /2, 3 in.

MAXIMUM FORCE A 2-1 1 /16 in. [68.3 mm] RADIUS FOR 7616BR DAMPER CRANK ARM (order separately): NOTE: Damper shaft drives damper crank arm in 1 direction only; optional return spring is available on damper shaft to

turn damper crank arm in opposite direction.

ACTUATOR

AMBIENT OPERATING TEMPERATURE RATING: -40 F to +I50 F [-40 C to +66 C] for 60 Hz models; -1 0 F to +158 F [-23 C to +70 C] for 50 Hz and 50/60 Hz models.

MOUNTING MEANS: Actuator mounts directly to valve bonnet with 2 setscrews, positioned 90 angular degrees apart. Valve and actuator can be mounted in any position.

MOUNTING DIMENSIONS: See Fig. 1. APPROVALS:

UNDERWRITERS LABORATORIES INC. LISTED: File No. MH1639, Guide No. YIOZ.

FACTORY MUTUAL APPROVED. AMERICAN GAS ASSOCIATION DESIGN CERTI-

FIED: 60 Hz models only. CANADIAN GAS ASSOCIATION CERTIFIED: 60 Hz

models only.

V4055 MODEL

Without return spring

With return spring

BRITISH GAS CORPORATION AND DUTCH GAS IN- STITUTE APPROVED-

V4055 with several V5055A and V5055B models. V4055D with V5055C models with an internal

screen. ACCESSORIES:

133533A Short Stem Adapter for mounting actuator on V5034 valve.

133534A Long Stem Adapter for mounting actuator on V5034 valve.

133568 Auxiliary Switch Bag Assembly. 133569 Valve-Closed Indication Switch Bag Assem-

bly (do not use with V5034 valve body). 7616BR Damper Crank Arm (damper arm and clip).

OPTIONAL SPECIFICATION: V4055 with NEMA 4 enclosure (weatherproof).

V4055A,Dc V40556,Ec

DIFF.~

-40 F TO +20 F [-40 C TO -7 C]

psi

5

3

5

3

5

5

CLOSE- OFF^ DIFF.~

Ib.

5

5

+20 F TO +I50 F [-7 C TO +66 C]

kPa

34.5

20.7

34.5

20.7

34.5

34.5

psi

15

15

15

15

75

45

psi

15

5

15

5

25

15

CLOSE- OFF^

N

22.2

22.2

Ib.

20

10

kPa

103.4

103.4

103.4

103.4

51 7.1

31 0.3

kPa

103.4

34.5

103.4

34.5

172.4

103.4

psi

15

15

15

15

75

45

N

89.0

44.5

kPa

103.4

103.4

103.4

103.4

51 7.1

31 0.3

ALLOW 4 in. [101.6 mml CLEARANCE FOR ACTUATOR REMOVAL.

ADD 11.9 in. 13.2 mm] TO DIMENSION FOR MODELS WITH NEMA 4 ENCLOSURE.

A :;;;:4,;"~6;; mm] TO DIMENS~ON A FOR MODELS WITH NEMA

E2013

FIG. 1-APPROXIMATE MOUNTING DIMENSIONS OF V4055 ACTUATORS AND V5055 VALVES, IN in. [mm IN BRACKETS].



4. After installation is complete, check out product operation as provided in these instructions.

ing connections to prevent electrical shock and equipment damage.

2. Voltage and frequency of the power supply connected to this control must agree with those marked on the device. CH SECURED

3. Maximum total connected load to both switches (if used) must not exceed 1800 VA. IF ONLY ONE SWITCH IS

USED. INSTALL BARRIER I N OPEN POSITION.

FIG. 2-V4055 ACTUATOR WITH COVER REMOVED.

INSTALL VALVE The actuator is mounted directly on the valve bonnet

after the valve is installed in the gas supply line. Refer to the instruction sheet packed with the gas valve for details of installation. When installing the valve, ensure that:

1. Sufficient clearance is left for installation and service of the actuator.

2. Ambient temperatures at the valve location will remain within -40 F to +I50 F [-40 C to +66 C].

3. Position of the valve permits hookup to the damper if one is controlled.

INSTALL ACCESSORY SWITCHES (If Needed)

A spdt switch may be installed to operate an auxiliary load up to 1/2 hp [0.37 kW]. The switch may be adjusted to operate at any point in the valve stroke.

A valve-closed indication switch may also be installed on any V4055 actuator to provide a valve seal overtravel interlock (valve-closed indication) when used with a V5055C or E valve (with double seal).

NOTE: A V5055A, B or D valve can also be fitted with a bonnet assembly with 2 seals to provide a valve seal overtravel interlock.

The spdt valve-closed indication switch is installed to make or break a circuit when the valve is in the closed position. The switch is not adjustable.

To install the switches, proceed as follows: 1. Remove the actuator faceplate (2 screws). 2. Remove the silver-colored barrier to expose the

actuator stem. 3. Insert the auxiliary switch in the position indicated

in Fig. 2. Fasten with 2 screws through the actuator base.

4. Insert the valve-closed indication switch in the position shown in Fig. 2. The valve-closed indication switch mounts against the side of the actuator housing. The mounting holes are spaced to mount the switch only in the correct position. Fasten with 2 screws through the actuator base.

5. If only 1 switch is used, install the narrow barrier included with the switch in the unused space.

6. Mount the actuator before making wiring connections and adjustments to the switch.

MOUNT ACTUATOR ON VALVE Check the final position of the valve body to be sure

that the actuator will be in the proper position when mounted on the valve. This is especially important if the actuator is used to drive a damper.

If 2 smaller size valves are mounted very close together, as in an Industrial Risk Insurers (formerly F.I.A.) type valve train, it may be necessary to mount the actuator "off center" to provide adequate clearance.

Slip the bottom collar of the actuator over the valve bonnet assembly. Rotate the actuator to the desired position and use a 5/32 inch Allen wrench to tighten the two setscrews securely (50 to 60 Ib.-in. [5.7 to 6.8 N.ml).

NOTE: Mark the actuator or valve to indicate any connect the damper linkage, if used. Refer to the changes made. instructions packed with the damper arm.

TO REPLACE A V4034 ON A V5034 VALVE

IMPORTANT When replacing a standard (26 sec) V4034

actuator on a V5034 valve, check the main burner flame-establishing period (MBFEP) of the burner programmer. If the MBFEP is 10 sec, you must use a fast-opening (13 sec) V4055 actuator on the older V5034 valve.

The initial action of the V4055 does not immediately open the V5034 valve because of a difference in stroke length. The pilot may be shut off before the main burner flame is established. The fast-opening V4055 will open the V5034 valve fast enough to establish the main burner flame within the 10 second flame-establishing period.

If it is desirable to maintain the slower opening characteristic of the standard actuator, both the actuator and valve should be replaced. Use a standard V4055 actuator on a V5055 valve.

Select the correct adapter, depending on whether the V5034 has a long or short stem (Fig. 3). Fasten the adapter to the V5034 valve bonnet, and then mount the actuator on the adapter. Follow the instructions for mounting the actuator on the valve.

If the V4034 being replaced is equipped with a heater, there will be a low limit control connected in series with the V4034 power supply to prevent actuator operation below 25 F [-4 C]. There will also be a constant source of line voltage power to the heater and its control thermostat.

USE NO. 133533A I I I I

ADAPTER^ SHORT STEM V5034

I t

I I

FIG. 3-ADAPTERS PERMIT USE OF V4055 ACTU- ATOR WITH V5034 VALVE.

The V4055 is rated for ambient temperature down to -40 F [-40 C] for 60 Hz models, or -10 F [-23 C] for 50 Hz and 50/60 Hz models, and does not require a heater. All of the wiring as associated with the heater should be removed. Disconnect the power supply for the heater as its source and remove the wires.

MOUNT AND ADJUST 7616BR DAMPER CRANK ARM (If Used)

r ?- - 1

REMOVE HEATER CIRCUIT

4- L2

VALVE TERMINAL ON BURNER CONTROL

FIG. 4- REMOVE HEATER CIRCUITS, IF INSTALLED, WHEN REPLACING V4034 ACTUATOR.

IMPORTANT

actuator which is exposed to ice or sleet, a suitable shield MUST be installed to prevent ice or

Follow installation and adjustment directions included with damper crank arm. Maximum pushrod travel is 2-5/16 in. [58.7 mm] through a stroke of 52 degrees.

ATTACHED TO ACTUATOR SHAFT TO DRIVE A DAMPER WHEN VALVE IS OPENED.

WIRING Disconnect power supply before making electrical

connections to prevent electrical shock or equipment damage.

Wiring must comply with all applicable electrical codes, ordinances, and regulations. Wiring to the actuator must be NEC Class 1.

Connect the power supply to terminals 1 and 2 on the V4055 terminal strip. Refer to Fig. 6 for auxiliary switch connections. For typical system hookups, refer to instructions packed with device used to control valve.

When all wiring connections are complete, replace the actuator faceplate. NOTE: Pipe sealant is required on the conduit threads

of actuators with NEMA 4 enclosures. ADJUST THE AUXILIARY SWITCH (If Used)

The auxiliary switch is adjustable throughout the stroke of the actuator. With the switch installed in the actuator, turn the adjusting screw (Fig. 2) clockwise

to cause the switch to operate earlier in the stroke or counterclockwise to cause the switch to operate later in the stroke. NOTE: The valve-closed indication switch is not

adjustable.

1 POWER SUPPLY; PROVIDE OVERLOAD PROTECTION A N 0 DISCONNECT

2 SWITCH BETWEEN THESE TWO LEADS IS C m WHEN VALVE IS SHUT (DE.ENERGIZED),

A ~~;TCCE;~;~~~; THESE TWO LEADS IS a WHEN VALVE I S SHUT

E2008

FIG. 6-EXTERNAL CONNECTIONS TO THE V4055 ACTUATOR.

PHOTOCELL. OR INFRA.

------

WHITE L 2 C - ------- J

BLACK

BLACK I POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

L2*--- ------ J PROTECTION AS REQUIRED. 3 VALVE-CLOSED INDICATION SWITCH I N PREIGNITION INTERLOCK

USE ALL NEC CLASS I WIRING. CIRCUIT; SWITCH IS CLOSED NC.C WHEN ACTUATOR IS DE.ENERGtZED. -----

FIG. 7-TYPICAL APPLICATION OF A V4055D/V5055C OR V4055E/V5055E COMBINATION TO MEET FACTORY MUTUAL OR UNDERWRITERS LABORATORIES INC. REQUIREMENTS FOR A VALVE SEAL OVERTRAVEL INTERLOCK (VALVE-CLOSED INDICATION).

Only a trained, experienced, flame safeguard control service technician should check out and service this control.

CHECKOUT After the installation is complete, cycle the valve

several times with the manual fuel shutoff cock closed before testing the system in actual operation.

SERVICE The actuator is not field repairable, except for re-

placing the auxiliary switch or valve-closed indication switch. See INSTALLATION section for procedure. Do not disassemble the valve actuator.

If the actuator should fail to operate properly, replace it.

UPGRADING ACTUATORS AND VALVES TO V4055D/V5055C OR V4055E/V5055E CAPABILITY

Any V5055 valve body can be fitted with a bonnet assembly with 2 seals to provide a valve seal overtravel interlock (valve-closed indication). Add a valve-closed indication switch, Part No. 133569, to the actuator when changing the bonnet. See Fig. 2. Identify this change by tagging the valve so that if the valve should require future replacing parts, the correct part may be ordered. This change is not approved by Underwriters Labor- atories Inc. or by Factory Mutual, but it does update the installation to the latest requirements specified by these approval bodies.

Honeywell lnc. International Sales Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland. 1885 Douglas Drive N. France, Germany. Japan, Mexico. Netherlands. Spain, Taiwan, United Kingdom. U.S.A.

Golden Valley. MN 55422-4386 PRINTED IN U.S.A.

THE V5055 GAS VALVES ARE USED WlTH THE V4055, V4062, AND V9055 FLUID POWER ACTUATORS TO CONTROL GAS FLOW TO COMMERCIAL AND INDUS- TRIAL BURNERS. THEY MAY BE USED WlTH NATURAL OR LP GASES.

V5055 single-seated, normally closed valves are suitable for service requiring tight shutoff.

V5055A,C,D,E valves are for On-Off service.

V5055B valve has a characterized guide to provide slow opening, Hi-Lo-Off, or Modulating service.

V5055C and E valves have 2 seals to provide a valve seal overtravel interlock (valve-closed indication).

V5055D and E valves are for high pressure applications.

Threaded connections for 7 pipe sizes from 3/4 to 3 in. NPT (or parallel BSP); V5055A,B,C are also available in a 4 in. size with flange connections.

Standard-1 /4 in. NPT or parallel BSP upstream tap and plug. Optional-1 /8 in. NPT downstream tap and plug; additional 1 /2 in. NPT upstream tap and plug.

Valve body rating of 75 psi [517.1 kPa]; body passes burst test of Underwriters Laboratories Inc.

Yellow "SHUT" indicator right on the valve stem represents an accurate indication of the actual position of the valve disc.

Unpainted, die-cast aluminum body.

V.F. REV. 11 -86.

Form Number 60-2307-8 @Honeywell Inc. 1986

MODELS: cation feature), but for high pressure applications. V5055A Industrial Gas Valve for On-Off service. TYPE OF GAS: Natural or LP (liquefied petroleum) V5055B Industrial Gas Valve with characterized only.

guide for slow opening, Hi-Lo-Off, or Modulating PIPE SIZE (in.): 3/4, 1, 1-1 /4, 1-1 /2, 2, 2-1 /2, 3, and service. 4 (only V5055A,B,C available in 4 in. size).

V5055C-Same as V5055A, but with 2 seals to pro- PIPE THREADS: NPT (National Pipe Threads) or vide a valve seal overtravel interlock (valve- parallel BSP (British Standard Pipe Threads- closed indication). equivalent to IS0 R7 and DIN 2999) available on

V5055D-Same as V5055A, but for high pressure inlet and outlet of 3/4 to 3 in. valves; 4 in. valves applications. have flange connections.

V5055E-Same as V5055C (with valve-closed indi- PRESSURE RATINGS: See Table I.

TABLE I-PRESSURE RATINGS OF VALVE-ACTUATOR COMBINATIONS

a~ax imum operating pressure differential.

VALVE

V5055A,C 3/4 to 3 in.

V5055A,C 4 in.

V5055B 3/4 to 3 in.

V5055B 4 in.

V5055D,E 314, 1, 1-114, 1-112 in.

V5055D,E 2, 2-1 /2, 3 in.

b ~ a x i m u m close-off pressure without seat leakage. This is the maximum allowable pressure drop to which a valve may be subjected while fully closed, and is independent of the valve body rating.

'use a V4055D, V4055E, V4062D, or V9055D (with valve-closed indication switch) with a V5055C or E (with double seal) for a Valve Seal Overtravel Interlock.

(continued on next page)

WHOLESALER OR YOUR DISTRIBUTOR, REFER TO THE TRADELINE CATALOG OR P COMPLETE ORDERING NUMBER, OR SPECIFY-

1. Order number. 4. Optional additional tapping and plug-1 I 8 in. downstream and/or 112 in. upstream.

3. NPT or parallel BSP threads (except for 4 in. 5. Replacement parts, if desired. models with flanges).


1. YOUR LOCAL HONEYWELL RESIDENTIAL DIVISION SALES OFFICE (CHECK WHITE PAGES OF PHONE

2. RESIDENTIAL DIVISION CUSTOMER SERVICE HONEYWELL INC., 1885 DOUGLAS DRIVE NORTH MINNEAPOLIS, MINNESOTA 55422-4386 (612)542-7500

(IN CANADA-HONEYWELL LIMITEDIHONEYWELL LIMITEE, 740 ELLESMERE ROAD, SCARBOROUGH, ONTARIO M1P 2V9) INTERNATIONAL SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES OF THE WORLD.

ACTUATOR

V4055A,Dc V4055B,Ec

psi

5

3

5

3

5

5

psi 15

15

15

15

75

45

psi

15

5

15

5

25

15

kPa

34.5

20.7

34.5

20.7

34.5

34.5

V4062, V9055c

kPa

103.4

103.4

103.4

103.4

517.1

310.3

psi 5

3

5

3

5

5

kPa

103.4

34.5

103.4

34.5

172.4

103.4

kPa

34.5

20.7

34.5

20.7

34.5

34.5

psi

15

15

15

15

75

45

kPa

103.4

103.4

103.4

103.4

517.1

310.3

psi

15

15

15

15

75

45

kPa

103.4

103.4

103.4

103.4

517.1

310.3

VALVE BODY RATING: 75 psi [517.1 kPa]; body passes REPLACEMENT PARTS: burst test of Underwriters Laboratories Inc. Replacement seal assembly-includes valve seal,

VALVE CAPACITIES: A.G.A. ratings at 1 in. [0.25 kPa] bonnet seal, and tube of lubricant. pressure drop; based on gas with specific gravity of 133393A for 3/4, 1, 1-1 /4, and 1-1 /2 in. valves. 0.64. (See Fig. 1 for other pressure drops.) 133392A for 2, 2-1 /2, and 3 in. valves.

137253A for 4 in. valves. Replacement bonnet assembly-includes complete bonnet assembly, plus the required replacement seal assembly.

FIG. 1-FLOW CURVES FOR V5055 VALVES.

VALVE SlZE (in .)

3 /4

1

1-1/4

1-1/2

2

2-1 /2

3

4 (V5055A)

4 V5055B,C)

UPSTREAM TAPPING AND PLUG: 1 / 4 in. NPT or parallel BSP is standard; additional 1 /2 in. NPT is optional.

DOWNSTREAM TAPPING AND PLUG (optional): 1 /8 in. NPT.

AMBIENT OPERATING TEMPERATURE RATING: -40 F to +I50 F [-40 C to +66 C]; (to +I25 F [52 C] when used with a V9055).

MATERIAL: Die-cast aluminum. MOUNTING MEANS: Mounts directly in the gas supply

line. DIMENSIONS: See Fig. 2 and 3. WEIGHT: 3/4, 1, 1-1 /4, 1-1/2 in. valve - 4 Ib. [1.8 kg]. 2 in. valve - 8 Ib. [3.6 kg]. 2-1 /2, 3 in. valve -1 1 Ib. [5.0 kg]. 4 in. valve -28 Ib. [ I 2.7 kg].

A.G.A. RATED CAPACITY

APPROVALS: The following combinations of V5055 Valves (3/4 through 4 in.) and V4055, V4062, and V9055 Fluid Power Actuators are approved by these agencies. UNDERWRITERS LABORATORIES INC. LISTED (File No. MH1639, Guide No. YIOZ):

V4055A,B,D,E/V5055A,B,C,D,E V4062/V5055A,B,C,E V9055/V5055A,B,C,E

INDUSTRIAL RISK INSURERS (FORMERLY F.I.A.) APPROVABLE:

V4055A,B,D,E/V5055A,B,C,D,E V4062 /V5055A,B,C, E V9055/V5055A,B,C,E

FACTORY MUTUAL APPROVED (Report Nos. 20698, 20835, 21172, and 24061) AND AMERICAN GAS ASSOCIATION DESIGN CERTIFIED (Report No. 21 -1 C).

V4055A/V5055A,B V4055E/V5055E V4055B/V5055D V4062/V5055B,C V4055D/V5055C V9055/V5055B,C

NOTE: The A.G.A. does not certify model equipped with BSP threads.

CANADIAN GAS ASSOCIATION CERTIFIED (Report No. 1029-SSV-4098; 60 Hz actuator models only):

V4055A,B,D,E/V5055A,B,C,D,E V4062/V5055B V9055/V5055B

(continued on next page)

cfh

665

960

1406

171 7

3620

4250

5230

10200

91 80

VALVE MODEL

V5055A (On-Off)

V5055B (Characterized

Guide)

V5055C (Valve-Closed

Indicator)

V5055D (High Pressure

. On-Off)

V5055C (High Pressure Valve-Closed

Indicator)

m3/hr

18.8

27.2

39.8

48.6

102.5

120.3

148.1

288.8

259.9

VALVE SIZE (in .)

3 4 1 1 - 1 4 1 - 1 2

. 2, 2-1 /2, 3

4

3 1 1 1 4 1 1 2

27 2-1 I2?

4

3 1 1 - 1 4 1 -

21 2-1 12,

4

3 / 4 1 1-1 4 , I - 2

2, 2-1 /2,3

3 / 4 1 1-1 4 1 - 1 2

2, 2-1 /2,2

REPLACE- MENT

BONNET ASSEMBLY

133398AA

13341 7AA

13691 1AA

133398BA

13341 7BA

1 3691 1 BA

137338AA

133964AA

13691 1 CA

136308AA

136307AA

136308BA

1 36307BA

BRITISH GAS CORPORATION AND DUTCH GAS AUSTRALIAN GAS ASSOCIATION APPROVED: INSTITUTE APPROVED: V505581242, -81259, -81 267, -81 275, -81283,

V4055 or V4062 with V5055A1129, -A1 137, -A1 145, -81 291, and -81 309. -A1 152, -A1 160, -A1 178, -81168, -81176, -81184, DIN-DVGW APPROVED (GERMANY): -81 192, -81200, -81218, -81317, -81325, and V5055A1129, -A1137, -A1145, -A1152, -A1160, -81 333. -A1 178, -A1 236, -81168, -81176, -81 184, -81 192,

V4055D or V4062D with V5055C1216, -C1224, and -81200, -81218, and -81226. -C1232.

FIG. 2-APPROXIMATE DIMENSIONS OF THE 314 THROUGH 3 in. V5055 VALVES WITH VALVE ACTUATOR, IN in. [mm IN BRACKETS].

4

OPTIONAL 118 8 " NPT DOWNSTREAM TAP AND PLUG (NOT FOUND ON INTER NATIONAL MODELS)

114 In NPT OR BSP UPSTREAM I-OCTAGON - TAP AND PLUG

A ALLOW 2 I" (50 8 mrnl FOR ACTUATOR REMOVAL

VALVE DIM A SIZE mm

L 3 1 5 < n C I ; ; 8 1 n I l l ( 8 1 2 8 2 6 I l 1 4 i n 1 1 1 1 8 2 8 2 6

DIM B ~ n m m

2 8 2 6 2 3 4 2 3 j 4 ' 6 9 9

-- - OCTAGON

~n 6 9 9 8 3 1 6 - ; b 1 8 ~ ~ ~ 5 ~ 4 ~ 1 4 6 1 2 1 4 5 7 2 4 3 1 6 , 1 3 5 4 2 1 3 1 6 7 1 4

1 1 1 2 n - 1 1 1 1 8 2 8 2 6 2314

El425

8 3 $ 1 6 2 0 8 0 _ _ 5 _ 3 / 4

1 4 6 1 2 1 2 7

2314 6 9 9 1 8 3 / 1 6

1 4 6 1 1461

2 1 4 2 15$16

2 3 5 0 2 314 91/4--235Oi 2-3/4--_j99

6 9 9 8 3 / 1 6 2 0 8 0

2 n - 1 1 ~ 4 - 2 8 5 ~ ! - 2 7 / 8 8 5/16 6 9 9 7 19/32 1 9 2 9 4 112 114 3

1 _ 7 1 9 / 3 2 j 1 9 1 9 1 4 112 ' 1 1 4 3 ,

. 2 154 2 114

5 7 2 5314 211 1

-223 8 ' 2 112 n 1 1 314 298 5 3 318 I1 314 ' 2 9 8 5 i 3318 ~3n

8318 9 114

2 0 8 0

85 7 8 13/16 8 5 7 [ 8 1 3 i 1 6 1

5 7 2 5 7 2

415116 1 3 5 4 ' 2 1 3 1 ' 6

2 2 2 8

5314 7 1 4

7 4 6 , 7 19/32 , 1 9 2 9 1 3 112

4151-4

8 8 9

415116 1 3 5 4 2 1 3 / 1 6 7 1 4 213:16 7 1 4

GAS VALVE SIZING 1. Check the burner nameplate for (a) the type of gas

used, and (b) the gas flow capacity. The capacity will be listed in Btuh (Btu's per hour) or in cfh (cubic feet per hour).

2. Call the gas utility for information on (a) the specific gravity (sp gr) and (b) Btu per cubic feet (Btu/cu ft) for type of gas used.

3. Find the capacity in cfh. If the capacity is listed in Btuh, convert to cfh by the following formula.

Btuh (from burner nameplate) Capacity in cfh =

Btu/cu ft (from gas utility) 4. For gases with specific gravities other than 0.64,

multiply the burner cfh by the proper conversion factor shown below.

TYPE OF MULTIPLY (average) cfh BY

LP-Propane

LP-Butane 1.98 1.76

5. Use the corrected capacity in cfh when determining the gas valve size on Fig. 1.

6. Determine the maximum pressure drop across the valve, and draw a horizontal line at this pressure on Fig. 1.

7. Draw a vertical line on Fig. 1 at the capacity (cfh) previously determined. Use the corrected capacity for a gas with a specific gravity other than 0.64.

8. Use the valve size at the intersection of the horizontal and vertical lines. If the intersection is between valve sizes, use the next higher valve size to the right.

TO SIZE 2 IDENTICAL VALVES PIPED IN SERIES 1. Find the cfh for the type of gas used. 2. Consider both valves as 1 unit. Determine the total

maximum pressure drop across the unit. 3. Find the pressure drop across the first valve by

assuming it to be 45% of the total pressure drop. 4. Find the valve size from Fig. 1. 5. The second valve will be the same size as the first

valve.

-5 [127.01-

27

..--- - FOR 112 In. 1 rr------------------. I

I, -1 11

I I

I I

I I I I I @ - _ _ _ - hzz _---- lr;d- ---J -------------------- 1 ,- ------ + ------------- 4

I t - 7

I I I I I

A ALLOW 2 I". 150.8 mm] CLEARANCE ABOVE V4055 5 0 I T MAY BE DIMENSIONSON DIN-APPROVED VALVES: 1/4-19 BSP.PL UPSTREAM PLUG (2). REMOVED FROM VALVE. 0.71 ~ n . 118.0 mm] DIA. BOLT HOLE (16). 7.087 8n [180.0mml DIA. BOLTCIRCLE. €1426

FIG. 3-APPROXIMATE DIMENSIONS OF THE 4 in. V5055 VALVES WITH VALVE ACTUATOR, IN in. [mm IN BRACKETS].

IMPORTANT MOUNTING (Figs. 4 through 6)

of gaseous fuel (natural gas, propane) flow in

to water. V5055 valves utilized in maritime, bev- erage, food processing, outdoor and other installations in which occasional exposure to water is experienced may be subject to valve stem and spring corrosion. The presence of corrosion decreases the operating life of the valve. V5055 valves utilized in such installations should be inspected at least annually and should have the valve bonnets replaced if corrosion is noted.

A valve actuator with a NEMA 4 rating is also recommended for such installations. The watertight design of the NEMA 4 rated actuator prevents water from entering the V5055 valve stem and spring chamber through the actuator. Under certain conditions, some water may be retained by the external upper portion of the valve body. The retained water is effectively excluded from the valve stem and spring chamber by a functional seal incorporated into the NEMA 4 rated actuator.

WHEN INSTALLING THIS PRODUCT. . . 1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazardous condition.



4. After installation is complete, check out product operations as provided in these instructions.

1. Turn off gas supply before starting installation. 2. Disconnect power supply for valve actuator

before beginning installation to prevent electrical shock and equipment damage.

3. The valve must be installed so the arrow on the valve points in the direction of gas flow. (Gas pressure helps to close the valve.)

LOCATION Install the valve in the gas supply line downstream of

the pressure regulator. The valve and actuator may be mounted in any position that allows sufficient clearance for installation and for repair or replacement.

1. The valve position indicators should be easily visible with the valve and actuator in their final position.

2. The final position of the valve and actuator must allow for damper linkage if used.

t IMPORTANT i

Allow room for turning the valve body (actuator not attached) onto the gas piping. "Swing" dimensions, measured from the center of the pipe are:

3/4 through 1-1 /2 in. valves-4 in. [101.6 mm]. 2 through 3 in. valves-5 in. [127.0 mm]. 4 in. valves-7 in. [177.8 mm].

If flow is not in direction of arrow on valve body, valve may not shut off.

1. Use new, properly reamed, pipe, free from chips. 2. Do not thread pipe too far (Fig. 4). Valve distortion

or malfunction may result from excess pipe in valve. 3. Remove the protective caps from the ends of the

valve. Do not attach the valve actuator until the valve body installation is complete.

4. Apply good quality pipe dope, putting a moderate amount on the male threads only. Use dope sparingly; if pipe dope lodges on the valve seat, it will prevent proper closure. If using LP (liquefied petroleum) gas, use pipe dope resistant to action of LP gas.

5. Install valve with the gas flow in the direction indicated by the arrow on the casting.

6. Apply a parallel jaw wrench only to the flat next to the pipe being inserted (Fig. 5). A wrench applied to the valve body itself or to the end farthest from the pipe being inserted may distort the casting, causing a malfunction. Do not use the valve for a lever.

7. The gas flow MUST be in the same direction as the arrow on the bottom of the valve body.

8. Two threaded companion flanges, 2 gaskets (included with valve), and 16 bolts (with washers and nuts) are required for mounting a 4 in. V5055 valve. Mount a threaded flange and gasket on each end of the valve as shown in Fig. 6. Then screw the pipes into the threaded flanges. Apply dope sparingly, and use wrenches and vises properly as shown in Figs. 4 and 5.

9. Make sure the power supply has been disconnected from the valve actuator. Then mount the actuator on the valve body and complete the electrical and linkage connections as instructed in the sheet packed with the actuator.

2 CLEAN THREAD5

NORMAL F U L L THREAD- NG

BLOW OUT DISTORTS VALVE

184sa CHIPS (THEY M A Y SEAT

LODGE ON SEAT)

E2127

FIG. 4-PREPARING THE PIPES.

VISE GRIPS END WRENCH HERE NEXT TO PIPE BEING INSERTED VALVE BODY

FIG. 5-INSTALLING A 3/4 THROUGH 3 in. V5055 VALVE.

WASHER INCLUDED) (16-NOT INCLUDED)

518 X 3 in. [76.2 mm] BOLT (16-NOT INCLUDED)

E2130

FIG. 6-INSTALLING A 4 in. V5055 VALVE.

7

OPERATION A V5055 Industrial Gas Valve is operated by a V4055,

V4062, or V9055 Fluid Power Gas Valve Actuator. The valve opens when the actuator is energized, and closes when power is removed. When closed, the valve seals off against the rated close-off pressure with no power applied. For further information, refer to the instructions sheet for the actuator.

CHECKOUT

4. Remove the leak test tap plug and connect the test apparatus to the Leak Tap (D).

5. Close the downstream manual gas cock (E). 6. Open the upstream manual gas cock (A). 7. Run the safety shutoff valve (C) to its fully open

position (through the safety system); then immediately de-energize the system to close the valve.

8. Immerse a 1 14 in. tube vertically 1 12 in. [12.7 mm] into a jar of water.

9. Slowly open the test petcock (F). 10. When the rate of bubbles coming through the

water stabilizes, count the number of bubbles appearing during a 10 second period. Each bubble appearing during a 10 second period represents a flow rate of approximately 0.001 cfh.

To meet all U.S. requirements leakage must not ex- ^^^-I *L-^ ..-,..-- -: I--,

Do not allow fuel to accumulate in the combustion chamber. If fuel is allowed to enter the chamber for longer than a few seconds without igniting, an explosive moisture could result.

NOTE: For international leak test requirements, contact the office of the appropriate approval agency.

NO. OF V5055 ALLOWABLE BUBBLES

SIZE (in.) LEAKAGE PER 10 sec

3 1 11-1141-112 400 cclhr

2, 2-1 12, 3, 4 650 cclhr

1. Do not put the system into service until you have satisfactorily completed the Valve Leak Test below, all applicable tests described in

After the installation is complete, cycle the valve several times with the manual fuel shutoff cock closed. Make sure the valve and actuator function properly. Also perform the Valve Leak Test described below before putting the valve into service.

FOLLOWING THE TEST: 11. Close the upstream manual gas cock (A). 17 C l n c a t h e tact n ~ t r n r k l F \ rtamn\ra t h e tact

the Checkout section of the instruction sheet for the flame safeguard control, and any other tests required by the burner manufacturer.

2. All tests must be performed by a trained, exper ienced f lame safeguard con t ro l technician.

3. Close all manual fuel shutoff valves as soon as trouble occurs.

VALVE LEAK TEST (Fig. 7) This is a test for checking the tightness of closure of

a gas safety shutoff valve. It should be performed (by qualified personnel) during the initial startup of a burner system, or whenever the valve or valve bonnet is replaced (see Service Information). I t is recommended that this test also be included in scheduled inspection and maintenance procedures. For a periodic inspection test, follow steps 1,3,4,5,8,9,10,12,14,16, and 17.

1. De-energize the control system to ensure that there is no power to the safety shutoff valve (C), shown in Fig. 7.

2. Close the upstream manual gas cock (A). 3. Make sure the manual test petcock (F) is closed

in the leak test tap assembly (D).

.-. W.""" "." ."". ,a".""".. \. ,, a " . . . " . " I.." L V Y .

apparatus, and replace the leak test tap plug (D). 13. Open the upstream manual gas cock (A) and

energize the safety shutoff valve (C). 14. Test with soap bubbles to ensure that there is no

leak at the test tap (D). 15. De-energize the safety shutoff valve (C). 16. Open the downstream manual gas cock (E). 17. Restore the system to normal operation.

114 8". ALUMINUM OR

FIG. 7-VALVE LEAK TEST.

1. Turn off the gas supply and disconnect all electrical power to the valve actuator before servicing.

2. Only qualified service technicians should attempt to service or repair flame safeguard controls and burner systems.

3. Do not disassemble the valve bonnet assembly; the valve seat is not replaceable.

4. Failure to properly position and seat the seals in the valve body may result in a hazardous gas leak.

SCHEDULED INSPECTION AND MAINTENANCE .

A schedule should be set up and followed for periodic inspection and maintenance, including the burner and all other controls as well as the valve(s). It is recommended that the Valve Leak Test in the CHECK- OUT section be included in this schedule. Refer to the instruction sheet for the flame safeguard control for more information.

VALVE BONNET REPLACEMENT The entire valve bonnet may be replaced without

removing the valve body from the gas line. Do not disassemble the valve bonnet assembly; the valve seat is not replaceable.

For part numbers, refer to Replacement Parts in the SPECIFICATIONS section. Complete instructions on replacing the bonnet assembly are included with the replacement part.

FIG. 8-PROPER POSITIONS OF VALVE AND BONNET

BONNET SEAL

VALVE SEAL

NOTE: Any V5055 valve body can be fitted with a SEALS IN 314 THROUGH 3 in. VALVES.

bonnet assembly with 2 seals to provide a valve seal overtravel interlock (valve-closed indication). Add a valve-closed switch (Part No. 133569) to the actuator when changing the bonnet. Identify this change by tagging the valve so that if the valve should require future replacement parts, the correct parts may be ordered. This change is not approved by Factory Mutual.

REPLACEMENT OF SEALS (Fig. 8 or 9) When removing the bonnet to inspect and clean the

valve, install new seals (see Replacement Parts). Coat the new seals with the grease provided, and position them in the valve body as shown in Fig. 8 or 9.

Failure to properly position and seat the seals in the valve body may result i n a hazardous gas leak.

After the new bonnet assembly has been installed, or the bonnet removed for any reason, check for gas leakage around the bonnet seal. Turn on the gas at the manual valve. Paint the seal area with a rich soap and water solution. Bubbles indicate a gas leak. If a leak is detected, check to see that the bonnet screws are tight. If necessary, turn off the gas again and remove the FIG. 9-PROPER POSITIONS OF VALVE AND BONNET bonnet to be sure the seals are properly seated. SEALS IN A 4 in. VALVE.

LARGE SEAL

-

Honeywell Inc. International Salesofiices in all principal cities of the world. Manufacturing in Australia, Canada. Finland. 1885 Douglas Drive N. France. Germany, Japan, Mexico, Netherlands. Spain. Taiwan. United Kingdom, U.S.A.

Golden Valley, MN 55422-4386 PRINTED IN U.S.A.

INDEX NO. 18

TEMPERATURE CONTROLLER

T I C - 0 1 5 - A , T I C - 0 1 5 - B

Honeywell

UDC 3000 Universal Digital

Controller Product Manual

Copyright, Notices, and Trademarks

Printed in U.S.A. - O Copyright 1992 by Honeywell Inc.

Rev. 0

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.

This document was prepared using Information Mapping@ methodologies and formatting principles.

UDC3000 is a trademark of Honeywell Inc.

Information Mapping is a trademark of Information Mapping Inc.

Honeywell Industrial Automation and Control

Automation College 1 100 Virginia Drive

Fort Washington, Pa 19034

ii UDC3000 Product Manual 10192

How this manual is This Product Manual is divided into 12 sections numbered 1 through 12. organized These sections contain all the information you need to configure, operate,

monitor, and troubleshoot your controller. To find infomation quickly, use the comprehensive Table of Contents in the front of the manual and the Index located in the back of the manual.

The device described herein has been manufactured and tested for correct operation and is warranted as follows:

The UDC3000 Universal Digital Controller canies a two year warranty. This warranty includes immediate technical assistance via a toll free telephone number and complete replacement of the controller, if necessary.

Technical Assistance If you encounter a problem with your UDC3000 controller, review all the configuration data under the Set-up groups to verify that your selections are consistent with your application; i.e. Inputs, Outputs, Alarms, Limits, etc. If the problem persists after checking the above, you can get technical assistance by dialing

1-800-423-9883 An engineer will discuss your problem with you. Please have your complete model number, serial number, and Software version available. The model and serial numbers can be found on the chassis nameplate. The software version can be viewed under Setup Group "Status." See Table 9-2.

If it is determined that a hardware problem exists, a replacement controller or part will be shipped with instructions for returning the defective unit. Do not return your controller without authorization from Honeywell's Technical Assistance Center or until the replacement has been received.

10192 UDC3000 Product Manual iii

.......................................................................................... . SECTION 1 OVERVIEW 1 Introduction ............................................................................................................ 1 Operator Interface ................................................................................................... 2

..................................................................................... . SECTION 2 INSTALLATION 4 ............................................................................................................ Overview 4

Model Number Interpretation ................................................................................... 6 ............................................................................................................ Mounting 7

Wiring ............................................................................................................ 9 Wiring Diagrams .................................................................................................... 11 Control and Alarm Relay Contact Information ........................................................... 24

SECTION 3 . CONFIGURATION ......................................................................... 25 Overview .......................................................................................................... 25 Configuration Prompts ...................................................................................... 2 6 How To Get Started ............................................................................................... 28 Configuration Tips ................................................................................................. 29 Configuration Procedure ....................................................................................... 30 Setup Groups

Tuning Parameters ...................................................................................... 32 ....................................................................................... SP RampIProgram 34

Adaptive Tune ............................................................................................ 35 Algorithm Data ............................................................................................. 36 Input 1 Parameters ...................................................................................... 37 Input 2 Parameters ...................................................................................... 39 Control Parameters ...................................................................................... 40 Options ...................................................................................................... 42

......................................................................................... Communications 43 Alarms ....................................................................................................... 4 4 Calib ........................................................................................................... 46 Status ......................................................................................................... 46

Configuration Record Sheet .................................................................................. 47

........................................... SECTION 4 . CONFIGURATION PROMPT DEFINITIONS 48 Overview ......................................................................................................... 48 Setup Groups

Tuning Parameters ...................................................................................... 49 Setpoint Ramp/Program ............................................................................. 52

............................................................................................ Adaptive Tune 53 Algorithm Data ............................................................................................. 55 Input 1 Parameters ...................................................................................... 59 Input 2 Parameters ...................................................................................... 63 Control Parameters ...................................................................................... 65 Options ...................................................................................................... 70

......................................................................................... Communications 73 Alarms ........................................................................................................ 75 Calibration Data ............................................................................................ 78

........................................................................................... Status Test Data 78 Continued on next page

1 0192 UDC3000 Product Manual v

Table of Contents. continued

SECTION 5 . OPERATION ....................................................................................... 79 Overview .......................................................................................................... 79

.................................................................................................. How to Power Up 80 Enter a Securiiy Code ........................................................................................... 82 Monitoring Your Controller ..................................................................................... 83 Start Up .......................................................................................................... 86 Operating Modes .................................................................................................. 87 Setpoints .......................................................................................................... 90 Setpoint Ramp Rate .............................................................................................. 92

........................................................................................... Single Setpoint Ramp 93 Using Two Set of Tuning Constants ....................................................................... 96 Alarm Setpoints .................................................................................................... 99 Three Position Step Control Algorithm ................................................................. 100 Digital Input Option .............................................................................................. 101

.................................................................................................... Adaptive Tune 102

SECTION 6 . SETPOINT RAMPISOAK PROGRAMMING OPTION ............................ 108 Overview ........................................................................................................ 108 Program Contents ............................................................................................... 109 Drawing a RampISoak Profile ............................................................................... 1 1 1 Entering the Setpoint Program Data ..................................................................... 113 RunlMonitor the Program ................................................................................... 116

SECTION 7 . INPUT CALIBRATION ....................................................................... 119 Overview ........................................................................................................ 119 Minimum and Maximum Range Values .................................................................. 120

........................................................................................ Preliminary Information 121 Input #1 Set Up Wiring ......................................................................................... 123 Input #I Calibration Procedure ............................................................................ 129 Input #2 Set Up Wiring ......................................................................................... 131 Input #2 Calibration Procedure ............................................................................. 133

.................................................................... SECTION 8 . OUTPUT CALIBRATION 135 ....................................................................................................... Overview 135

Current Proportional Output Calibration ................................................................ 136 Position Proportional and Three Position Step Output Calibration .......................... 138 . . .................................................................................. Aux~l~ary Output Calibration 142

SECTION 9 . TROUBLESHOOTING 1 SERVICE ...................................................... 144 ........................................................................................................ Overview 144

.......................................................................................... Troubleshooting Aids 146 Power-up Tests .................................................................................................. 148 Status Tests ....................................................................................................... 149 Background Tests ............................................................................................... 151

................................................................................ Controller Failure Symptoms 153 Troubleshooting Procedures ............................................................................. 154

........................................................................... Parts Replacement Procedures 162 Maintenance ....................................................................................................... 172

. ................................................................................... SECTION 10 PARTS LIST 173 Exploded View ................................................................................................... 173

Continued on next page

vi UDC3000 Product Manual 10192

Table of Contents. continued

. .................................................... SECTION 11 . APPENDIX A MANUAL TUNING 176 Overview ...................................................................................................... 176

......................................... Time. Position. or Current Proportional Simplex Control 177 Time Proportional Duplex .................................................................................... 179 Two Sets of Tuning Parameters ........................................................................... 179

SECTION 12 . APPENDIX B ............................................................................... 180 .............................. How to Apply Digital Instrumentation in Severe Electrical Noise 180

Potential Noise Sources ...................................................................................... 181 Prevention Methods ........................................................................................... 182 Recommended Wiring Practices .......................................................................... 183 Power Source Considerations ............................................................................. 185 Noise Suppression at the Source ......................................................................... 186

10192 UDC3000 Product Manual vii

Figure 1-1 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-1 1 Figure 2-12 Figure 2-13 Figure 2- 1 4 Figure 2-15 Figure 2-1 6 Figure 3-1 Figure 5-1 Figure 6-1 Figure 6-2 Figure 7-1 Figure 7-2 Figure 7-3

Figure 7-4 Figure 7-5

Figure 7-6 Figure 7-7 Figure 7-8 Figure 7-9 Figure 8-1 Figure 8-2 Figure 9-1 Figure 9-2 Figure 9-3 Figure 9-4 Figure 10-1 Figure 12-1 Figure 12-2 Figure 12-3 Figure 12-4

............................................ Operator Interface Displays and Indicators 2 Model Number Interpretation .............................................................. 6 Dimensions ................................................................................... 7 Mounting Method .............................................................................. 8

................................................................ Composite Wiring Diagram 11 Line Voltage Wiring .......................................................................... 12 Input #1 Connections ....................................................................... 13 Input #2 Connections ...................................................................... 14

....................................................... Electromechanical Relay Output 15 Solid State Relay Output .................................................................. 16 Open Collector Output ..................................................................... 17 Current Output ................................................................................ 18 Position Proportional Output ............................................................ 19 Auxiliary Output Connections ........................................................... 20 Digital Inputs Connections ................................................................ 21 RS4221485 Communications Option Connections ............................. 22 DMCS Communications Option Connections ..................................... 23 Overview of UDC3000 Prompt Hierarchy ........................................... 26 Operator Interface ............................................................................ 83 RampISoak Profile Example ............................................................ 111 Program Record Sheet ................................................................... 112

..................................................... Input # I and #2 Wiring Terminals 121 Wiring Connections for Thermocouple Inputs Using an Ice Bath ........ 123 Wiring Connections for Thermocouple lnputs Using a Precision Resistor ......................................................................... 124 Wiring Connections for RTD (Resistance Thermometer Device ......... 125 Wiring Connections for Radiamatic. Millivotts. or Volts (except 0 to 10 Volts) ......................................................... 126 Wiring Connections for 0 to 10 Volt inputs ....................................... 127 Wiring Connections for 4 to 20 mA inputs ........................................ 128 Wiring Connections for 4 to 20 mA input - Input #2 .......................... 131

. ............................. Wiring Connections for 1 to 5 Volt input Input 2 132 Wiring Connections for Calibrating Current Proportional Output ........ 136 Wiring Connections for Calibrating Auxiliary Output .......................... 142 Chassis Removal ............................................................................ 163 DisplayIKeyboard Replacement ...................................................... 164 Removing the Printed Wiring Boards ............................................... 165 Printed Wiring Board Identification ................................................... 166

............................................................... UDC3000 Exploded View 173 ................................................... Transformer for Digital Equipment 185

Transient Suppression in Inductive Coils ......................................... 187 Contact Noise Suppression ............................................................ 188 DC Load Noise Suppression ........................................................... 189

viii UDC3000 Product Manual 10192

Table 1-1 Table 2-1 Table 2-2 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table 3-8 Table 3-9 Table 3-1 0 Table 3-1 1 Table 3-1 2 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 4-6 Table 4-7 Table 4-8 Table 4-9 Table 4-1 0 Table 5-1 Table 5-2 Table 5-3 Table 5-4 Table 5-5 Table 5-6 Table 5-7 Table 5-8 Table 5-9 Table 5-1 0 Table 5-1 1 Table 5-12 Table 5-13 Table 5-14 Table 5-15 Table 5-1 6 Table 5-1 7 Table 5-18 Table 5-1 9 Table 5-20 Table 5-21 Table 5-22 Table 5-23 Table 5-24 Table 5-25 Table 5-26 Table 5-27 Table 6-1 Table 6-2 Table 6-3

Function of Keys ................................................................................ 3 Operating Limits ................................................................................. 5 Permissible Wiring Bundling ............................................................... 9 Configuration Tips ............................................................................ 29 Configuration Procedure .................................................................. 30 Tuning Group Function Prompts ....................................................... 33

.................................................... SP Ramp Group Function Prompts 34 Adaptive Tune Group Function Prompts ............................................ 35 Algorithm Group Function Prompts ................................................... 36 Input 1 Group Function Prompts ..................................................... 3 7 Input 2 Group Function Prompts ....................................................... 39 Control Group Function Prompts ....................................................... 40 Options Group Function Prompts ...................................................... 42 Corn Group Function Prompts ........................................................... 43 Alarms Group Function Prompts ........................................................ 44 Tuning Group Prompt Definitions ...................................................... 49 Setpoint RampIRatelProgram Group Definitions ................................ 52 Adaptive Tune Group Definitions ...................................................... 53 Algorithm Group Definitions .............................................................. 55 Input 1 Group definitions .................................................................. 59 Input 2 Group Definitions .................................................................. 63 Control Group Definitions ................................................................. 65 Option Group Definitions .................................................................. 70 Communications Group Definitions ................................................... 73 Alarms Group Definitions .................................................................. 75 Power Up Diagnostic Tests ............................................................... 80 Testing the Displays and Keys .......................................................... 81 Entering a Security Code .................................................................. 82 Lower Display Key ............................................................................ 84 Error Messages ................................................................................ 85 Starting Up the Controller ................................................................. 86 Operating Mode Definitions ........................................................... 8 7 Changing Operating Modes .............................................................. 87 Selecting Automatic or Manual Mode ................................................ 88 Selecting the Local Setpoint Source ................................................. 90 Changing the Local Setpoint ............................................................ 90 Enabling (or disabling) the Remote Setpoint ...................................... 91 Switching Between Setpoints ........................................................... 91 Setpoint Selection Indication ............................................................ 92 Configuring a Setpoint Ramp ............................................................ 93 Running a Setpoint Ramp ................................................................. 94 Selecting Two Set of Tuning Constants ............................................. 96 Setting Switchover Values ................................................................ 97 Setting Tuning Constant Values ....................................................... 97 switching PID SETS from the Keyboard ............................................ 98 Displaying or Changing the Alarm Setpoints ....................................... 99 Displaying the 3PSTEP Motor Position ............................................ 100 Digital Input Option Action on Contact Closure ................................. 101 Configuring Adaptive Tune Parameters ........................................... 103 Using Adaptive Tune at Start-up ...................................................... 104 Accessing Adaptive Tune Error Codes ............................................ 106

............................................. Adaptive Tune Error Code Definitions 107 .......................................... Setpoint Program Data Entry Procedure 113

Prompt Hierarchy and Available Selections ...................................... 114 RunlMonitor Functions ................................................................... 116

10192 UDC3000 Product Manual ix

Tables. continued

Table 7-1 Table 7-2 Table 7-3 Table 7-4

Table 7-5 Table 7-6 Table 8-1 Table 8-2 Table 8-3

Table 8-4 Table 8-5 Table 9-1 Table 9-2 Table 9-3 Table 9-4 Table 9-5 Table 9-6 Table 9-7 Table 9-8 Table 9-9 Table 9-1 0 Table 9-1 1 Table 9-1 2

Table 9-1 3 Table 9-14 Table 9-15 Table 9-16 Table 9-1 7 Table 9-18 Table 9-19 Table 9-20 Table 9-21 Table 9-22 Table 9-23 Table 10-1 Table 10-2 Table 1 1-1 Table 1 1-2 Table 12-1 Table 12-2 Table 12-3

Voltage and Resistance Equivalents for 0% and 100% Range Values 1 20 Equipment Needed ....................................................................... 122 Set Up Wiring Procedure for Thermocouple Inputs Using An Ice Bath 123 Set Up Wiring Procedure for Thermocouple Inputs Using a Precision Resistor .............................................................. 124

........................................................ Input #1 Calibration Procedure 129

........................................................ Input #2 Calibration Procedure 133 ...................... Set Up Wiring Procedure Current Proportional Output 136

.......................... Current Proportional Output Calibration Procedure 137 Position Proportional and 3 Position Step Output Calibration Procedure ..................................................................................... 139 Set Up Wiring Procedure for Auxiliary Output ................................... 142

............................................ Auxiliary Output Calibration Procedure 143 Error Message Prompts .................................................................. 146 Identifying the Software Version ..................................................... 147

Power-up Tests .......................................................................... 148 Displaying the Status Tests Results ................................................. 149 Status Tests .................................................................................. 150 Background Tests .......................................................................... 151

........................................................... Controller Failure Symptoms 153 ...................................... Troubleshooting Power Failure Symptoms 154

....................... Troubleshooting Current Proportional Output Failure 155 ...................... Troubleshooting Position Proportional Output Failure 156

........................... Troubleshooting Time Proportional Output Failure 157 Troubleshooting Timetcurrent or Currentflime Proportional Output Failure ............................................................................... 158 Troubleshooting Alarm Relay Output Failure ................................. 159 Troubleshooting a Keyboard Failure ................................................ 160

..................................... Troubleshooting a Communications Failure 161 How to remove the chassis ............................................................. 163

...................... DisplaytKeyboard Assembly Replacement Procedure 164 ......................................................... Printed Wiring Board Removal 165

.................................. Second Input Board Replacement Procedure 167 Power Input Board Replacement Procedure .................................... 168

..................................... Digital Input Board Replacement Procedure 169 ............... Aux.Out/Communications Board Replacement Procedure 170

................................... MCUtOutput Board Replacement Procedure 171 .......................................................................... Parts Identification 174

............................................................................ Parts Not Shown 175 .............................................................. Manual Tuning Procedure 177

Manual Tuning Formulas ................................................................. 178 External Wiring ............................................................................... 183

................................................................................. MOV Devices 186 ...................................................... Coil Voltage vs Resistor Voltage 187

x UDC3000 Product Manual 10192

Acronyms

3PSTEP .................................................................................... 3 Postion Step Control DMCS ........................................................... Distributed Manufacturing Control System EM1 .................................................................................. electromagnetic interference HID ........................................................................................... high intensity discharge MOVs ........................................................................................... M e t Oxide Varistors NC ....................................................................................................... normally closed NO ......................................................................................................... normally open PID ......................................................................... P r o o n a Integral, and Derivative RC ............................................................................................ resistance-capacitance RFI .................................................................................... radio frequency interference RH ..................................................................................................... Relative Humidity RTD ............................................................................ e s a e Thermometer Device . . SCRs .................................................................................. S~l~con controlled rectifiers UDC ...................................................................................... Universal Diglal Controller

Parameters

21N .................................................................................................................... Input 2 2SP .................................................................................................... Local Setpoint 2 A1 S1 EV ............................... SP Programming Event Alarm State for Alarm 1. Setpoint 1 A1 S1 VaL ........................................................................................ Alarm 1. Setpoint 1 A1 S1TYPE .............................................................................. Alarm 1. Setpoint 1 Type A1 S2 EV .............................. SP Programming Event Alarm State for Alarm 1. Setpoint 2 A1 S2 HL ................................................................................ Alarm 1. Setpoint 2 State A1 S2 VAL ....................................................................................... Alarm 1. Setpoint 2 A1 S2TY PE .............................................................................. Alarm 1. Setpoint 2 Type A2S1 EV ............................... SP Programming Event Alarm State for Alarm 2. Setpoint 1 A2S1 HL ................................................................................ Alarm 2. Setpoint 1 State A2S1 VAL ....................................................................................... A m 2. Setpoint 1 A2S1 TY PE ...................................................................................... A m 2. Setpoint 1 A2S2 EV ............................... SP Programming Event Alarm State for Alarm 2. Setpoint 2 A2S2 HL ................................................................................ Alarm 2. Setpoint 2 State A2S2 VAL ....................................................................................... Alarm 2. Setpoint 2 A2S2TY PE .............................................................................. A m 2. Setpoint 2 Type ACTION ................................................................................... Control Output Direction ADAPTIVE ............................................................................................ Adaptive Tune AL HYST ............................................................................................. Alarm Hysteresis AT ERROR .......................................................................... Adaptive Tune Error codes AUTO .................. Lower display automatically displays setpoint value in engineering units AUTO MAN ............................................................................ ManuaAto Key Lockout AUX OUT ...................................................................... Auxiliary Output Representation BAUD ........................................................................................................... B a d Rate BIAS IN1 ..................................................................................................... Input 1 Bias

......................................................... CAL MTR suggests that the controller be calibrated .................................................................................... CAL TEST Calibration test failure ................................................................. Com ADDR Communications Station Address ..................................................................... CornSTATE Communications Option State

CONF ERR ....................................................................................... configuration error ............................................................................. CONFTEST Configuration test failure ........................................................................................ CONT ALG Control Algoriihm

CSP .................................................................................. Computer Setpoint Override .................................................................................................... CYC SEC .Cycle Time

CYC2 SEC ....................................................................................... Cycle Time 2 (Cool)

10192 UDC3000 Product Manual

Parameters. continued

DEADBAND .......................................................................... Output Relay Deadband D EV .............................................................................................................. Deviation DIG 1 COM .......................................................................... Digital Input 1 Combinations DIG 2 COM ......................................................................... Digital Input 2 Combinations DIG IN 1 .................................................................................. Digital Input 1 selections DIG IN 2 ................................................................................... Digital Input 2 selections DROPOFF ............................................................................... Controller Dropoff Value DUPLEX ............................................................................................ Duplex Operation E E FAIL .............................................................. Unable to write to non-volatile memory EMSSIV ........................................................................................................ Emissivity END SEG ................................................................................... End Segment Number EUIHR DN ....................................................................................... a Down Value EUIHR UP .............................................................................................. Rate Up Value FACT CRC .................................................... Factory Calibration Cyclic Redundancy test FAILSAFE .................................................................................... Controller in Failsafe FAILSAFE ................................................................................... Failsafe Output Value FILTER 1 ................................................................................................... Input 1 Filter FILTER2 .................................................................................................... Input 2 Filter FINAL SP ........................................................................ Single Setpoint Final Setpoint GAIN ................................................................................................................ .Gain GAIN2 ............................................................................................................... Gain 2 IN1 HI .................................................................................... Input 1 High Range Value IN1 LO ................................................................................... Input 1 Low Range Value IN1 TYPE .................................................................................... Input 1 Actuation Type IN2HI ..................................................................................... Input 2 High Range Value IN2LO .................................................................................. Input 2 Low Range Value INP1 RNG ..................................................................................... Input 1 Out of Range INP1 FAIL ................................................. Two consecutive failures of Input 1 integration INP2 RNG ..................................................................................... Input 2 Out of Range INP2FAIL ................................................. Two consecutive failures of Input 2 integration KPG ......................................................................................................... Process Gain LOCKOUT ................................................................................. Configuration Lockout LOOPBACK ........................................................................................ Local Loop Back MAN .................................................... Lower display automatically indicates output in % . MAN RSET .............................................................................................. Manual Reset MlNorRPM .................................................................................................. Reset Units OUT ALG ............................................................................................ Output Algorithm OUT HYST ............................................................................... Output Relay Hysteresis OUT ........................................................................................................ Output Value OUT RATE ................................................................................... Output Change Rate OUTHILIM ......................................................................................... High Output Limit OUT ................................................................................................... Low Output Limit PARITY ............................................................................................................... Parity PBorGAIN .................................................................... Proportional Band or Gain Units PCTIMIN .................................................................................................... O u t Rate PCTIMIN .................................................................................................... p u t Rate PID SETS .................................................................................. Tuning Parameter Sets PIDSETX ..................................................................................... Tuning Parameter Set POS ....................................................................................................... Motor Position PROG END ........................................................................... P r a m Termination State PROP BD ......................................................................................... Proportional Band PROP BD2 .................................................................................... P o o n a Band 2 PV LIMIT ........................................................................................... PV Out of Range PWR FREQ ............................................................................... Power Line Frequency

xii UDC3000 Product Manual 10192

Parameters. continued

RAM TEST ............................................................................................ RAM test failed RAMPUNIT ........................................................... Engineering units for ramp segments RAMPXXOM ........................................................... Minutes remaining in Setpoint Ramp RATE MIN ............................................................................................. Rate in Minutes RATE2MIN ........................................................................................ Rate 2 in Minutes RECYCLES ...................................................................... Number of Program Recycles RLY TYPE ....................................................................................... Output Relay Type RSET MIN ................................................................................. Reset in minuteslrepeat RSET RPM ............................................................................... Reset in repeatslminute RSET2MIN ............................................................................ Reset 2 in minuteslrepeat RSET2RPM .......................................................................... Reset 2 in repeatslminute RSP ................................................................................................... Remote Setpoint RSP SRC ............................................................................... Remote Setpoint Source RUN HOLD ........................................................................................... RuntHoId key RV LIMIT ......................................................................... Remote Variable Out of Range SECURITY .............................................................................................. Security Code SEG 1 rate ................................................................................ Segment #1 Ramp Rate SEG1 ramp .............................................................................. Segment #1 Ramp Time SHED SP ..................................................................................... Shed Setpoint Recall SH EDMODE .............................................. S h e d Controller Mode and Output Level SHEDTIME .................................................................................................. Shed Time SOAK DEV ................................................................ Guaranteed Soak Deviation Value SP CHANG ......................................................................................... Setpoint Change SP HlLlM ......................................................................................... Setpoint High Limit S P ...................................................................................................... Local Setpoint 1 SP LOLIM ......................................................................................... Setpoint Low Limit SP PROG ................................................................................... Setpoint Programming SP PROG ................................................................. Setpoint RarnpISoak Programming SP RAMP ................................................................................ S e t Ramp selection SP RAMP .................................................................................... Singe Setpoint Ramp SP RATE ................................................................................................ S e n t Rate SP SEL ................................................................................................ Setpoint Select SP SOURC ............................................................................ Local Setpoint Source SP TRACK ........................................................................... Local Setpoint Tracking SPn ........................................................................................................ Stpoint Now STATE ............................................................................. Program state at program end STRT SEG ................................................................................. Start Segment Number

. SW FAIL ............................................................................... Auto Cal never performed SW FAIL ....................................................... Position Proportional slidewire input failure SW VALUE ......................................................................... Automatic Switchover Value TIME MIN ............................................................................. Single Setpoint Ramp Time UNITS .......................................................................................... Communication Units XMllTER ............................................................................ Transmitter Characterization XMITTER2 ............................................................... Transmitter Characterization Input 2

1 0192 UDC3000 Product Manual xiii

Publication Title

UDC3000 Limit Controller 51-52-25-09

UDC3000/UDC5000/UDC6000 RS422/485 Communications 51-51-25-35 Option Manual

UDC3000 DMCS Communications option Section of the Gateway Manual

xiv UDC3000 Product Manual 10/92

Section 1 - Overview

Introduction

Function The UDC3000 Universal Digital Controller is a microprocessor-based stand alone controller. It combines the highest degree of functionality and operating simplicity offered in a 114 DIN size controller. With a typical accuracy of *.20% of span, the UDC3000 is an ideal controller for regulating temperature and other process variables in numerous heating and cooling applications, in metal working, food, and pharmaceuticals, and testing and environmental work.

Easy to read displays The dedicated vacuum fluorescent displays with English prompts make the operator interface easy to read, understand and operate. Programmed sequences of displays assure quick and accurate entry of all configurable parameters.

Easy to operate Simple keystrokes let you select input and range configuration, set the operating parameters that meet your process control needs now, and change them later to meet new ones. The tactile keyboard provides positive operator feedback. Self diagnostics, fault tolerant design and keyboard security provide maximum assurance of trouble-free operation.

Mount anywhere The UDC is environmentally hardened and can be mounted virtually anywhere in plant or factory; on the wall, in a panel, or even on the process machine. It withstands ambient temperatures up to 55°C and resists the effects of vibration and mechanical shock.

10192 UDC3000 Product Manual 1

Operator Interface

Displays and indicators Figure 1-1 shows the operator interface and defines the displays and indicators. The function of the keys is shown in Tablel-1.

Figure 1 - 1 Operator Interface Displays and Indicators

Upper Display - Six Characters Normal Operation - four digits dedicated to display the process variable Configuration Mode - displays parameter value or selection

Lower Display - Eight characters Normal Operation - displays operating parameters and values Configuration Mode - displays function groups and parameters

Indicator definition when lit r EZLZ ootion active MAN - controller in manual mode 4

A - controller in automatic mode F - "Fahrenheit being used

9Centigrade being

center bar indicates PV is within f 1% of setpoint

Next bar will light if PV is between f 1% but less than +_PA in deviation

If PV is equal to or greater than f 10% deviation, the center bar plus all ten deviation bars will light



Operator Interface, contimed

Function of keys Table 1-1 shows each key on the operator interface and defines its function.

Table 1 - 1 Function of Keys

Functbn

allows the [FUNCTION] key to display individual functions in each Set Up group.

Used in conjunction with the [SET UP] key to select the individual functions of a selected Configuration Set Up group.

Used during field calibration procedure. I

Selects and operating parameter to be shown in the lower display:

SP = Local Setpoint 1 2s P = Local Setpoint 2 RSP = Remote Setpoint 21N = Input 2 DEV = Deviation RAMPXXOM = Minutes remaining in Setpoint Ramp PIDSETX = Tuning Parameter Set X=l or 2 OUT = Output Value* CSP = Computer Setpoint Override SPn = Setpoint Now (for setpoint rate) POS = 3 Position Step motor position when

slidewire is connected or estimated 3 Position Step motor position when no

slidewire exists.

Alternately selects: AUTO Lower display automatically displays setpoint

value in engineering units. MAN Lower display automatically indicates output in %.

Alternately selects Local Setpoint 1 and Remote Setpoint or between the two local setpoints.

Alternate action switch initiates or holds the Setpoint Ramp or Setpoint Program.

Restores the original value or selection if you do not want to enter a change you are making to a parameter.

Increases the setpoint, output, or configuration values displayed.

Decreases the setpoint, output, or configuration values displayed.

10/92 UDC3000 Product Manual 3

Section 2 - Installation

Overview

Introduction Installation of the UDC 3000 Controller consists of mounting and wiring the controller according to the instructions given in this section. Read the pre-installation information, check the model number interpretation and become familiar with your model selections, then proceed with installation.

What's in this sectbn? This section contains the following information:

If the controller has not been removed from its shipping carton, inspect the carton for damage and remove the controller. Inspect the unit for any obvious shipping damage and report any damage due to transit to the canier. Make sure a bag containing mounting hardware is included in the carton with the controller. Check that the model number shown on the inside of the case agrees with what you have ordered.

Topic

Pre-installation information Operating Limits Model Number Interpretation Mounting

Physical Considerations Overall Dimensions Mounting Procedure

Wiring Taking Electrical Noise Precautions Permissible Wire Bundling Identify Your Wiring Requirements Wiring the Controller

Composite Wiring Diagram AC Line Voltage Input #1 Input #2 Relay Output

Electromechanical Solid State Open Collector

Current Output Position Proportional Output Auxiliary Output Digital Inputs Communications

RS4221485 DMCS

Control and Alarm Relay Contact Information


See Page

4 5 6 7 7 7 8 9 9 9 10 10 11 12 13 14 15 15 16 17 18 19 2 0 2 1 22 22 23 24


Overview, Continued

Operating limits We recommend that you review and adhere to the operating limits listed in Table 2-1 when you install your controller.

( Relative Humidity ( 5 to 90°/~ RH at 40°C (1 04°F) 1

Table 2-1 Operating Li t s

--

Vibration Frequency Acceleration

Condltkn

Ambient Temperature

mmm I

32 to 13lQF (0 to 55%)

Mechanical Shock Acceleration Duration


5 9 30ms

Power

Power Consumption

90 to 264 Vac 50/60 Hz (CSA models rated to 250V Maximum)

18VA Maximum

Model Number Interpretation

Model number The model number interpretation is shown in Figure 2-1. Write the model number into the spaces provided and compare it to the model number interpretation. This information will also be useful when you wire your con troller.

Figure 2- 1 Model Number Interpretation I Ky-

1-1 1-2 1-9 1-4 T & k S

I

Output #1 C = Current 4 - 20mA without Alarms K = Current 4 - 20mA with Alarm 1 E = Relay, Electromechanical - 5AMP with Alarm 1 A = Relay, Solid State AC - 1AMP with Alarm 1 T = Open Collector Output - 20mA with 1 Alarm

Output #2 or Alarm #2 0 = None E = Relay, Electromechanical - SAMP (SPDT) A = Relay, Solid State AC - 1 AMP (SPST) T = Open Collector Output - 20mA

0- -= None 1 - - = RS4221485 2 - - = Auxiliary Output 4---DMCS

Softwar Options -0-= None - A - = Adaptive Tune - B - = Setpoint Program and Adaptive Tune

0 0 0 0 ~ None - A - - = Approval Body-CSA, FM, UL, IEC 348

- F -- = Approval Body-FM

- - T - = Customer I.D.

--- Tag D = DIN Cutout

Adapter

Optional Input - 0 = None - 1 = 4-20mA or 1-5V - 2 = Slidewire lnput for Positio~

Proportional or 3 Position Step with motor position indication

1 - = T/C, RTD, mV, 1 S V Digital Inputs 2 - = TIC, RTD, mV, 1 S V , 2 1 440rnA 1 - - 3 = Digital Inputs (2) 3-=TIC, RTD, mV, l S V ,

4-20mA,O-1 OV


Mounting

Physlcal considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied. Adequate access space must be available at the back of the panel for installation and servicing activities. The overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 2-2. The controller's mounting enclosure must be grounded according to CSA standard C22.2 No. 0.4 or Factory Mutual Class No. 3820 paragraph 6.1.5.

- - -

Overall dimensions Figure 2-2 shows the overall dimensions for mounting the controller. Figure 2-2 Dimensions

Panel Cutout


UDC3000 Product Manual 7

Mounting, Continued

Mounting method Before mounting the controller, refer to the nameplate on the inside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration. Figure 2-3 shows you the mounting method for the UDC3000 controller. Figure 2-3 Mounting Method

Mounting procedure Refer to Figure 2-3 and follow the procedure below to mount the controller.


step

1

2

3

4

Actbn

Mark and cut out the controller hole in the panel according to the dimension information in Figure 2-2.

Remove the screw cover and loosen the screw on the front of the controller. Pull the chassis out of the case.

Orient the case properly and slide it through the panel hole from the front.

Remove the mounting kit from the shipping container, and install the kit as follows:

Install the screws into the threaded holes of the clips. Insert the prongs of the clips into the two holes in the top and bottom of the case. Tighten both screws to secure the case against the panel. Carefully slide the chassis assembly into the case, press to close and tighten the screw. Replace the screw cover.

Wiring

Taking electrical noise Elecmcal noise is composed of unabated electrical signals which produce precautions undesirable effects in measurements and control circuits.

Digital equipment is especially sensitive to the effects of electrical noise. Your controller has built-in circuits to reduce the effect of electrical noise from various sources. If there is a need to further reduce these effects:

Separate External Wiring - separate connecting wires into bundles (see Table 2-2) and route the individual bundles rhrough separate conduits or metal trays. Use Suppression Devices - for additional noise protection, you may want to add suppression devices at the external source. Appropriate suppression devices are commercially available.

For additional noise information, refer to Section 12 .

Permissible wire Table 2-2 shows which wire functions should be bundled together. bundling

Table 2-2 Permissible Wiring Bundling


Bundle No.

1

2

3


Wire Functions

Line power wiring Earth ground wiring

Control relay output wiring Line voltage alarm wiring

Analog signal wire, such as: Input signal wire (thermocouple, 4 to 20 mA, etc.) 4-20mA output signal wiring Slidewire feedback circuit wiring Digital input signals

Communications

Low voltage alarm relay output wiring

Low voltage wiring to solid state type control circuits

Wiring, Continued

Mentlfy ywr wiring requirements

To determine the appropriate diagrams for wiring your controller, refer to the model number interpretation in this section. The model number of the controller can be found on the inside of the case.

Wring the controller Using the information contained in the model number, select the appropriate wiring diagrams from the figures listed below and wire the controller accordingly.


Wiring Requirements

Composite Wiring Diagram

Line Power 90-264 Vac

Input #1 Wiring

Input #2 Wiring

Relay Output Electromechanical Relay Output Solid State Relay Output Open Collector Output

Current Output

Position Proportional Output

Auxiliary Output wiring

Communications Wiring RS422 DMCS

Digital Inputs Wiring

Figure

2-4

2-5

2-6

2-7

2-8 2-9

2-1 0

2-1 1

2-1 2

2-1 3

2-1 4 2-1 6

2-1 7

Wiring Diagrams

Composite widng Figure 2-4 is a composite wiring diagram of the UDC3000 controller. It d i g ram identifies the terminal designations and their functions. Refer to the

individual diagrams listed to wire the controller according to your requirements.

Figure 2-4 Composite Wiring Diagram

~igitai inputs Terminals

See Figure 2-14

Outputs and A l m s Terminals

Relay Output See Figures 2-8,2-9,2-10

Current Output See Figure 2-1 1

Position Proportional I output

See Figure 2-12

For Control and Alarm Relay Contact information, See

Tables 2-3 and 2 4 .

Communications Auxiliary Output Terminals Terminals

See Figures See Figure 2-1 3 2-15. 2-16



Wiring Diagrams, Continued

Line voltage wiring Figure 2-5 shows the wiring connections for the line voltage.

Figure 2-5 Line Voltage Wiring

@ AC Line

Voltage

@ AC Line Voltage, 90 - 264 Volts Ground separately and directly to earth. Ground using 12 gauge stranded wire.

@ External fuses or circuit breakers must be rated at 112 Amp, 250Vac




Input #1 connections Figure 2-6 shows the wiring connections for Input #l.

Figure 2-6 Input #1 Connections

MV or Volts except 0 -10 Volts

he 250 $2 load resistor for 4-20mA or the Voltage divider for 0-1 0 Volts or the 500 Ohm CIJ compensation resistor are supplied with the controller when the input is specified.

These items must be installed when you wire the controller before startup.




lnput #2 connections Figure 2-7 shows the wiring connections for Input #2.

Figure 2-7 Input #2 Connections

ATTENTION: lnput #2 not available with Position Proportional Output

4-20 mA or

1-5 Volts only

@ 4-20 mA requires a 250 Q resistor which is supplied with the controller. It must be installed when wiring the controller before startup.



Wiring Diagrams, continued

Relay wtput There are three types of relay outputs available on the UDC 3000. Electromechanical Relay Output - Figure 2-8 Solid State Relay Output - Figure 2-9 Open Collector Output - Figure 2-10

The A l m wiring connections are the same for all three outputs. For Control and Alarm Relay Contact information, see Tables 2-3 and 2-4. Figure 2-8 shows the Output and Alarm wiring connections for models with Electromechanical Relay Output.

Figure 2-8 Electromechanical Relay Output

Time Proportional Simplex - - - - - -

-Load Supply

-Power

Time Proportional Duplex or Three Position Step Control - - - - - -

- - - - - - @ Snubber assembly is supplied by Honeywell.

@ Alarm #2 not available with Time Proportional Duplex or Three Position Step Control or Position Proportional Control

@ Electromechanical relays are rated at 5 Amps@ 12OVac or 2.5 Amps at 240Vac. Customer should size fuses accordingly.




Relay output Figure 2-9 shows the Output and Alarm wiring connections for models with (continued) Solid State Relay Output.

For Control and Alarm Relay Contact information, see Tables 2-3 and 2-4.

Figure 2-9 Solid State Relay Output

Time Proportional Simplex - - -

0- AC Load Supply

0- Power

- - - 7or9

Time Proportional Dupl - - - ee Position Step Control

0

@ Alarm #2 not available with Time Proportional Duplex or Three Position Step Control or Position Proportional control.

@ Solid State relays are rated at 0.5 Amps. Customer should size fuses accordingly.




Relay OlJWUt Figure 2- 10 shows the Output and Alarm wiring connections for models (continued) with Open Collector Output.


Figure 2- 10 Open Collector Output

Time Proportional Simplex Customer Supplied Customer Supplied

Electromechanical Relay - - - - - - Solid State Relay - - - - - -

: Alarm I Relaye

; I 1 Alarm Load I To terminal

I t--2

'output #I = I 0-3

s L-0

Time Proportional Duplex or Three Positlon Step Control Customer Supplied Customer Supplied

- - &ct[o~pchanical Relay ? - - Solid state Relay

I L 'output #I = : @ - - 3 %%

a VI Open collector outputs are internally powered. Connecting an external supply will damage the controller.

@ Alarm #2 not available with Time Proportional Duplex or Three Position Step Control or Position Proportional control.




Current output Figure 2- 1 1 shows the Output and Alarm wiring connections for models connections with Current Output.


Figure 2- 1 1 Current Output

(internal connection)

-----

For Duplex Current Output use Auxiliary Output for Output 2 (cool)




Posttbn proportional Figure 2-12 shows the Output and Alarm wiring connections for models mPut connections with Position Proportional Output.


Callbratbn Position Proportional Output or Three Position Step models must have the output calibrated after installation (see section &Position Proportional Output Calibration) to ensure that the displayed output (slidewire position) agrees with the actual final control element position. Three Position Step models only require that the motor time be entered. Full calibration is not required.

Figure 2-12 Position Proportional Output

. w i r e 100 to 1 000 n /ll,l mechanically linked f - - - - - -

to motor

Connect shield to ground 25 at one end only

26

Motor Power

r p P l y a

- - - -

Output Relay#l

Output ReIayt2

0

Alarm Relay#l

- - - - @ Snubber assemblies supplied by Honeywell for electromechanical relays only.

@ Alarm #2 not available with Time Proportional Duplex, Position Proportional output or Three Position Step control

@ Do not run slidewire cable in the same conduit as AC power.

@ Electrical noise suppression may be required. Refer to Section 12.



Wiring Diagrams, continua

Auxllia~y output Figure 2-13 shows the wiring connections for the Auxiliary Output option. connections

Figure 2- 13 Auxiliary Output Connections -

- Connect shield to ground at one end only




DigW inputs Figure 2- 14 shows the wiring connections for the Digital Inputs option. connections

Figure 2- 14 Digital Inputs Connections

I 1 Digital Input

Switch #1 r.Q , ? ! ! I Switch #2

connect shield!

Common

!


10192 UDC3000 Product Manual 2 1


Communications optbn There are two types of Communications option available: connections RS4221485 - Figure 2-15 (also refer to Document # 51-5 1-25-35)

DMCS - Figure 2- 16 (also refer to Document # 82-50- 10-23)

Figure

Communication lines in the same Instruments conduit as AC power

(maximum 15)

)] Do not mix half and full duplex wiring.

I I

RS4221485 I

FULL DUPLEX I 1

Do not mn these liner in the smne

conduit rw AC power

120 Ohm Resistor on Last Leg


2 2 UDC3000 Product Manual 10192

Wiring Diagrams, continued

Communicatbns optbn Figure 2- 16 shows the wiring connections for the DMCS Communications connections Option. (also refer to Document # 82-50- 10-23) (continued)

Figure 2- 16 DMCS Communications Option Connections

DMCS

conduit as AC power

Communication Instruments


Control and Alarm Relay Contact Information

Control Relays

Abrm Relays

Table 2-3 lists the Control Relay Contact information.

1 I Control relays operate in the standard control mode. - - i.e. Energized when output state is on.

Table 2-3 Control Relay Contact Information

Table 2-4 lists the Alarm Relay Contact information.

Alarm relays are designed to operate in a failsafe mode. i.e. De-energized during alarm state. This results in alarm actuation when power is OFF or when initially applied, until the unit completes self diagnostics. If power is lost to the unit, the alarms will function.

Table 2-4 Alarm Relay Contact Information

#lor #2 Output Indicator Status

Off

Off On

Off On

Control Relay Contact

Open

Closed

Open Closed

Closed Open

Untt Power

Off

On

2 4 UDC3000 Product Manual 1 0192

Control Relay wflng

N.O.

N.C.

N.O.

N.C.

Unl Power

Off

On -

- Relay Wifing

N.O.

N.C.

N.O.

N.C.

Varlable NOT In Alarm State

Relay Contact

Open

Closed

Closed

Open

Variable In Alarm State

Indicators

Off

Off

Relay Comact

Open

Closed

Open

Closed

Indicators

Off

On

Section 3 - Configuration

Overview

Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent control data best suited for your application.

W h l s in thissection? The table below lists the topics that are covered in this section.

To assist you in the configuration process, there are prompts that appear in the upper and lower displays. These prompts let you know what group of configuration data (Set Up prompts) you are working with and also, the specific parameters (Function prompts) associated with each group.

Topk

Overview

Prompt Hierarchy

How to Get Started

Configuration Tips

Configuration Procedure

Setup Groups Tuning SP Ramp Adaptive Algorithm Input 1 Input 2 Control Options Communications Alarms Calib Status

Configuration Record Sheet

Figure 3-1 shows you an overview of the prompt hierarchy. As you will see, the configuration data is divided into 10 main Set Up groups plus prompts for calibration and prompts that show the status of the continuous background tests that are being performed.

See Page

25

26 & 27

2 8

29

30

32 3 4 35 36 37 3 9 40 42 4 3 4 4 46 46

47



Configuration Prompts

D b g m : prompt Figure 3-1 shows an overview of the UDC3000 Set Up prompts and their hierarchy associated Function prompts. - Read from left to right.

Figure 3-1 Overview of UDC3000 Prompt Hierarchy

UP] key to access the Set Up prompts

[FUNCTION] key to access Function prompts within each Set Up group.

SP RAMP

OPTIONS 4 pih-p/ Used for Field Calibration ( ~ e f e r to the Calibration section for prompts.)


26 UDC3000 Product Manual 1 0/92

Configuration Prompts, Continued

' Press [A] or[ V] to change the value or selection of the Function prompt.

Refer to the operation section for Setpoint programming prompts.

FLTER 1 H BURNOUT H EYSSIV

SP HIUM H S P L O W H ACTION

HEDMODE H SHED SP H UNITS

t 0192 UDC3000 Produ,ct Manual 2 7

How To Get Started

Read the configuration Read "Configuration Tips" shown on the next page. These tips will help trpS you to easily and quickly accomplish the tasks at which you will be

working when you configure your controller.

Read configuration Read "Configuration Procedure". This procedure tells you how to access procedure the Set Up groups, and the Function parameters within each of these groups

that are shown in the Prompt Hierarchy in figure 3- 1.

set UP groups The Set Up groups and Function parameters are listed in the order of their appearance. The list includes the name of the prompt, the range of setting or selections available, and the factory setting.

Parameter explanations If you need a &tailed explanation of any prompt listed, refer to Section 4 - or definitions Conjiguration Parameter Dt$nitions.

This section lists the Set Up and Function prompts, the selections or range of settings that you can make for each, plus a detailed explanation or definition of each parameter.

Configuration record Located on the last page of this section is a "Confguration Record Sheet". sheet When you make your configuration selections, record them on this sheet.

Then you will have a record of how the controller was configured.


Configuration Tips

Introduction Listed below in table 3-1 are a few tips that will help you enter the configuration data more quickly.

Table 3- 1 Configuration Tips


Function

Displaying Gmps

D&)krying Functions

Scrolling

Changing values Wwb

Restoring to the Mglnal value

Exiting SET UP mode

Timing out from Set up mode

Key Error

Tip

Use the [Set Up] key to display the Set Up groups. The group titles are listed in this section in the order that they appear in the controller.

Use the [Function] key to display the individual parameters under each group. The prompts are listed in the order of their appearance in each group.

To get to a Set Up group prompt more quickly, hold the [Set Up] key in. To get to a Function prompt more quickly, hold the [Function] key in. The display will scroll through the parameters.

The prompting scrolls at a rate of 2/3 seconds when the [Set Up] or [Function] key is held in. Also, [A ] [ v ] keys will move group prompts forward or backward at a rate twice as fast.

When Changing the value of a parameter, you can adjust a more significant digit in the upper display by holdin in

the same time. 4 one key [A] or [ v ] , and pressing the other [A ] or [ ] at

The adjustment will move one digit to the left. Press the key again and you will move one more digit to the left.

When you change the value or selection of a parameter while in Set Up mode and decide not to enter it, press [RunIHold] once, the original value or selection will be recalled.

To exit Set Up mode, press the [Lower Display] key. This returns the display to the same state it was in immediately preceding entry into the Set Up mode.

If you are in Set Up mode and do not press any keys for one minute, the controller will time out and revert to the mode and display that was being used prior to entry into Set Up mode.

When a key is pressed and the prompt "KEY ERROR" appears in the lower display, it will be for one of the following reasons:

parameter not available not in Set Up mode, press [SET UP] key first key malfunction, do keyboard test (operation)

Configuration Procedure

Procedure

Each of the Set Up groups and their functions are preconfigured at the factory. The factory settings are shown in the Set Up group tables that follow this procedure. If you want to change any of these selections or values, follow the procedure in table 3-2. This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt. If you need a detailed explanation of any prompt, refer to Section 4 - Confi&&on Prnmne&r QfEdiom.

Follow the procedure listed in table 3-2 to access the Set Up groups and Function ~ r o m ~ t s .

w k e prompting scrolls at a rate of 2/3 seconds when the [Set Up] or Function] key is held in. Also, [A] [v] keys will move group prompts forward or backward at a rate twice as fast.

Table 3-2 Configuration Procedure



Resutl

Upper Display

Lets you know you are in the configuration mode and a Set Up group title is being displayed in the lower display.

Lower Display

This is the first Set Up group title.

Successive presses of the [Set Up ] key will sequentially display the other Set Up group titles shown in the prompt hierarchy in figure 3-1. You can also use the [A] [v] keys to scan the Set Up groups in both directions. Stop at the Set Up group title which describes the group of parameters you want to configure. Then proceed to the next step.

Upper Display

Shows you the current value or selection for the first function prompt of the particular Set Up group that you have selected.

Lower Display

Shows lhe first Function prompt within that Set Up group.

Example displays show Set Up group "Tuning", Function prompt "Gainn and the value selected.

Press

Fl

/I

step

1

2

3

Operation

Select Set Up mode

Select any Set Up group

Select a Function Parameter

Configuration Procedure, c o r n e d

Procedure (continued)

Table 3-2 Configuration Procedure, continued

UDC3000 Product Manual 3 1

Result

Successive presses of the [Function] Key will sequentially display the other function prompts of the Set Up group you have selected.

Stop at the function prompt that you want to change, then proceed to the next step.

These keys will increment or decrement the value or selection that appears for the function prompt you have selected.

See "Configuration Tips" for instructions to increase or decrease value quickly.

Change the value or selection to meet your needs.

If the display flashes, you are trying to make an unacceptable entry.

This key selects another function prompt.

This key selects another Set Up group.

The value or selection you have made will be entered into memory after another key is pressed.

This exits configuration mode and returns the controller to the same state it was in immediately preceding entry into the Set Up mode. It stores any changes you have made.

Press

F U ~ O N 0 m

j l or

Fl

Step

4

5

6

7

Operation

Select other Function Parameters

Change the value or selection

Enter the value or selection

Exit Configuration

Tuning Parameters Set Up Group

lntroductlon The Tuning Set Up group contains the Function parameters that will allow your controll,er to respond correctly to changes in process variable or setpoint. You can start with predetermined values but you will have to watch your process to determine how to modify them. If you have the Adaptive Tune option, this will automatically select Gain, Rate, and Reset values.

set this group last Because this group contains functions that have to do with Security and Lockout, it is best to configure this group last, after all the other configuration data has been loaded.



Tuning Parameters Set Up Group, conltued

Function prompts Table 3-3 lists all the function prompts in the Tuning Set Up group. How the "Algorithm and "Control" Set Up groups are configured determines which prompts will appear.

Table 3-3 Tuning Group Function Prompts

I Function Prompt Lower Display

Function Name

Selections or Range of Settlng

PPer Dl:~lay

0.1 to 9999% PROP BD or

GAIN

RATE MIN

RSET MIN

- --

0.08 to 10.00 minutes

0.00 to 50.00

Proportional Band, or Gain

Rate in Minutes

Reset in minuteslrepeat

or RSET RPM

or MAN RSET

-

I RATESMIN I Rate 2 in Minutes 1 0.08 to 10.00 minutes 1 0.00 1

Factary Settlng

1 .o

0.00

1 .o

1 .o

0.0

Reset in repeatslminute

Manual Reset

PROP 802 or

GAIN 2

I RSETIMIN I Reset 2 in minuteslrepeat / 0.00 to 50.00

0.00 to 50.00

-1 00 to 100% Output

Proportional Band 2, or Gain 2

or I Reset 2 in repeatslminute I RSETSRPM 1 0.00 to 50.00


CYC SEC

CYCSSEC ,

SECURITY

LOCKOUT

AUTO MAN

SP SEL

RUN HOLD

Cycle Time (Heat)

Cycle Time 2 (Cool)

Security Code

Configuration Lockout

ManuaVAuto Key Lockout

Setpoint Select Key Lockout

RunIHold key Lockout

1 to 120 seconds

1 to 120 seconds

1 to 4095 In order to change a LOCKOUT selection, a code must be entered (1 to 4095). Make code selection here.

NONE CALlB +CONF +VIEW MAX

DISABLE ENABLE

DISABLE ENABLE

DISABLE ENABLE

20.0

20.0

CALlB

ENAB

ENAB

ENAB

SP RarnpfProgram Set Up Group

Single Setpoint Ramp The Setpoint Ramp Set Up group contains the Function parameters that let you to configure a single set point ramp to occur between the current local setpoint and a final setpoint over a time interval (SP RAMP).

k

Setpoint rste The Setpoint Ramp Set Up group also contains the function parameters that let you configure a specific rate of change for any Local Setpoint change (SP RATE). It includes selections for Rate Up and Rate Down.

Setpoint Program Also included under this group are prompts for configuring a Setpoint program (SP PROG). The prompts and instructions for Setpoint programming are in the Operation section.

Function prompts Table 3-4 lists all the function prompts in the SP RAMP Set Up group.

Table 3-4 SP Ramp Group Function Prompts

34 UDC3000 Product Manual 10/92

Function Prompt Lower Display

SP RAMP

TIME MIN

FINAL SP

SP RATE

EUlHR UP

EUMR DN

SP PROG

Functkn Name

Single Setpoint Ramp Selection "

Single Setpoint Ramp Time

Single Setpoint Final Setpoint

Setpoint Rate

Rate Up Value (SP Rate Enabled)

Rate Down Value (SP Rate Enabled)

Setpoint Programming

Selectkns or Range of Setting

pper Maplay

DISABLE ENABLE

0 to 255 minutes

Enter a value within the setpoint limits

DISABLE ENABLE

0 to 9999 in Units per Hour

0 to 9999 in Units per Hour

DISABLE ENABLE

Factory Setting

DISABL

3

DISABL

DISABL

Adaptive Tune Set Up Group

Adapt hre Tune Adaptive Tune continuously adjusts the PID parameters in response to setpoint changes.You can select tuning on minimum setpoint changes of 5% up to 15% span. Perform adaptive tuning after you have configured the controller.

Function prompts Table 3-5 lists all the function prompts in the "ADAPTIVE" Set Up group.

Table 3-5 Adaptive Tune Group Function Prompts


Functlon prompt Lowof Dlqlay

ADAPTIVE

SP CHANG

KPG

AT ERROR

Selections or Ran e of Setting

L m w

DISABLE SPoNLY

5 to 15% Input Span

0.01 to 50.00 (Normally Read Only)

Read Only NONE OUT LIM ID FAIL ABORT

Function Name

Adaptive Tune

Setpoint Change

Process Gain

Adaptive Tune Emr codes

Factory Setting

Disabl

10

1 .O

Algorithm Data Set Up Group

Introduction This data deals with various algorithms residing in the controller: Control Algorithm and Output algorithms, enabling the Second Input or the Current Duplex range, and selecting the type of relay.

Functlon prompts Table 3-6 lists all the function prompts in the "ALGORITHM" Set Up group.

Table 3-6 Algorithm Group Function Prompts


CONT ALG

Function Name

Selections or Ranfe of Setting

pper Display

Control Algorithm ON-OFF" PID A PID B PD+MR SPSTEP*

Factory Setting

PID A

INPUT 2 Input 2 ENABLE DISABLE

OUT ALG" Output Algorithm TIME CURRNT POSITN TIME D CUR D CUR TI TI CUR

Depends on model

4-20RNG Current Duplex Range 100PCT (FULL) 1 50 PCT (SPLIT)

MECHAN SOL ST

RLY TYPE*

* For Time Proportional only.

Output Relay Type

** Selections a& model dependent. For example, current output models cannot be configured for Time Proportioning Simplex Output.

- -

UDC3000 Product Manual

lnput 1 Parameters Set Up Group

Introduction This data deals with various parameters required to configure Input 1.

Function prompts Table 3-7 lists all the function prompts in the "INPUT 1" Set Up group.

Table 3-7 Input 1 Group Function Prompts

Function Prompt Lower Dlsphy

Function Name

- -

UNITS

DECIMAL

Temperature Units

Decimal Point Location

IN1 TYPE

lnput 1 High Range Value (Linear Inputs only

Input 1 Actuation Type

XMilTER

IN1 LO Input 1 Low Range Value (Linear Inputs only)

Transmitter Characterization


8pper Display

XXXX None XXXX One XX.XX Two

DEG F DEG C NONE

ETCL JTC H J TC L KTCH KTCL NNM TC H NNM TC L NIC TC R TC S TC

TTC H TTCL WTC H W TC L 100 PT 100 LO 500 PT RADIAM 4-20mA 0-1 OmV 10-50m 1-5 v 0-1 ov

B TC ETCH ETCL JTC H JTCL KTC H KTCL NNM TC H NNM TC L NIC TC R TC S TC

TTC H TTC L WTCH WTCL 100 PT 100 LO 500 PT RADIAM LINEAR SQROOT

-999.9 to 999. or -999 to 9999 in engineering units


Factory Setting

XXXX

NONE

0-1 OmV

LINEAR



lnput 1 Group, Continued

Functbn prompts, Table 3-7 lists all the function prompts in the "INPUT 1" Set Up group. continued

Table 3-7 Input 1 Group Function Prompts, continued


Functbn Prompt Lower Dlsplay

BIAS IN1

FILTER 1

BURNOUT

EMlSSlV

PWR FREQ

Functbn Name

Input 1 Bias

Input 1 Filter

Burnout Protection

Ernissivity

Power Line Frequency

Selectbns or Ran e of Seltlng L cwaY

-999.9 to 9999.

0 to 120 seconds

NONE UP DOWN

0.01 to 1.00

60 Hz 50 Hz

FaOrY Setting

0

0

NONE

0

60 Hz


lntroductlon This data deals with various parameters required to configure Input 2. This only appears when input 2 in the "Algorithm" Group is enabled.

Function prompts Table 3-8 lists all the function prompts in the INPW 2 Set Up group.

Table 3-8 Input 2 Group Function Prompts

Function Prompt Lower Dlsphy

FILTER 2

Function Name

-

Transmitter Characterization

--

Input 2 High Range Value

lnput 2 Low Range Value

lnput 2 Filter

Selections or Range of Settlng

wm QW.Y

B TC ETCH ETCL JTC H JTCL KTCH KTCL NNM TC H NNM TC L NIC TC R TC S TC

TTC H T TC L WTCH WTCL 100 PT 100 LO 500 PT RADIAM LINEAR SQROOT


, (Adjustable for linear inputs only)

-999.9 to 999.

-999 to 9999 in engineering units (Adjustable for linear inputs only)

0 to 120 seconds 0 = No Filter

Factory Settlng

LINEAR


Control Parameters Set Up Group

introduction This data deals with various parameters required to effectively control your process. -

Function prompts Table 3-9 lists all the function prompts in the "CONTROL" Set Up group.

Table 3-9 Control Group Function Prompts

Table continued on next page


Function Prompt Lower D~sphy

PID SETS

SW VALUE

SP SOURC

RSP SRC

RATIO

BIAS

SP TRACK

POWER UP

SP HlLlM

SP LOLlM

ACTION

OUT RATE

Selections or Range of Setting

pper Display

1 ONLY 2KEYBD 2PV SW 2SP SW

Value in Engineering Units

1 LOCAL 2 LOCAL

NONE IN 2

-20.00 to 20.00

-9999 to 9999 in engineering units

NONE PV RSP

MANUAL A LSP A RSP AM SP AM LSP

0 to 100% of span input in engineering units with decimal place.

0 to 100% of span input in engineering units with decimal place.

DIRECT REVERSE

ENABLE DISABLE

Function Name

Tuning Parameter Sets

Automatic Switchover Value

Local Setpoint Source

Remote Setpoint Source

Ratio

Bias

Local Setpoint Tracking

Power Up Recall

Setpoint High Limit

Setpoint Low Limit

Control Output Direction

Output Change Rate

FmorY Settlng

1 ONLY

0.00

1 LOCAL

NONE

1 .O

0

NONE

MANUAL

1000

1000

REVERSE

DISABL

Control Group, Continued

Function prompts, Table 3-9 lists all the function prompts in the "CONTROL" Set Up group. continued

Table 3-9 Control Group Function Prompts, continued



PCTIM UP

PCTIM DN

OUTHlLlM

OUTLOLIM

DROPOFF

DEADBAND

OUT HYST

FAiLSAFE

MAN OUT

AUTO OUT

PBorGAiN

MlNorRPM

Function Name

Output Rate Up Value

Output Rate Down Value

High Output Limit

Low Output Limit

Controller Dropoff Value

OutputRelayDeadband

Output Relay Hysteresis

Failsafe Output Value

Power-up Manual Mode Output Preset Value

Power-up Automaticn Mode Output Preset Value

Proportional Band or Gain Units

Reset Units

Selections or Ran e of Settlng

3wsr Display

0 to 9999% 1 minute

0 to 9999% / minute

-5.0 to 105.0% of output



TimeProportionalDuplex: -5.0 to 25.0%

On-Off Duplex: 0.0 to 25.0%

Position Proportional or Three Position Step: 0.5 to 5.0%

0.0 to 5.0%

Set within the range of the output limits.

0.0 to 100.0%

0.0 to 100.0%

PB PCT GAIN

RPM MIN

Factw Settlng

0

0

100.0

0

0.0

2.0

0.5

0.0

0.0

0.0

GAIN

MIN

Options Set Up Group

This data deals with various options that are available with your controller. If your controller does not have any of these options the prompts will not appear.

Function prompts Table 3-10 lists all the function prompts in the "Options" Set Up group.

Table 3-10 Options Group Function Prompts


Function P m p t L O W ~ I Display

AUX OUT

4mA VAL

20mA VAL

DIG IN 1

DIG1 COM

DIG IN 2

DIG 2 COM

Function Name

Auxiliary Output Representation

Auxiliary Output Low Scaling Factor

Auxiliary Output High I

Scaling Factor

Digital Input 1 selections

Digital Input 1 Combinations

Digital Input 2 selections

Digital Input 2 Combinations

Selections or Rang of Setting

pp.r D ~ P w

DISABL IN 1 IN 2 PV DEV OUTPUT SP

Low scale value to represent 4 mA.

Value in % for output. All other in Engineering units.

High scale value to represent 20 mA.

Value in O/O for output. All other in Engineering units.

NONE To MAN To LSP To 2SP To DIR To HOLD ToPID2 PV 21N To RUN To BEGN STOP l EN ADT MAN FS

DISABL +PID2 +TO DIR +TO SP2 +DISAT

Same as DIG IN 1

Same as DIG1 COM

Factory Setting

DISABL

o

0

NONE

DISABL

NONE

DISABL

Communications Group

lntrodudion This data deals with the Communications option that is available with your controller. This option allows the controller to be connected to a host computer via a RS422 or DMCS bus. If your controller does not have this option the prompts will not appear.

Functbn p m p t s Table 3- 11 lists all the function prompts in the "Com" Set Up group.

Table 3- 1 1 Com Group Function Prompts


Function P m p t Lower Msplay

ComSTATE

Com ADDR

SHEDTIME

PARITY

(RS422 Only)

BAUD

(RS422 Only)

DUPLEX

(RS422 Only)

LOOPBACK

(DMCS Only)

SHEDMODE

(DMCS Only)

SHED SP

(DMCS Only)

UNrl'S

Selections or Range of Setting

pper Display

DISABL DMCS RS422

1 to 99

1 to 255 sample periods

ODD EVEN

300 4800 600 9600 1200 19200 2400

HALF FULL

DISABL ENABLE

LAST TO MAN FSAFE ToAUTO

TO LSP TO CSP

PERCNT ENG

Functbn Name

Communications Option State

Communications Station Address

Shed Time

Parity

Baud Rate

Duplex Operation

Local Loop Back

Shed Controller Mode and Output Level

Shed Setpoint Recall

Communication Units

F&w Setting

DISABL

0

0

ODD

300

DISABL

LAST

TO LSP

PERCNT

Alarms Set Up Group

lntmdudbn This data deals with the Alarms function that is available with your controller. There are two alarms available. Each alarm has two setpoints. You can configure each of these two setpoints to alarm on one of nine events and you can configure each setpoint to alarm High or Low. You can also configure the two setpoints to alarm on the same event and to alarm both high and low, if desired.

Function prompts Table 3-12 lists all the function prompts in the "Alarms" Set Up group.

Table 3-12 Alarms Group Function Prompts


Function Name


&sr Display

I A1S1 VAL Alarm 1, Setpoint 1 I Value in Engineering Unls I Value

I A1S2 VAL Alarm 1, Setpoint 2 I Value in Engineering Units I Value

I A2S2 VAL Alarm 2, Setpoint 2 I Value in Engineering Units

I A2S1 VAL Alarm 2, Setpoint 1

Alarm 1, Setpoint 1 Type


NONE IN 1 (Input 1) IN 2 (Input 2) PV (Ptocess Variable) DEV (Deviation) OUTPUT SHED (Communications) EVON(sp Programming) EVOFF(sp programming)

I A1 SPTYPE I Alarm 1, Setpoint 2 Type I Same as AlSlTYPE -- - - I APSITYPE Alarm 2, Setpoint 1 I Same as AlSlTYPE I Type

APSPTYPE

setting

Alarm 2, Setpoint 2 Type

Alarm 1, Setpoint 1 State

SP Programming Event Alarm State for Alarm 1, Setpoint 1

NONE

Same as A1 S1TYPE

LO H

BEGIN END

NONE

NONE

NONE



Alarms Set Up Group, Continued

Function prompts, Table 3-12 lists all the function prompts in the "Alarms" Set Up group. continued

Table 3-12 Alarms Group Function Prompts, continued


I


A1S2 H L

A1S2 EV

A2S1 H L

A2S1 EV

A2S2 H L

A2S2 EV

AL HYST

Function Name







Alarm Hysteresis

Selections or Ran e of Setting g Display

LO HI

BEGIN END

LO HI

BEGIN END

LO HI

BEGIN END

0.0 to 5.0 % of Output or Span as appropriate

Factory Setting

HI

HI

HI

0.1

Calib Group

Callbration data The prompts used here are for field calibration purposes. Refer to Section 7 - Calibration in this manual for complete information and instructions.

Status Group

Status Test Data The prompts used here are read only. They are used to determine the reason for a controller failure. Refer to Section 9 - Troubleshooting in this manual for complete information.


Configuration Record Sheet

Keep a tecord Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured.


G W Prompt

Valueor Selection

Function P m p

TUNING PROP BD 1 .O or GAIN 1 .O RATE MIN 0.00 RSET MIN 1 .O or RSET RPM 1 .0 or MAN RSET 0.0 PROP BD2 1 .O or GAIN 2 1 .O RATE2MIN 0.00 RSET2MIN 1 .O or RSET2RPM 1 .O CYCSEC 20.0 CYC2SEC 20.0 SECURITY - LOCKOUT CALIB AUTO MAN ENAB SP SEL ENAB RUN HOLD ENAB

SP RAMP SP RAMP DISABL TIME MIN 3 FINAL SP - SP RATE DISABL EUMR UP - EUMR ON - SP PROG DISABL

ADAPnVE ADAPTIVE DISABL SP CHANG 10 KPG 1 .O

ALGORITHM CONT ALG PID A INPUT 2 DISABL OUT ALG - 4-20RNG SOPCT - RLY TYPE

INPUT 1 DECIMAL XXXX UNITS NONE IN1 TYPE &1 OmV XMlTl€R LlNEAR IN1 HI 1000 IN1 LO 0 BIAS IN1 0 FILTER 1 1 BURNOUT NONE EMlSSlV 0 PWR FREQ 60HZ

INPUT 2 XMITIER 2 LINEAR IN2 HI 1000 IN2 LO 0 FILTER 2 1

CONTROL PID SETS 1 ONLY SW VALUE 0.00 SP SOURC 1 LOCAL RSP SRC NONE RATIO 1 .O BIAS 0 SP TRACK NONE POWER UP MANUAL SP HlLlM 1000 SP LOLlM 1000 ACTION REVERSE OUT RATE DISABL PCTM UP 0 PCTM DN 0 OUT HlLlM 100.0 OUT LOLIM 0 DROPOFF 0.0 DEADBAND 2.0 OUT HYST 0.5 FAILSAFE 0.0 MAN OUT 0.0 AUTO OUT 0.0 PBorGAlN GAIN MlNorRPM M IN

OPTIONS AUX OUT DISABL 4mA VAL 0 20mA VAL 0 DIG IN 1 NONE DIG IN 2 NONE

Can ComSTATE DISABL Com ADDR 0 SHEDTIME 0 PARITY ODD BAUD 300 DUPLEX - LOOPBACK DISABL SHEDMODE LAST SHED SP TO LSP UNITS PERCNT

ALARMS A1S1 VAL 90 A1 S2 VAL 90 A2S1 VAL 90 A2S2 VAL 90 AlSlTYPE NONE A1 S2TYPE NONE A2SlTYPE NONE A2S2TYPE NONE A1S1 H L HI A lS l EV - A1S2 H L HI A1 S2 EV - A2S1 H L HI A2S1 EV - A2S2 H L HI A2S2 EV - AL HYST 0.1

Factw Setting

G m P p m p t

Function Prompt

Valueor Selection

Factory Settlng

Section 4 - Configuration Prompt Definitions

Overview

This section provides information for all the user configurable parameters listed in the configuration section. If you aren't familiar with these parameters, this section gives you the parameter prompt, the selection or range of setting that you can make, and a definition of how each parameter setting affects controller performance. It will also refer you to any other prompts that might be affected by your selection.

What's in this sectbn? The table below lists the topics that are covered in this section. They are listed in the order of their appearance in the controller.

I Set up ~roups I see Page - -

Tuning Parameters 4 9

Setpoint Ramp/Rate/Program

Adaptive Tune

I Options I 70

5 2

53 - - -

Algorithm Data

Input 1

55

59


-

Calibration Data

Status Test Data

7 8

78

Tuning Parameters Set Up Group

Introduction Tuning consists of establishing the appropriate values for the tuning constants you are using so that your controller responds correctly to changes in process variable and setpoint. You can start with pre-determined values but you will have to watch the system to see how to modify them. Adaptive Tune feature automatically selects Gain, Rate, and Reset.

Set thls group hst Because this group contains functions that have to do with security and lockout, we recommend that you configure this group last, after all the other configuration data has been loaded.

Tuning gtoup prompts Table 4- 1 lists all the function prompts in the Tuning setup group and their definitions.

Table 4-1 Tuning Group Prompt Definitions

Lower Display Prompt Upper Dm@' Range of Setting

or Selection

PROP BD or

GAIN

Parameter Definition

0.1 to 999.9% or 0.1 to 9999

RATE MIN

, PROPORTIONAL BAND is the percent of the range of the measured variable for which a proportional controller will produce a 100% change in its output.

0.08 to 10.00 minutes 0.08 or less = OFF

GAlN is the ratio of output change (%) over the measured variable change (%) that caused it.

I where PB is the proportional band (in Oh) I If the PB is 20% then the Gain is 5. Likewise, a 3% change in the error signal (SP-PV) will result in a 15% change in the controller's output due to proportional action. If the gain is 2, then the PB is 50%.

Defined as "HEAT" Gain on Duplex models for variations of HeaVCool applications.

The selection of Prop. Band or Gain is made in the control parameter group under prompt "PBorGAIN."

RATE action affects the controller's output whenever the deviation is changing; and affects it more when the deviation is changing faster.

Defined as "HEAT" Rate on Duplex models for variations of HeaVCool applications. I



Tuning Parameters Set Up Group, w i e d

- - - - - - -

Table 4-1 Tunkg Group h m p t Definitions, continued




RSET MIN = RESET IN MINUTES 1 REPEAT

RSET RPM = RESET IN REPEATS PER MINUTE

RESET adjusts the controller's output in accordance with both the size of the deviation (SP-PV) and the time it lasts. The amount of the corrective action depends on the value of Gain. The Reset adjustment is measured as how many times proportional action is repeated/minute.

Used with control algorithm PID-A or PID-B.

Defined as "HEAT" Reset on Duplex models for variations of HeatICool applications.

The selection of minutes per repeat or repeats per minute is made in the control parameters group under prompt "MINorRPM."

MANUAL RESET is only applicable if you have control algorithm PD WITH MANUAL RESET. Because a proportional controller will not necessarily line out at setpoint, there will be a deviation (offset) from setpoint. This eliminates the offset and lets the PV line out at setpoint.

PROPORTIONAL BAND 2 or GAIN 2, RATE 2, and RESET 2 parameters are the same as previously described for "Heat" except that they refer to the cool zone tuning constants on duplex models or the second set of PID constants, whichever is pertinent.

CYCLE TIME (HEAT) determines the length of one time proportional output relay cycle. Defined as "HEAT" cycle time for HeatICool applications.

CYCLE TIME 2 (COOL) is the same as above except it applies to Duplex models as the cycle time in the "COOL" zone of HeatICool applications or for 2nd set of PID constants.

Lower D@My Prompt

RSET MIN 0 r

RSET RPM

MAN RSET

PROP 002 or

GAIN 2

RATEPMIN

RSET2MlN or

RSET2RPM

CYC SEC

CYC2 SEC

Upper D m Range of Setting

or Selection

0.00 to 50.00

-100 to +I00 (in % output)

0.1 to 999.9% or 0.1 to 999.9

0.08 to 10.00 minutes 0.08 or less = OFF

0.02 to 50.00

1 to 120 seconds

1 to 120 seconds

Tuning Parameters Set Up Group, contmueci

Table 4-1 Tuning Group Prompt Defmitions, continued



SECURITY CODE - To change configuration or keyboard Lockout selection, a four-digit code between 0001 and 4095 must be entered. After selecting this number here, be sure to copy and keep it in a secure location. NOTE: The Security Code is for keyboard entry only and is not available via communications. Can only be changed if "LOCKOUT" selection is "NONE".

LOCKOUT applies to one of the functional groups: Configuration, Calibration, Tuning, Adaptive Tune. DO NOT CONFIGURE UNTIL ALL CONFIGURATION IS COMPLETE. No Lockout - all groups readlwrite. Allows individual key lockout. CALiB - All are available for readlwrite except for the Calibration and Keyboard Lockout groups. +CONF - Tuning, SP Ramp, and Adaptive Tune groups are read/write. All other groups are read only. Keyboard Lockout and Calibration groups are not available. +VIEW - Tuning and Setpoint Ramp parameters are readhrite. No other parameters are viewable. MAX - Tuning and Setpoint Ramp parameters are available for read only. No other parameters are viewable

MANUAUAUTO KEY LOCKOUT - Albws you to disable the ManuaVAuto key. Disable Enable Can only be viewed if "LOCKOUT" is configured for "NONE".

SETPOINT SELECT KEY LOCKOUT - Allows you to disable the Setpoint Select key. Disable Enable Can only be viewed if "LOCKOUT" is configured for "NONE".

RUN/HOLD KEY LOCKOUT - Allows you to disable the Run/Hold key. Disable Enable Can only be viewed if "LOCKOUT" is configured for "NONE".

b m r isp play prompt

SECURITY

LOCKOUT

AUTO MAN

SP SEL

RUN HOLD

Upper DIsphy Range of Setting

or Selectkn

0001 -4095

NONE

CALI B

+CONF

+VIEW

MAX

DISABL ENABLE

DISABL ENABLE

DISABL ENABLE

Setpoint RampIProgram Set Up Group

lntrodudion A single setpoint ramp can be configured to occur between the current local setpoint and a final local setpoint over a ti= interval of from 1 to 255 minutes. There is also a configurable rate of change for any local setpoint change. You can also configure a 12 segment program from a RampISoak profile. You can start and stop the ramp/program using the RUN/HOLD key.

Setpoint Ramp/ Table 4-2 lists all the function prompts in the Setpoint Ramp/Rate/Prograrn RateJProgram group setup group and their definitions. Prompts

- - -

SP RAMP

Table 4-2 Setpoint Ramp/Rate/Program Group Definitions

ENABLE

DISABL

SINGLE SETPOINT RAMP - Make selection to enable or disable the setpoint ramp function. Make sure you configure a ramp time and a final setpoint value. "SP RATE" and "SP PROG" must be disabled. ENABLE SETPOINT RAMP - Allows you to start the setpoint ramp (in automatic mode). DISABLE SETPOINT RAMP - Disables the setpoint ramp.


Lower Display Prompt Upper Disphy Range of Setting

or Selection

SETPOINT RAMP TIME - Enter the number of minutes desired to reach the final setpoint. A ramp time of "Om implies and immediate change of setpoint. I

--

FINAL SP

- - -

0 to 255 minutes

Within SP limits SETPOINT RAMP FINAL SETPOINT - Enter the value desired for the final setpoint. The controller will operate at the setpoint set here when ramp is ended.

SP RATE

ENABLE

DISABL

SETPOINT RATE - Lets you configure a specific rate of change for any local setpoint change. "SP RAMP" and "SP PROG" must be disabled. ENABLE SETPOINT RATE - allows the SP rate feature DISABLE SETPOINT RATE - disables the setpoint rate

SP PROG

(option)

I EUIHRUP

ENABLE

DISABL

0 to 9999 in Engineering Units per hour

1 0 to 9999 in Engineering , Units per hour

SETPOINT RAMPISOAK PROGRAM Available only with controllers that contain this option. For reasons of convenience, the information for the prompts when SP PROG is enabled are included in Section 5 - Setpoint Programming Option. "SP RAMPn and "SP RATE" must be disabled.

RATE UP - Value for SP Rate selection

RATE DOWN - Value for SP Rate selection


Adaptive Tune Set Up Group

Introduction Adaptive Tune continuously adjusts the PID parameters in response to setpoint changes. Also, it can be used during start-up without prior initialization or process knowledge.

Adaptive Tune group Table 4-3 lists all the function prompts in the Adaptive Tune setup group Prompts and their definitions.

SP CHANG

Table 4-3 Adaptive Tune Group Definitions

KPG

SPoNLY


ADAPTIVE TUNE

Lower Display Prompt

ADAPTIVE

DISABLE ADAPTIVE TUNE - Disables the Adaptive Tune function.

UPPerDwW Range of Settlng

or Selection

SETPOINT ONLY -This selection tunes on setpoint changes only. It employs time domain analysis to accelerate line out at any desired setpoint without prior initialization or process knowledge. SP Only is the recommended start-up mode - to be used when no knowledge of the process tuning ' values is available. In the Start-up mode, and after enabling ADAPTIVE, the operator simply lines out the process variable in manual mode, selects the desired SP value and switches to automatic mode.

I Note vou must disable Ada~tive 1

5 to 15%

0.01 to 50.00

tune to change tuning-constant values from the keyboard. I

SETPOINT CHANGE - The minimum setpoint change that will result in re-tuning must be configured between 5% and 15%:

i.e. If the range is 0 to 2400 and 5% is configured, re-tuning will occur if the

setpoint change is 120 or larger.

PROCESS GAIN - This is the Gain of the process being tuned. It is automatically calculated during tuning process. This is normally a READ only value. It should only need to be changed if the controller fails to identrfy the process. In this case, set the value to algebraic value of PV in percent, divided by output in percent while in the manual mode.



Adaptive Tune Set Up Group, Continued

Table 4-3 Adaptive Tune Group Definitions, continued


Lower Dlspby Prompt

AT ERROR

UPW D i e Range of Setting

or Selectkn

NONE

OUTLIM

IDFAL

ABORT


ADAPTIVE TUNE ERROR STATUS - When an error is detected in the Adaptive Tune process, an error prompt will appear.

NO ERRORS

OUTPUT GREATER OR LESS THAN OUTPUT LIMITS - Output set insufficiently to get Setpoint value.

IDENTIFICATION PROCESS FAILEb - An illegal value for Gain, Rate, or Reset was calculated.

CURRENT ADAPTIVE TUNE PROCESS ABORTED -caused by one of the following conditions:

changing to manual mode digital input detected In heat region of output and a cool output calculated or vice versa.

Algorithm Data Set Up Group

Introduction This data deals with various algorithms in the controller: Control algorithm, Output algorithm, Enabling the second input, or the Current Duplex range.

AlgOahm group Table 4-4 lists all the function prompts in the Algorithm setup group and PromPS their definitions. Table 4-4 Algorithm Group Definitions

--


C O M ALG

Upper~lsplay Range of Setting

or Selectbn

' ON-OFF

PID A

NOTE: PID A should not be used for Proportional only action. i.e. no integral (reset) action. Instead, use PD+MR with rate set to 0.

The CONTROL ALGORITHM lets you select the type of control that is best for your process.

ONIOFF is the simplest control type. The output can be either ON (100Y0) or OFF (0%). The Process Variable (PV) is compared with the setpoint (SP) to determine the sign of the error (ERROR = PV-SP). The ONIOFF algorithm operates on the sign of the error signal. In Direct Acting Control, when the error signal is positive, the output is 100%; and when the error signal is negative, the output is 0%. If the control action is reverse, the opposite is true. An adjustable overlap (Hysteresis Band) is provided between the on and off states. Other prompts affected: "OUT HYST" DUPLEX ONIOFF is an extension of this algorithm when the output is configured for Duplex. It allows the operation of a second ONIOFF output. There is a deadband between the operating ranges of the two inputs and an adjustable overlap (hysteresis) of the on and off states of each output. Both Deadband and Hysteresis are separately adjustable. With no relay action the controller will read 50%. Other prompts affected: "OUT HYST" and "DEADBAND"

PID A is normally used for three-mode control. This means that the output can be adjusted somewhere between 100% and 0%. It applies all three control actions - Proportional (P), Integral (I), and Derivative (D) -to the error signal. -- regulates the controller's output in proportion to the error signal (the difference between Process Variable and Setpoint). p-- regulates the controller's output to the size of the error and the time the error has existed. (The amount of corrective action depends on the value of proportional Gain.)

-- regulates the controller's output in proportion to the rate of change of the error. (The amount of corrective action depends on the value of proportional Gain.)



Algorithm Data Set Up Group, conti-

Table 4-4 Algorithm Group Definitions, continued

CONT ALG continued

Lower Display P m p t

PID B

PD+MR

PID B Unlike the PID-A equation, the controller gives only an integral response to a setpoint change, with no effect on the output due to the gain or rate action, and it gives full response to PV changes. Otherwise controller action is as described for the PID-A equation. See note on PID-A.


or Selection

PD WITH MANUAL RESET is used whenever integral action is not wanted for automatic control. The equation is computed with no integral contribution. The MANUAL RESET, which is operator adjustable, is then added to the present output to form the controller output.


I Switching between manual and automatic mode will not be bumpless. If you select PD with Manual Reset you can also configure the following variations

PD (Two Mode) control, P (Single Mode) control.

Set Rate(D) and/or Reset Time(l) to 0. ( Other prompts affected: *'MAN RSET"

The THREE POSITION STEP algorithm allows the control of a valve (or other actuator), with an electric motor driven by two controller Time Proportional outputs; one to move the motor upscale, the other downscale without a feedback slidewire linked to the motor shaft. The deadband and hysteresis are adjustable in the same manner as the duplex output algorithm. The Three Position Step Control algorithm provides an output display (OUT) which is an estimated motor position since the motor is not using any feedback. Although this output indication is only an approximation, it is "corrected " each time the controller drives the motor to one of its stops (0% or 100%). It avoids all the control problems associated with the feedback slidewire (wear, dirt, noise). When operating in this algorithm, the estimated "OUT' display is shown to the nearest percent (i.e. no decimal). Refer to the Operation section for motor position displays. Other prompts affected: "DEADBAND"

ENABLE DISABLE

INPUT 2 algorithm allows you to enable or disable the second input. Appears only when input 2 is ordered.



Algorithm Data Set Up Group, continued





The OUTPUT ALGORITHM lets you select the type of output you want. Not applicable with Control Algorithm prompt "3PSTEP." Selections are model dependent. For example, current output models cannot be configured for Time Proportioning Simplex Output.

RELAY SIMPLEX - Type of output using one SPDT relay. Its normally open (NO) or normally closed (NC) contacts are selected when wiring the rear terminals.

Other prompts affected: "OUT HYST"

CURRENT SIMPLEX -Type of output using one 2 to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 1000 ohms. The signal can be recalibrated for any desired range from 2 to 20 mA for 0 to 100% output.

POSITION PROPORTIONAL SIMPLEX - Type of output using two SPDT relays and a motor which has a 100 to 1000 ohms feedback slidewire.

Other prompt affected: "DEADBAND"

RELAY DUPLEX - Type of output using two SPDT relays. Its normally open (NO) or normally closed (NC) contacts are selected when wiring the rear terminals (see Installation section).

Other prompts affected: "DEADBAND"

CURRENT DUPLEX is similar to current simplex but provides a second current output if Auxiliary output is used. The second output is usually scaled so that zero and span correspond with 0% and 50% output (cool zone). When the output is 0 to 50%, the controller uses tuning parameter set #2, when the output is 50 to 100% it uses set # l .

NOTE: Auxiliary Output must be configured for "OUTPUT."

CURRENTIRELAY DUPLEX (RELAY = HEAT) is a variation of duplex with current active for 0 to 50% output (tuning set 2) and relay active 50 to 100% output (tuning set 1).

Other prompts affected: "4-20 RNG," "DEADBAND"

RELAY CURRENT DUPLEX (RELAY = COOL) is similar to "CUR-TI" except that current is active for 50 to 100% and relay is active for 0 to 50%.

Other prompts affected: "4-20 RNG," "DEADBAND"

W r Display Prompt

OUT ALG

Upper Range of Setting

or Selection

TIME

CURRNT

POSITN

TIME D

CUR D

CUR TI

TI CUR

Algorithm Data Set Up Group, Continued


50 PCT

100PCT

bum Dlsplay prompt

4-20 RNG

Parameter Upper Dlspley Range of Setting

or Selection

CURRENT DUPLEX RANGE ALGORITHM - Used with Output Algorithm selections "CUR-D," "CUR-TI", or "TI-CUR."

CURRENT DUPLEX RANGE (SPLIT) enables the normal control current output to provide heat control and the Auxiliary output to provide cool control. To enable this, the auxiliary output must be:

Selected for Output Auxiliary current output is scaled as desired for 0-5O0/0 controller output (4mA set to 50; 20mA set to 0). Deadband for this configuration only applies to the current output. Auxiliary output must have Deadband scaled in.

For example: If a 2% Deadband is desired, then enter a 2.0" for the "Deadband" selection in the Control Algorithm Group. This will apply Deadband to the Current Output. In the "Options" group, set the Auxiliary Output "4mA" selection to "49.0" and the "20mA" selection to 0.0.

Other prompts affected: "AUX OUT"

CURRENT DUPLEX RANGE (FULL) enables the normal control current output to provide duplex Heat control and the Auxiliary Output to provide cool control over 0 - 100% of the controller output.

The PID heat parameters apply to both outputs when the controller output is greater than 50% and the PID cool parameters apply to both outputs when the controller output is less than 50%.

RLY TYPE I MECHAN

I SOL ST

RELAY TYPE - For Time Proportional only I ELECTROMECHANICAL RELAY - This selection allows cycle times of from 1 to 120 seconds.

SOLID STATE RELAY OR OPEN COLLECTOR . OUTPUT - This selection allows cycle times of 0.333 seconds through 40.0 seconds in 0.333 second increments.



Introduction These are the parameters required for input 1; temperature units, decimal location, actuation, transmitter characterization, high and low range values in engineering units, filter, burnout, emissivity, and power line frequency.

lnput 1 groy, prompts Table 4-5 lists all the function prompts in the Input 1 setup group and their definitions.

Table 4-5 Input 1 Group definitions



DECIMAL

UNITS



or Selection

XXXX X X X X XX.XX

DEG F DEG C NONE


DECIMAL POINT LOCATION -- This selection determines where the decimal point appears in the display.

None One Place Two Places

NOTE: Auto-ranging will occur when one decimal position has been selected and the value increases above 999.9 but auto-ranging will not similarly occur when two decimal positions are selected.

TEMPERATURE UNtTS -- This selection will be indicated on the annunciator. What display of temperature do you want.

Degrees Fahrenheit Degrees Celsius None

Input 1 Parameters Set Up Group, Contimed

-- -

Table 4-5 Input 1 Group definitions, continued

IN1 TYPE

UPPer D m @ Range of Setting

or Selectkn --

I3 TC ETC H ETCL JTCH JTCL KTC H K TC L NNM H

NNM L

NIC TC

R TC S TC TTC H TTC L WTCH WTC L 100 PT 500 PT 100 LO RADIAM 4-20mA 0-1 OmV 10-50m 1-5 V 0-10 v

Parameter DefinRion

INPUT 1 ACTUATION TYPE -- This selection I determines what actuation you are going to use for 1 input one.

B thermomple 0 to 3300°F -18 to 1815°C Ethmocoqle high -454 to 1832°F -270 to 1000°C E t h e r m v l e b w -200 to 1100°F -129 to 593°C J thermocouple h i 0 to 1 600°F -18 to 87I0C J thermocouple bw 20 to 770°F -7 to 410°C K thermocouple high 0 to 2400°F -18 to 1316°C K thermocouple bw -20 to 1000°F -29 to 538°C NNM NNiMo

thermocouple high 32 to 2500°F 0 to 1371°C NNM N N i

thermocouple low 32 to 1260°F 0 to 682°C NIC NimsilNisil

thermocouple 0 to 2372O,F -17.8 to 1300°C R thermocouple 0 to 3100°F -18 to 1704°C S thermocoqle 0 to 3100°F -18 to 1704°C T thermocouple high -300 to 700°F -1 84 to 371 OC T t h m q l e bw -200 t o 500°F -129 to 260°C Wthemumuple hgh 0 to 4200°F -18 to 2316°C W thermocouple low 0 to 2240°F -18 to 1227°C 100 Ohm-RTD -300 to 1200°F -184 to 649°C 500 Ohm-RTD -300 to 1200°F -184 to 649°C 100 Ohm RTD low 0 to 300°F -18 to 149°C Radiamatic (RH) 0 to 34OO0F -18 to 1871°C 4 to 20 Milliamps 0 to 10 Millivolts 10 to 50 Millivolts 1 to 5 volts 0 to 10 Vok



Input 1 Parameters Set Up Group, Continued




B TC E TC H ETCL JTC H JTCL K TC H KTCL NNM H NNM L NIC TC R TC S TC TTC H TTC L WTCH WTC L 100 PT 500 PT 100 LO RADIAM LINEAR SQROOT

Upper Dispby Range of Setting

or Selection

-999 to 9999 in Engineering units

TRANSMITER CHARACTERIZATION - This selection lets you instruct the controller to characterize a linear input to represent a non-linear one.

NOTE: Prompt only appears when a linear actuation is selected at prompt 'IN1 TYPE".

FOR EXAMPLE: If input 1 is a 4 to 20 mA signal, but the signal represents a type "K" thermocouple; select "K TC H" and the controller will characterize the 4 to 20 mA signal so that it is treated as a type "K" thermocouple input (high range).

B Type Thermocouple E Type Thermocouple High E Type Thermocouple Low J Type Thermocouple High J Type Thermocouple Low K Type Thermocouple High K Type Thermocouple Low NNM NiNiMo Type Thermocouple High NNM NiNiMo Type Thermocouple Low NIC Nicrosil Nisil Thermocouple R Type Thermocouple S Type Thermocouple T Type Thermocouple High T Type Thermocouple Low W Type Thermocouple High W Type Thermocouple Low 100 Ohm-RTD 500 Ohm-RTD 100 Ohm RTD low Radiarnatic (RH) Linear Range Extracts Square Root

INPUT 1 HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization.

Scale the #1 input signal to the display value you want for 100%.

EXAMPLE: Actuation (Input) = 4 to 20 mA Process Variable = Flow Range of Flow = 0 to 250 GaVMin High Range display value = 250 Then 20 mA = 250 GaVMin

The control setpoint will be limited by the range of units selected here.



lnput 1 Parameters Set Up Group, Continued



Parameter Deflnltkn

INPUT 1 LOW RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or Square Root transmitter characterization. Scale the #1 input signal to the display value you want for 0%. See example on previous page. The control setpoint for Input 1 will be limited by the range of units selected here.

BIAS ON INPUT 1 - Bias is used to compensate the input for drift of an input value due to deterioration of a sensor, or some other cause. Select the bias value you want on input one.

FILTER FOR INPUT ONE - A software digital filer is provided for input 1 to smooth the input signal. You can configure the first order lag time constant from 1 to 120 seconds. If you do not want filtering, enter 0.

BURNOUT PROTECTION (SENSOR BREAK) provides most input types with upscale or downscale protection if the input fails. Not available for inputs 1 -5V, 0-1 OV, or 4-20mA

NO BURNOUT - Failsafe output applied for failed input.

UPSCALE BURNOUT will make the indicated PV signal increase when a sensor fails, and flash the upper display.

DOWNSCALE BURNOUT will make the indicated PV signal decrease when a sensor fails, and flash the upper display.

NOTE: For no Burnout, i.e. "None," to function properly on a linear input, there must be a dropping resistor directly across the input terminals (i.e., not remote), then the unit can detect the "zero" voltage that occurs when the 4-20 mA line is opened.

EMlSSlVlTY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator. Available only for "Radiamatic" inputs.

POWER LINE FREQUENCY - select whether your controller is operating at 60 Hz or 50 Hz.

60 HERTZ 50 HERTZ


IN1 LO

BIAS IN1

FILTER 1

BURNOUT

EMlSSlV

PWR FREQ

UPPer D m Range of Setting

or Selectbn

-999.9 to 999.

or


-999.9 to 9999

0 to 120 seconds No filer = 0

NONE

UP

DOWN

0.01 to 1.00

60 Hz 50 Hz


Introduction These are the parameters required for input 2; actuation, transmitter characterization, high and low range values in engineering units, filter, and burnout.

lnput 2 gray, prompts Table 4-6 lists all the function prompts in the Input 2 setup group and their definitions.

Table 4-6 Input 2 Group Definitions



Parameter Deflnltbn

TRANSMITER CHARACTERIZATION - This selection lets you instruct the controller to characterize a linear input to represent a non-linear one.

FOR EXAMPLE: If input 2 is a 4 to 20 mA signal, but you want the signal to represent a type "K" thermocouple; select " K TC H" and the controller will characterize the 4 to 20 rnA signal so that it is treated as a type "K" thermocouple input.

B Type Thermocouple E Type Thermocouple High E Type Thermocouple Low J Type Thermocouple High J Type Thermocouple Low K Type Thermocouple High K Type Thermocouple Low NNM NiNiMo Type Thermocouple High NNM NiNiMo Type Thermocouple LOW' NIC Nicrosil Nisil Thermocouple R Type Thermocouple S Type Thermocouple T Type Thermocouple High T Type Thermocouple Low W Type Thermocouple High W Type Thermocouple Low 100 OhmRTD 500 Ohm-RTD 100 Ohm RTD Low Radiamatic (RH) Linear Range Square Root


XMllTER2

UPP@' D i w Y Range of Settlng

or Selection

B TC E TC H ETCL JTCH JTCL K TC H KTCL NNM H NNM L NIC TC R TC S TC TTC H TTC L WTCH WTC L 100 PT 500 PT 100 LO RADIAM LINEAR SQROOT

Input 2 Parameters Set Up Group, Continued

Table 4-6 Input 2 Group Definitions, continued

Upper DLsplay Range of Setting

or Selection

Parameter


INPUT 2 HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root actuations only. Scale the #2 input signal to the display value you want for 100%.

This is what you want 20mA or 5 volts to represent.

EXAMPLE: Same as input one.


INPUT 2 LOW RANGE VALUE in engineering units, for linear or Square Root characterization only. Scale the #2 input signal to the display value you want for 0%.

This is what you want 4mA or 1 volt to represent.

EXAMPLE: Same as input one.

FILTER 2 0 to 120 seconds No filter = 0

FILTER FOR INPUT TWO - A software digital filter is provided for input 2 to smooth the input signal. You can configure the first order lag constant from 1 to 120 seconds. If you do not want filtering, enter 0.


Control Parameters Set Up Group

introduction The functions listed in this group deal with how the UDC 3000 will control the process including: Number of tuning parameter sets, Setpoint source, Ratio, Bias, Tracking, Power-up recall, Setpoint limits, Output direction and limits, Deadband and Hysteresis.

Control group prompts Table 4-7 lists all the function prompts in the Control setup group and their definitions.

Table 4-7 Control Group Definitions




NUMBER OF TUNING PARAMETER SETS -This selection lets you choose one or two sets of tuning constants (gain, rate, and reset).

ONE SET ONLY - Only one set of tuning parameters is available. Configure the values for:

Gain (proportional band) Rate Reset Time Cycle Time (if time proportional is used)

TWO SETS KEYBOARD SELECTABLE - Two sets of tuning parameters can be configured and can be selected at the operator interface or by using the Digital Inputs. Press [LOWR DISP] key until you see "PID SET1" or "PID SET2" to switch between sets. Configure the values for:

Gain, Rate , Reset, Cycle Time Gain #2, Rate #2, Reset#& Cycle#;! Time

TWO SETS PV AUTOMATIC SWITCHOVER - When the process variable is GREATER than the value set at prompt "SW VALUE" (Switchover Value), the controller will use Gain, Rate, Reset, and Cycle Time. The active PID SET can be read in the bwer display.

When the process variable is LESS than the value set at prompt "SW VALUE," the controller will use Gain #2, Rate #2, Reset #2, and Cycle #2 Time. The active PID SET can be read in the lower display. Other prompts affected: SW VALUE

TWO SETS SP AUTOMATIC SWITCHOVER - When the setpoint is GREATER than the value set at prompt "SW VALUE" (Switchover Value), the controller will use Gain, Rate, Reset, and Cycle.

When the setpoint is LESS than the value set at prompt "SW VALUE," the controller will use Gain #2, Rate #2, Reset #2, and Cycle #2.

Other prompts affected: SW VALUE

Lower Displsry Prompt

PID SETS


or Selection

1 ONLY

2KEYBD

2PV SW

2SP SW

Control Parameters Set Up Group, Continued

Table 4-7 Control Group Definitions, continued


6 6 UDC3000 Product Manual 10/92

Parameter Definitbn

AUTOMATIC SWlTCHOVER VALUE -This is the value of Process Variable or Setpoint at which the controller will switch from Tuning Constant Set #2 to Set #l. Only appears when PI0 SETS selections '2PV S W or "2SP SW" are selected.

SETPOINT SOURCE - This selection determines what your setpoint source will be; One local or Two local. Toggled by the "SETPOINT SELECT" key.

LOCAL SETPOINT - The setpoint entered from the keyboard.

NVO LOCAL SETPOINTS -This selection lets you switch between two local setpoints. Mutually exclusive with Remote setpoint.

REMOTE SETPOINT - A signal is brought in ttirough the input 2 terminals and used as the control Qetpoint. Ratio and Bias can be applied to the remote setpoint. Mutually exclusive with 2 Local setpoints

Other prompts affected: RATIO, BlAS

NONE - No remote setpoint IN 2 - RSP using second Input (Input 2 must be enabled)

RATIO - Used when input 2 operates as a remote setpoint, prompt "REMOTE." This ratio value can be applied to the remote setpoint. It establishes the correct relationship between the remote setpoint and the input 2 signal applied according to the formula below ...( under Bias).

lnput 2 must be enabled.

BIAS - Used when input 2 operates as a remote setpoint (prompt "REMOTE"). Bias, together with ratio, establishes the correct relationship between the remote setpoint and the input 2 signal applied according to the formula:

REMOTE SETPOINT = (IN2 VALUE - IN2 LO) RATIO + IN2 LO + BlAS

NOTE: IN2 VALUE = Actual (engineering units) IN2 LO = IN2 LO Scaling (engineering units)

All values must be within configured setpoint high and low limits.

lnput 2 must be enabled.

Lower Dlspllay Prompt

SW VALUE

SP SOURC

RSP SRC

RATIO

BIAS

UpperD- Range of Setting

or Selectbn

Value in engineering units

1 LOCAL

2LOCAL

NONE IN 2

-20.00 to 20.00

-9999 to 9999 (Engineering Units)





Parameter Deflnttlon

SETPOINT TRACKING -The bcal setpoint can be configured to track either PV or RSP as listed below:

NO TRACKING - If local setpoint tracking is not configured, the LSP will not be altered when transfer from RSP to LSP is made.

LSP (LOCAL SETPOINT) TRACKS PV IN MANUAL

LSP (LOCAL SETPOINT) TRACKS RSP (REMOTE SETPOINT) IN AUTO - If configured, when the controller transfers out of remote setpoint, the last value of the remote setpoint (RSP) is inserted into the local setpoint.

POWER UP CONTROLLER MODE RECALL - This selection determines which mode and setpoint the controller will use when the controller restarts after a power loss. Select one from below:

MANUAL, LSP - At power-up, the controller will use manual mode with the local setpoint displayed.

AUTOMATIC, LOCAL SETPOINT - At power-up, the controller will retum to the automatic mode and will use the local setpoint for control.

AUTOMATIC, REMOTE SETPOINT - At power-up, the controller will retum to the automatic mode and will use the remote setpoint for control.

LAST MODEILAST SETPOINT

LAST MODULAST LOCAL SETPOINT

SETPOINT HIGH LIMIT -This selection prevents the local and remote setpoints from going above the value selected here. The setting must be equal or less than the upper range of input 1 and input 2. lnput 2, when configured for remote setpoint, will be restricted to this upper limit.

SET POINT LOW LIMIT - This selection prevents the local and remote setpoints from going below the value selected here. The setting must be equal or greater than the lower range of input 1 and input 2. lnput 2, when configured for remote setpoint, will be restricted to this lower limit.

to be within the setpoint limit range. For example, if


SP TRACK

POWER UP

SP HlLlM

SP LOLlM

'The Local Setpoint SP = 1500 and the SP HlLlM is changed to 1200, the new Local Setpoint will be 1200.

Upper DlsPlaY Range of Setting

or Selectkn

NONE

PV

RSP

MANUAL

A LSP

A RSP

AM SP

AM LSP

0 to 100% of span input in engineering units with decimal place

0 to 100% of span input in engineering units with decimal place

will automatically adjust itself




Lower Dispby Prompt

ACTION

OUT RATE

PCTIM UP

PCTIM DN

OUTHlLlM

OUTLOLIM

DROPOFF

DEADBAND


UPPw Dlsphy Range of Setting

or Selection

DIRECT

REVRSE

DISABL ENABLE

0 to 9999%/minute

0 to 9999%/minute



-5 to 105.0% of output

-5.0 to 25.0% 0 to 25.0% 0.5 to 5.0%


CONTROL OUTPUT DIRECTION - In what direction do you want the controller output to go when the process variable increases.

DIRECT ACTING CONTROL -The controller's output increases as the process variable increases.

REVERSE ACTING CONTROL - The controller's output decreases as the process variable increases.

OUTPUT CHANGE RATE - Enables or Disables the Output Change Rate.The maximum rate is set at Prompt "PCTIM UP" or "PCTIM DN" shown below.

Disable Enable

OUTPUT RATE UP VALUE - This selection limits the rate at which the output can change upward. Enter a value in percent/minute. Appears only if "OUT RATE" is enabled. "0" means no output rate applied.

OUTPUT RATE DOWN VALUE - This selection limits the rate at which the output can change downward. Enter a value in percentlminute. Appears only if "OUT RATE" is enabled. "0" means no output rate.

HIGH OUTPUT LIMIT - This is the highest value of output beyond which you do not want the controller automatic output to exceed. Use 0 to 100°/~ for time proportional output type.

LOW OUTPUT LIMIT - This is the lowest value of output below which you do not want the controller automatic output to exceed. Use 0 to 100% for time proportional output type.

CONTROLLER DROPOFF VALUE - Select an output value that below which the controller output will dropoff to the low output limit value set in prompt "OUT LOLIM." DROPOFF is not displayed if On-Off or 3 Position Step is configured.

DEADBAND is an adjustable gap between the operating ranges of output 1 and output 2 in which neither output operates (positive value) or both outputs operate (negative value). It is the difference between the nominal trip points of relay 1 and relay 2.

Time Duplex On-Off Duplex Position Proportional and Three Position Step





HYSTERESIS (OUTPUT RELAY ONLY) is an adjustable overlap of the ON/OFF states of each control output. This is the difference between the value of the process variable at which the control outputs energize and the value at which they de- energize. Only applicable for ON-OFF control.

FAILSAFE OUTPUT VALUE - The value used here will also be the output level when you have Communications SHED or when NO BURNOUT is configured and input 1 fails.

POWER UP PRESET MANUAL OUTPUT - At power -up, the controller will go to manual, and the Output value set here.

POWER UP PRESET AUTOMATIC OUTPUT - At power -up, the controller will go to automatic mode, and the Output value set here.

PROPORTIONAL BAND UNITS -Select one of the following for the Proportional (P) term of the PID algorithm:

PROPORTIONAL BAND - Selects units of percent proportional band for the P term of the PID algorithm. Where: PB% = 1 OO%FS

GAlN

GAIN selects the unitless term of gain for the P term of the PID algorithm. Where: GAIN =I OOY.

P 8%

RESET UNITS - Selects units of minutes or repeat per minutes for the I term of the PID algorithm. 20 Repeats per Minute = 0.05 Minutes per Repeat.

REPEATS PER MINUTE - The number of times per minute that the proportional action is repeated by reset.

MINUTES PER REPEAT - The time between each repeat of the proportional action by reset.


OUT HYST

FAILSAFE

MAN OUT

AUTO OUT

PBorGAlN

MlNorRPM

Upper Disphy Range of Setting

or Selection

0.0 to 5.0% of PV span

0 to 100%

0 to 100%

0 to 100%

PB PCT

GAIN

RPM

MIN

Options Set Up Group

Configure the remote mode switch (Digital Inputs) to a specific contact closure response, or configure the Auxiliary Output to be a specific selection with desired scaling.

Table 4-8 lists all the function prompts in the Option setup group and their functions.

Table 4-8 Option Group Definitions


AUX OUT

Upper Display Range of Setting

or Selectbn

DISABL

IN 1

IN 2

PV

DEV

OUTPUT

SP

Parameter Ddnitbn

AUXILIARY OUTPUT SELECTION provides an mA output representing any of six control parameters. The display for auxiliary output viewing will be in engineering units for lnput 1, lnput 2, Process Variable, Deviation, and Setpoint. Output will be displayed in percent.

Other prompts affected by these selections: "4mA VAL" and "20mA VAL."

NO AUXILIARY OUTPUT

INPUT 1 -This represents the configured range of input 1. FOR EXAMPLE:

Type "J" Thermocouple (0 to 1 600°F) 0°F display = 0% output 1600°F display = 100% output

INPUT 2 represents the value of the configured range of input 2.

PROCESS VARIABLE - Represents the value of the Process Variable. PV = lnput 1 + Bias

DEVIATION (PROCESS VARIABLE MINUS SETPOINT) - Represents -1 00 to +100% of the selected PV span in engineering units. FOR EXAMPLE:

Type Y" Thermocouple PV range = -300 to +700°F PV span = 1 000°F

Deviation Range = -1 000 to +1 000°F If PV = 500°F

and SP = 650°F then Deviation Display = -150°F

Auxiliary Output = 42.5%

NOTE: A deviation of 0°F yields an auxiliary output of 50%.

OUTPUT - Represents the displayed controller output in percent (%). Cannot be used with Position Proportional or 3 Position Step Control.

SETPOINT - Represents the value of the setpoint in units of PV.



Options Set Up Group, Continued

Table 4-8 Option Group Definitions, continued



1

Parameter Deflnlion

AUXILIARY OUTPUT LOW SCALING FACTOR - Use a value in engineering units for: Input 1, Input 2, Process Variable, Deviation and Setpoint.

Use value in percent (%) for Output. (Output can be between -5 and +lOSoA.)

AUXILIARY OUTPUT HIGH SCALING FACTOR - Use a value in engineering units for: Input 1, Input 2, Process Variable, Deviation,' and Setpoint.

Use a value in percent (%) for Output. (Output can be between -5 and +105%.)

'When Deviation is selected, only one operating parameter will be entered. This value represents the deviation level that will produce 20 mA output. Zero deviation will produce a center scale (12 mA) output. A negative deviation equal in magnitude to the Auxiliary Output High Value will produce a low end (4 mA) output.

DIGITAL INPUT SELECTIONS - All selections are available for either Input. The controller returns to its original state when contact opens, except when overruled by the keyboard.

NO DIGITAL INPUT SELECTIONS

TO MANUAL - Contact closure puts the controller into manual mode. Contact open returns controller to former mode unless [AUTO/MAN] key is pressed while digital input is active.

TO LOCAL SETPOINT - Contact closure puts the conttoller into local setpoint 1. When contact opens, the controller returns to former operation local or remote setpoint unless [Setpoint Select] key is pressed while digital input is active.

TO LOCAL SETPOINT TWO - Contact closure puts the controller into local setpoint 2.

TO DIRECT ACTION - Contact closure selects direct controller action.

TO HOLD - Contact closure suspends Setpoint Program or Setpoint Ramp. Contact open runs program.

TO PID2 - Contact closure selects PID Set 2.


4mA VAL

20mA VAL

DIG IN 1 DIG IN 2

UPW DbPlaY Range of Settlng

or.Selectlon

Low Scale Value within the range of the selected variable to represent 4 mA

High Scale Value within the range of the selected variable to represent 20 rnA

NONE

To MAN

To LSP

To 2SP

To DIR

ToHOLD

ToPID2

Options Set Up Group, Continued

Table 4-8 Option Group Definitions, continued

m r Dlsplsry Prompt

DIG IN 1 DIG IN 2

continued

DIG 1 COM DIG 2 COM

Upper Drsplay Range of Settlng

or Selectbn

PV 21N

To RUN

ToBEGN

STOP l

EN ADT

MANIFS

DISABLE

+PI D2

+To DIR

+ToSP2

+DISAT

Parameter Deflnitbn

PV = INPUT 2-Contact Closure selects PV = Input 2.

RUN - Contact closure starts a stopped SP Program. Left character blinks "R"

EXTERNAL PROGRAM RESET - Contact closure resets SP Program back to the beginning of the first segment in the Program. Program cycle number is not affectedxeopening switch has no effect

NOTE: Once the last segment of the setpoint program has timed out, the controller enters the mode of action specified in the configuration data and the program cannot be reset back to the beginning of the first segment by digital input closure.

INHIBIT INTEGRAL (RESET) - Contact closure disables PID Integral (Reset) action.

ENABLE ADAPTIVE TUNE - Contact closure enables Adaptive Tune process. Opening contact aborts the current Adaptive Tune process.

MANUAL FAILSAFE - Unit goes to Manual Mode, output goes to the Failsafe value.

DIGITAL INPUT COMBINATIONS SELECTIONS - All selections are available can be combined with either Input.

DISABLES INPUT COMBINATIONS

ANY DIGITAL INPUT SELECTION PLUS TO PID2 - Contact closure selects PID Set 2.

ANY DIGITAL INPUT SELECTION PLUS TO DIRECT ACTION - Contact closure selects direct controller action.

ANY DlGlTAL INPUT SELECTION PLUS TO LOCAL SETPOINT TWO - Contact closure puts the controller into local setpoint 2.

ANY DIGITAL INPUT SELECTION PLUS DISABLE ADAPTIVE TUNE - Contact closure Ddisables Adaptive Tune process.


Communications Set Up Group

Introduction This option allows the controller to be connected to a host computer via a RS42u485 or DMCS bus. Fifteen units can be configured over this link. The controller looks for messages from the computer at regular intervals. If these messages are not received within the configured shed time, the controller will SHED from the communications link and return to stand alone operation. The device address, parity, and baud rate are configurable. You can also set the SHED output mode and setpoint recall, and communication units.

Communications group Table 4-9 lists all the function prompts in the Communications setup group Prompts and their definitions.

Table 4-9 Communications Group Definitions




COMMUNICATIONS SELECTION RS-4221485 - Allows RS4221485 communication prompts. DMCS - Allows DMCS communication prompts. DISABL - Disables the communications option.

COMMUNICATIONS STATION ADDRESS - This is a number that is assigned to a controller that is to be used with the communications option.

SHED TIME - The number that represents how many sample periods there will be before the controller sheds from communications. Each period equals 113 seconds or 0 = No shed.

PARITY pertains to the use of a self-checking code employing binary digits in which the total number of ONE'S (or ZERO'S) in each permissible code expression is either ODD or EVEN.

ODD PARITY EVEN PARITY

BAUD RATE is the transmission speed in bits per second.

300 BAUD 600 BAUD 1200 BAUD 2400 BAUD 4800 BAUD 9600 BAUD 19200 BAUD

Lower Dlsplay Prompt

ComSTATE

Corn ADDR

SHEDTIME

PARITY

(RS4221485 only)

BAUD

(RS4221485 only)

Upper Display Range of Setting

or Selection

RS-4221485

DMCS DISABL

1 to 99 (RS422) 1 to 99 (DMCS)

0 to 255

ODD EVEN

300 600 1200 2400 4800 9600 19200

Communi~ations Set Up Group, Continued

Table 4-9 Communications Group Definitions, continued

- - -



DUPLEX - Transmission Type

HALF DUPLEX - Two wires FULL DUPLEX - Four wires

LOCAL LOOPBACK tests the communications hardware.

ENABLE - Allows loopback test. The UDC goes into Loopback mode in which it sends and receives its own message. The UDC displays "PASS or "FAIL" in the upper display and "LOOPTEST" in the bwer display as long as the test is running. The UDC will go into manual mode. The test will run until the operator disables it here.

DISABLE - disables the Loopback test.

SHED CONTROLLER MODE AND OUTPUT LEVEL - determines the mode of local control you want when the controller is shed from the communications link.

LAST -SAME MODE AS BEFORE SHED - The controller will retum to the same mode (manual or automatic) that it was in before shed.

TO MAN -TO MANUAL MODE BUMPLESS OUTPUT - The controller will return to manual mode at the same output level that it had before shed.

FSAFE -TO MANUAL MODE, FAILSAFE OUTPUT - The controller will return to manual mode at the output value selected at "CONTROL" prompt "FAILSAFE".

ToAUTO - To aufomatic mode.

SHED SP - Shed setpoint (DMCS only).

TO LSP - Controller will use last local SP used. TO CSP - Controller will use computer setpoint.

COMMUNICATION UNITS - This selection determines how the controller values are expressed during communications.

PERCENT OF SPAN ENGINEERING UNITS


DUPLEX

(RS4221485 only)

LOOPBACK

SHEDMODE

(DMCS only)

SHED SP

(DMCS only)

UNITS

Upper DlsPlaY Range of Setting

or Selectbn

HALF FULL

ENABLE

DISABL

LAST

TO MAN

FSAFE

ToAUTO

TO LSP TO CSP

PERCNT ENG

Alarms Set Up Group

An alarm is an indication that an event that you have configured (far example-Process Variable) has exceeded one or more alarm limits. There are two alarms available. Each alarm has two setpoints. You can configure each of these two setpoints to alarm on various controller parameters. There are two alarm output selections, High and Low. You can configure each setpoint to alarm either High or Low. These are called single alarms. You can also configure the two setpoints to alarm on the same event and to alarm both high and low. A single adjustable Hysteresis of 0.0% to 5.0% is configurable for the alarm setpoint. See Table 2-4 in the Installation section for Alarm =lay contact information.

Alatms g m p prompts Table 4-10 lists all the function prompts in the Alarms setup group and their de f~ t ions .

Table 4- 10 Alarms Group Definitions


Lower Dlsphy Prompt

A1S1 VAL

A1 S2 VAL

A2S1 VAL

A2S2 VAL



or Sekctkn





Parameter Definltbn

ALARM 1 SETPOINT 1 VALUE - This is the value at which you want the alarm type chosen in Prompt "AlSlTYPE" to actuate. The value depends on what the setpoint has been configured to represent. NO setpoint is required for Communications SHED. For SP Programming the value is the segment number for which the event applies.

ALARM 1 SETPOINT 2 VALUE - This is the value at which you want the alarm type chosen in Prompt "A1 S2TYPE" to actuate. The details are the same as "A1S1 VAL".

ALARM 2 SETPOINT 1 VALUE -This is the value at which you want the alarm type chosen in Prompt "APSITYPE" to actuate. The details are the same as "A1 S1 VAL".

ALARM 2 SETPOINT 2 VALUE - This is the value at which you want the alarm type chosen in Prompt "A2S2TYPEU to actuate. The details are the same as "A1S1 VAL".


Table 4-10 Alarms Group Definitions, continued



parameter Definttion

ALARM 1 SETPOINT 1 TYPE - Select what you want Setpoint 1 of Alarm 1 to represent. It can represent the Process Variable, Deviation, lnput 1, lnput 2, Output, and if you have a model with communications, you can configure the controller to alarm on SHED. If you have setpoint programming, you can alarm when a segment goes ON or OFF.

NO ALARM INPUT 1 INPUT 2 PROCESS VARIABLE DEVIATION OUTPUT (cannot be used with Position Proportional or 3 Position Step control) SHED FROM COMMUNICATIONS EVENT ON (SP PROGRAMMING) EVENT OFF (SP PROGRAMMING)

ALARM 1 SETPOINT 2 TYPE - Select what you want Setpoint 2 of Alarm 1 to represent. The selections are the same as A1 S1TYPE.

ALARM 2 SETPOINT 1 TYPE - Select what you want Setpoint 1 of Alarm 2 to represent. The selections are the same as A1 SlTYPE.

NOTE: Not applicable with Relay Duplex or Position Proportional outputs.

ALARM 2 SETPOINT 2 TYPE - Select what you want Setpoint 2 of Alarm 2 to represent. The selections are the same as A1 SITYPE.

NOTE: Not applicable with Relay Duplex or Position Proportional outputs.

ALARM 1 SETPOINT 1 STATE - Select whether you want the alarm type chosen in Prompt "A1S1TYPEW to alarm High or Low or the beginning or end of a segment in setpoint RamplSoak programming.

HI ALARM LO ALARM BEGIN (SP PROGRAMMING) END (SP PROGRAMMING)


A1 S1TYPE

A1 S2TYPE

ASS1 TY PE

A2S2TYPE

A1S1 H L

A1S1 EV

UPPef' D i m Range of Setting

or Select Ion

NONE IN 1 IN 2 PV DEV OUTPUT

SHED EV ON EV OFF

Same as A1 S1 TYPE

Same as A1S1 TYPE

Same as AlS1 TYPE

H LO BEGIN END


Table 4- 10 Alarms Group Definitions, continued

10/92 UDC3000 Product Manual 7 7

Parameter Definlion

ALARM 1 SETPOINT 2 STATE - Select whether you want the alarm type chosen in Prompt "A1S2TYPEW to alarm High or Low or the beginning or end of a segment in setpoint RampISoak programming.


ALARM 2 SETPOINT 1 STATE - Select whether you want the alarm type chosen in Prompt "A2SlTYPE" to alarm HlGH or LOW or the beginning or end of a segment in setpoint RampISoak programming.


ALARM 2 SET POINT 2 STATE - Select whether you want the alarm type chosen in Prompt "A2S2TYPEW to alarm HlGH or LOW or the beginning or end of a segment in setpoint RampISoak programming.


ALARM HYSTERESIS -A single adjustable hysteresis is provided on alarms such that when the alarm is OFF it activates at exactty the alarm setpoint; when the alarm is ON, it will not deactivate until the variable is 0.0% to 5.0% away from the alarm setpoint.

Configure the hysteresis of the alarms based on INPUT signals as a % of input range span.

Configure the hysteresis of the alarm based on OUTPUT signals as a % of the full scale output range.


A1S2 H L

A1S2 EV

A2S1 H L

A2S1 EV

A2S2 H L

A2S2 EV

AL HYST

upper D w Range of Setting

or Selection

HI LO BEGIN END

HI LO BEGIN END

HI LO BEGIN END

0.0 to 5.0% of span or full output as appropriate

lntFoductkn The prompts used here are for field calibration purposes. Refer to Section 7 - Cdibration in this manual for complete information.

Status Test Data

The prompts used here are for determining the reason for a controller failure. Refer to the Section 9 - Troubleshooting in this manual for complete information.


Section 5 - Operation

Overview

Introduction This section gives you all the infomation necessary to monitor and operate your controller. Review the Operator Interface shown in "Monitoring" to make sure you are familiar with the indicator definitions. The key functions are listed in Section 1 - Overview.

WhaYs in thissectkn? This section contains the following topics:

--


ToPk

How to Power Up the Controller

How to Enter a Security Code

Monitoring Your Controller Operator Interface Decimal Point Position Viewing the Operating Parameters Diagnostic Error Messages

Start-up Procedure

Operating Modes Definitions Changing Operating Modes Selecting Manual or Automatic Position Proportional Backup Mode

Setpoints Selecting the Local Setpoint Source Changing the Local Setpoint Enabling the Remote Setpoint Switching between Setpoints Setpoint Selection Indication Setpoint Ramp Rate

Single Setpoint Ramp Configuring the Ramp Running the Ramp

Using Two Sets of Tuning Constants

Alarm Setpoints

Three Position Step Control Algorithm

Digital Input Option (Remote Switching)

Adaptive Tune Configuration Start-up mode SP Adapt Re-tuning Error Codes

See Page

8 0

82

8 3 8 3 83 84 8 5

86

87 87 87 88 89

9 0 90 90 9 1 9 1 9 2 92

93 93 94

96

99

100

101

102 103 104 105 106 106

How to Power Up The Controller

When power is applied, the controller will run three diagnostic tests. All the displays willlight and then the controller will go into automatic mode.

Diagnostic tests

Test failures

Troubleshooting

Table 5- 1 lists the three diagnostic tests.

Table 5- 1 Power Up Diagnostic Tests

If one or more of these tests fail, the controller will go to the Fail-safe Manual Mode, and "FAILSAFE will flash in the lower display.

Prompt on Lower Display

WAFI TEST

COnFTEST

CAL TEST

If the output type is Position Proportional, and AUTO-CAL has never been done, a prompt "CALMTR" will appear suggesting that the controller be calibrated

Condition

Check RAM

Check Non-volatile memory

Check Calibration

Refer to "STATUS TESTS" in Section 9 - Troubleshooting to identify and c o m t the problem.



How to Power Up The Controller, Continued

Check the displays and Use the procedure in table 5-2 to run the display and key test. keys

Table 5-2 Procedure for Testing the Displays and Keys

I Press I Resul I

and hold in,

at the same time

The controller will run a display test. All the displays will light for 8 seconds, then the displays will look like this:

Upper Display p z F l Lower Display

I TRY R L I

Press each key to see a it works

When the key is pressed, the lower display will indicate the name of the key pressed.

If no key is presses for 20 seconds, the test will time out and the controller will go into control mode.

If any test fails, go to "Controller Failure Symptoms" in Section 9 - Troubleshooting.

Key error When a key is pressed and the prompt "KEY ERROR appears in the lower display, it will be for one of the following reasons:

parameter not available, not in Set Up mode, press [SET UP] key first, Key malfunction, do keyboard test.


Enter a Security Code

Introduction The LOCKOUT feature in the UDC3000 is used to inhibit changes (via keyboard) of certain functions or parameters by unauthorized personnel. There are different levels of LOCKOUT depending on the level of security required. These levels are:

NONE CALIBRATE +COW +VIEWING MAXIMUM

See Section 4 - Confguration Definitions for details.

Security code numbers The level of keyboard lockout may be changed in the Set Up mode. However, knowledge of a security code number (1 to 4095) may be required to change from one level of lockout to another. When a controller leaves the factory, it has a security code of 0 which permits changing from one lockout level to another without entering any other code number.

Procedure If you require the use of a security code, select a number from 001 to 4095 and enter it when the lockout level is configured as "NONE. Thereafter, that selected number must be used to change the lockout level from something other than "NONE.

configuration section so you will have a permanent record.

Use the procedure in Table 5-3 to enter a security code.


Table 5-3 Procedure for Entering a Security Code

Actbn

Until yousee Upper Display

Lower Display

piq Until you see

Upper Display

m Lower Display

-1 to enter a four digit number in the upper display (I to 4095)

This will be your security code.

*

Step

1

2

Press

I] A 0

Monitoring Your Controller

Operator Interface The indicators and displays on the Operator Interface let you see what is happening to your process and how the controller is responding.

Figure 5-1 is a view of the Operator interface. A description of the displays and indicators is included.

Figure 5- 1 Operator Interface

Upper Display - Six Characters Normal Operation - four digits dedicated to display the process variable Configuration Mode - displays parameter value or selection

Lrma Ohplay - eight characters Normal Operation - displays operating parameters and values Configuration Mode - displays function groups and parameters

Indicator definition when lit MAN and A off - communications option active

MAN - controller in manual mode A - controller in automatic mode F - "Fahrenheit being used C - "Centigrade being

Indicator definition when lit

ALM - Alarm conditions exist

Dl - Digital Input

RSP - Remote SP or SP2 acti OUT - Control Relay 1 or 2 on

center bar indicates PV is within f 1% of setpoint

Next bar will light if PV is between f 1% but less than f 2% in deviation

If PV is equal to or greater than f 10% deviation, the center bar plus all ten deviation bars will light

Decimal point position In each display, when no decimal place is configured, the right-most character is blank. When a single decimal position has been configured and values greater than 1000 are displayed, the right-most character is blank but the decimal point will be lit.



Monitoring Your Controller, continued

Vlewing the operating parameters Press the key to scroll through the operating parameters listed in

table 5-4. The lower display will show only those parameters and its value that apply to your specific model and the way in which it was configured.

Table 5-4 Lower Display Key Parameter Prompts

** You can p ~ s s A or V to change the value of this parameter.

SP * *

2SP * *

RSP

2 1n

dEU

ZZRFIXX .XX

ZZSZXX .XX

PldSETX * *

OUT * *

CSP

S P ~

PI35


-ptm

Local Setpoint 1

Local Setpoint 2 (where remote setpoint does not apply)

Remote Setpoint (when available)

Input 2

PV deviation from setpoint (5999.9 maximum)

Time remaining in Setpoint Ramp ZZ = Segment Number XX .XX = HWMinutes

Time remaining in Setpoint Soak ZZ = Segment Number XX .XX = HWMinutes

Tuning Parameter Set X=1 or 2

Output Value in Percent (%); also 3PStep estimated motor position when no slidewire exists

Computer Setpoint (when setpoint is in override)

Setpoint Now (for setpoint rate)

3 Position Step motor position when slidewire is connected


Monitoring Your Controller, c o w

The UDC3000 perfoms background tests to verify data and memory integrity. If there is a malfunction, an e m r message will be displayed. In the case of more than one simultaneous malfunctions, only the one with the highest priority will appear on the lower display.

A list of error messages is contained in table 5-5. If any of these error messages occur, refer to Section 9 - Troubleshooting for information to correct the failure.

Table 5-5 E m r Messages

-


prompt

EE FRlL

FR I LSRFE

InBlFRlL

! PPZFR I L

SW FAIL

EElF ERR

cnec r in~

InPZ RflG

BU LIPIIT

RU LcPIIT

M p t h

Unable to write to non-volatile memory

Failsafe

Two consecutive failures of input 1 integration

Two consecutive failures of input 2 integration

Position Proportional slidewire input failure

Low limit greater than high limit for PV, SP, Reset or Output

Input 1 out-of-range Linear: +lo% out-of-range Characterized: f 1 O/O out-of -range

Input 2 +lo% out-of-range

PV *lo% out-of-range

Remote Variable out-of-range Note: RV = (input 1 x ratio) + bias

Start Up

Procedure The Start-up procedure is given in table 5-6. Table 5-6 Procedure for Starting Up the Controller

I Step I Opewon I Press I Action I Select manual I mode 1 1 wo I

controller + 2

until "MAN" indicator is ON. The controller is in manual mode.

to adjust the output value and ensure that the final control element is functioning correctly. Upper Display

-shows the PV value Lower Display

-shows OUT and the output value in %.

Adjust the output

Make sure the controller has been configured properly and all the values and selections have been recorded on the Configuration Record Sheet.

A t

To tune your controller manually, see Section 11 - Appendix B Refer to Set Up group 'TUNING" to ensure that the proper selections for PROP BD or GAIN, RATE MIN, and RSET MIN or RSET RPM have been entered.

For controllers with ADAPTIVE TUNE, see the procedure in this section.

Upper Display

-shows the PV Value

Lower Display

)SP and the local setpoint value

To adjust the local setpoint to the value at which you want the process variable maintained.

The local setpoint cannot be changed if the Setpoint Ramp function is enabled. "H" or "R" appears in the upper display.

Select Automatic Mode

until " A indicator is ON. The controller is in Automatic mode.

The controller will automatically adjust the output to maintain the process variable at setpoint, if the controller is


Operating Modes

AvaiWle modes The controller can operate in any of three basic modes: 6 Manual 6 Automatic with Local Setpoint

Automatic with Remote Setpoint Manual and Automatic with Local set point are standard features and Automatic with Remote Setpoint is optional.

Mode definitions Table 5-7 lists the three modes and their definitions. Table 5-7 Operating Mode Definitions

What happens when Table 5-8 explains what happens to the controller when you switch from you change modes one mode to another.

Table 5-8 Changing Operating Modes

Operating Mode

MANUAL

AUTOMATIC with LOCAL SETPOINT

AUTOMATIC with REMOTE SETPOINT

Definition

When switched to manual mode, the controller holds its output at the last value used during automatic operation and stops adjusting the output for changes in setpoint or process variable. Instead, you adjust the output by changing the value shown in the lower display. See "Selecting Modes".

In automatic local mode, the controller will operate from the local setpoint and automatically adjust the output to maintain the setpoint at the desired value. In this mode you can adjust the setpoint. See "Setpoints".

In automatic remote mode, the controller will operate from the setpoint measured at input 2. Adjustments are available to ratio this input and add a constant bias before it is applied to the control equation. See Section 3 - Configuration. Set up group "Control".


Mode Change

Manual to Automatic Local Setpoint

Manual or Auto Local to Automatic Remote SP

Automatic Remote SP to Manual or Auto Local Setpoint


Description

The local setpoint is usually the value previously stored as the local setpoint. PV Tracking is a configuaable feature which modifies this. Wheh it is selected, the local setpoint value tracks the process variable value continuously while in manual. LSP=PV at the moment you switch from manual to automatic. LSP holds at this one value.

The second Input value with Ratio and Bias applied is used to calculate the control setpoint.

If configured for Local Setpoint Tracking, when the UDC transfers out of remote setpoint, the last value of the control setpoint is inserted into the local setpoint. If LSP tracking is not configured, the local setpoint will not be altered when the transfer is made.

Operating Modes, continued

Selecting Manual or An alternate action switch places the controller in Automatic or Manual Automatkmode mode of operation.

Switching between manual and automatic will be bumpless, except when PD+MR algorithm is selected. Table 5-9 includes procedures for selecting automatic or manual mode and changing the output while in manual.

Table 5-9 Procedure for Selecting Automatic or Manual Mode


~ ~ ~ 3 0 0 0 Product Manual 1 0192

Actbn

until " A indicator is ON. The controller regulates its output to maintain the PV at the desired setpoint.

Upper Display

-shows the PV value Lower Display

shows SP and the setpoint value

The deviation bargraph indicates the PV deviation from the setpoint.

until "MAN" indicator is ON. The controller holds its output at the last value used during automatic operation and stops adjusting the output for changes in setpoint or process variable.

Upper Display

I shows the PV value Lower Display

-shows OUT and the output value in (%).

The deviation bargraph indicates the PV deviation from the setpoint.

to adjust the output value while in manual mode. Upper Display

s h o w s the PV value Lower Display

-shows OUT and the output value in %.

The "A" indicator will appear indicating Automatic mode.

Press

rn

El

+

Step

1

2

3

4

-

Operation

Selecting Automatic Mode

Selecting Manual Mode

Adjust the Output in Manual Mode

Return to Automatic Mode

Operating Modes, Continued

Position Proportional This feature provides for Position Proportional models to automatically Backup- change to a Three Position Step algorithm if the slidewire input signal fails.

This will maintain control of your process. "IN2 RNG or "SWFAIL" will flash in the lower display and the b'OUT" display will show a estimated motor position WITHOUT a decimal point.


Setpoints

Introduction

Selecting the local seapolnt source

Changing the kacai setpoints

You can configure the following setpoints for the UDC3000 controller. A single local setpoint 2 local setpoints A local setpoint and a remote setpoint (Remote setpoint is an option)

These setpoint can be toggled by the [SETPOINT/SELECTJ key.

Use the procedure in table 5-10 to select a single local setpoint source or two local setpoints. Table 5-10 Procedure for Selecting the Local Setpoint Source

Use the procedure in Table 5-1 1 to change either of the local setpoint value.

Table 5-1 1 Procedure for Changing the Local Setpoints

Step

1

2

3

4


Operatbn

Enter Set Up mode

Display Local Setpoint Source selections

Select the desired source

Return to control

Press Action

until the displays read:


Fl

1(L

i

Step

1

2

Lower Display p E i K ]

until the displays read: rprDisq

Setpoint source selections

Lower Display 1 LOCAL 2 LOCAL

to select the desired setpoint source in the upper display.

The controller will assume normal control.

Operatbn

Enter Auto mode

Change the value

Press Action

until "A" indicator is

1(L

Upper Display

[-* The PV value

Lower Display SF or ZSP and the local setpoint value

Press [Lower Display] key to select SP or 2SP

to change the local setpoint to the value at which you want the process maintained. The deviation bargraph indicates PV deviation from setpoint.

Setpoints, Continued

Enabling (or disabling) Use the procedure in Table 5- 12 to enable the remote setpoint s o w a as the remote set Point Input 2.

Table 5-12 Procedure for Enabling (or disabling) the Remote Setpoint

I Step I Operation I Press I Actbn

Select Set Up Group

Until vou see:

Lower Display

~--rmZq Select the Until you see: Remote I"crn.1 upper Display Setpoint The Remote Source Prom~t - Setpoint source I ,;y TI selection

n3nE - not used

Change selection

to enable or disable the remote setpoint.

i Return to normal operation

This will return the controller to normal operation.

Swltchlng between You can switch between Local and Remote setpoints or between two Local setpoints setpoints when configured. Use the procedure in Table 5- 13 to switch

between setpoin ts.

Table 5-13 Procedure for Switching Between Setpoints



Step

1

2

Press

i

Operatbn

Switch between Setpoints

Change the Local setpoint value

Action

This will alternately select Local setpoint 1 and Remote setpoint or switch between the 2 Local Setpoints.

"KEN ERROR" will appear in the lower display if the remote setpoint or 2nd local setpoint is not configured as a setpoint source, or if you attempt to change the setpoint while a setpoint ramp is enabled.

The REMOTE setpoint cannot be changed at the keyboard.

Setpoints, Continued

Setpolnt selection indication

Table 5-14 shows how the indicators react and what the displays show for each type of setpoint.

Setpoint Rate

Configuration

Table 5-14 Setpoint Selection Indication

Operation

You can confiure a Setpoint Ramp Rate that will apply to any Local setpoint change immediately. Refer to the Configuration Section to enable the ramp and set an upscale or downscale rate value. Make sure SP RAMP and SP PROG are disabled

Using 2nd Local Setpoint

ON

PV

582 and the 2nd Local Setpoint Value

RSP Indicator

Upper Display

Lower Dhpky

When a Local setpoint change is made, the controller will ramp from the original setpoint to the new one at the rate specified. This changing (current) setpoint can be viewed on the lower display. - Press the -Uv key until you see SPn and the setpoint value in the lower

Uslng Local setpoint

OFF

PV

SP and the Local Setpoint Source

display.

Using Remote Setpoint

ON

PV

RSP and Remote Setpoint Value


Single Setpoint Ramp

Conflgurlng the You can configure a single setpoint ramp to occur between the current local =mint ramp setpoint and a final local setpoint over a time interval of from 1 to 255

minutes. You can RUN or HOLD the ramp at any time.

Procedure Table 5-15 lists the procedure for configuring the Setpoint Ramp parameters. The procedure for SP Promam is in Section 6 - Setpoint Programming Option. Table 5-15 Procedure for Configuring a Setpoint Ramp

Continued on next page \


Action Until you see: Upper Disday

1-1 Lower Display

EEiEl Until you see:

,U;T-,

Lower Display

p=q I Until you see:

Upper Display p E z q Lower Display

p - E i s q NOTE: You cannot change the current local setpoint if the setpoint ram function is enabled. Make sure !!P RATE and SP PROG are disabled. Until you see: Upper Display r+ The ramp time

in minutes Lower Display I n i n )

-

to change the upper display value to the number of minutes in which you want the final setpoint to be reached. Setting Range = 1 to 255 minutes NOTE: Entering " 0 will imply an immediate step change to the final SP. Upper Display

The ~ i n a l Setpoint value

Lower Display ~~~ to change the upper display value to the desired final setpoint value. Setting Range = within the setpoint limits

Press

I

mruzm

IRwcmw)

A

Step 1

2

3

4

5

6

Operatkn Select SP RAMP Set Up Group

Select the Setpoint Ramp function

Enable Setpoint Ramp

Set the Ramp Time

Set the Final Setpoint value

Single Setpoint Ramp, C o R i W

Running the setpoint Running a Setpoint Ramp includes starting, holding, viewing the ramp ranP time, ending the ramp and disabling it.

Procedure Table 5-16 lists the procedure for running the Setpoint Ramp. Table 5-16 Procedure for Running a Setpoint Ramp

Procedure continued on nexf page


Action !3tep

1

2

3

4

5

Operation Press

Putthe controller into Automatic mode

Set Start SP

Start the Ramp

Hold the Ramp at the current value

View the remaining ramp time

until "A" indicator is ON and you will see:

H and the PV value Lower Display

SP and the present setpoint value

until the start setpoint value you desire is indicated in the lower display: Upper Display

H and the PV value

Lower Display

SP and the start setpoint value

You will see: Upper Display

FI

R and the PV value

Lower Display

SP and a changing setpoint value

NOTE: The value in the lower display will be increasing or decreasing toward the final setpoint value. The PV value in the upper display will also change.

This holds the ramp at the current setpoint value.

Press again to continue run.

A "KEY ERROR" prompt will appear if [RUNIHOLD] key is pressed while "SP RAMPw is disabled.

Until you see: upper Display

R or Hand Lower Display the PV value

I-+RR~P n x m (Time remaining)

Single Setpoint Ramp, Continued

Procedure, continued Table 5-16 Procedure for Running a Setpoint Ramp, continued


Step

6

7

8

Operatbn

End the Ramp

Disable the setpoint ramp function

Return to normal operating mode

Press

F]

Action

When the final setpoint is reached, the "R" changes to "H" in the upper display and the controller operates at the new setpoint.

Anytime the local setpoint is different from the final setpoint value and the [RUNIHOLD] key is pressed -the ramp will start again.

Until you see:

,U~;DF]

Lower Display

I2zEzI You will see:

Lower Display

[ - zz=q Until you see: Upper Display ITGGq Lower Display

)pxiy

Using Two Set of Tuning Constants

introduction You can use two set of tuning constants for single output types and choose the way they are to be switched The sets can be:

Keyboard selected Automatically switched when a predetermined Process Variable value is reached. Automatically switched when a predetermined Setpoint value is reached.

The following procedures show you how to: Select two sets Set the switch-over value Set tuning constant value for each set Switch between two sets via the keyboard (without automatic switch-

over)

Select two sets The procedure in Table 5-17 tells you how to select two sets. Table 5-17 Procedure for Selecting Two Set of Tuning Constants



Step Press Operation Action

1

2

Select Control Until you see:

Select PID SETS function F)

i

Lower Display p m K - I

Until you see: Upper Display

[-+ Av;;;;h.; ~eiions Lower Display

1 ONLY - 1 set of constants 2 KEYBD - 2 sets, keyboard selectable 2 PVSW - 2 sets, auto switch at PV value 2 SPSW - 2 sets, auto switch at SP value

to select the type of PID SET.

Using Two Set of Tuning Constants, Continued

Set switchover value If you select 2 PVSW or 2 SPSW, you must set a value at which the sets will switch over. The procedure in Table 5-18 shows you how to set this value. Table 5-18 Procedure for Setting Switchover Values

switchover value.

Step

1

--

Set Tuning constant There are specific tuning constant that must be set for each set. The values for each set procedure in Table 5-19 shows you how to access these constants and

change their values. Table 5-19 Procedure fur Setting Tuning Constant Values


Press

FI assuming you am still in Set

UP QrwP .CONTROL"

i

Operatkn

Select Switchover value function


Actian


;;;e~~itch~ver

Lower Display

to select the switch-over value.in the upper display.

J

Step

1

2

'PIDSETl switchover value. "PIDSET2 -will be used when PV or SP, whichever is selected, is laSS than the

Press

Fl

FU- CI

i PV or SP,

Operatkn

Select Tuning set up Group

Select the tuning constants

-will be used when

~ction

Until you see:

r r w ; D p ,

Lower Display p c q to successively display the following constants: Upper Display -;:wing constant

Lower Display

PROP BD or GAIN* RATE* RSET' PROP BD2 or GAINr* RATE 2" RSET2"

To change the value of any of the above listed prompts in the lower display.

whichever is selected, is than the

Using Two Set of Tuning Constants, Continued

Switch between two This p d u r e is operational only if 2 PID SETS was configured at sets the ke-rd "CONTROL" set up group. (withwtautomatic switckover) The procedure in Table 5-20 shows you how to switch from one set to

another. Table 5-20 Procedure for switching PID SETS from the Keyboard

I step 1 Operation I press I Action I 1 Access the PID I / set display 1 El 1 Until you see:

Upper Display 1 - 7 - The PV value

Lower Display 1 X=lor2

to change PID SET 1 to PID SET 2 or vice versa.

I I YOU can use Adaptive Tune on each set. 1


Alarm Setpoints

An alarm consists of a relay contact and an operator interface indication. The alarm relay is de-energized if Setpoint 1 or Setpoint 2 is exceeded. The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis. The relay contacts can be wired for normally open (NO)-energized or normally closed (NC)-de-energized at the rear terminals. See Section 2 - Installation (Table 2-4) for alarm relay contact information. There are four alarm setpoints, two for each alarm. The type and state (High or Low) is selected during configuration. See Section 3 - Configuration for details. The procedure for displaying and changing the alarm setpoints is listed in Table 5 -2 1.

Procedure for displaying the abnn setpoints

Table 5-21 Procedure for Displaying or Changing the Alarm Setpoints

10/92 UDC3000 Product Manual 9 9

I

Step

1

2

3

Operation

Access the Alarmset Up group

Access the Alarm Setpoint Values

Return to normal operation

Press

)I

Fl DtSPLAY

Action

Until you see:

;g;~i$v, Lower Display

E E c l to successively display the alarm setpoints and their values. Their order of appearance is shown below. Upper Display I+ The alarm setpoint

value

A1S1 VAL = (Alarm 1, Setpoint I value) A1 S2 VAL = (Alarm 1, Setpoint 2 value) A2S1 VAL = (Alarm 2, Setpoint 1 value) A2S2 VAL = (Alarm 2, Setpoint 2 value)

to change any alarm setpoint value you select in the upper display.

Three Position Step Control Algorithm

JnVoductlon The Three Position Step Control algorithm allows the control of a valve (or other actuator) with an electric motor driven by two controller output relays; one to move the motor upscale, the other to move it downscale, without a feedback slidewire linked to the motor shaft.

Estimated motor The Three Position Step control algorithm provides an output display WRion ("OUT") which is an estimated motor position since the motor is not using

any feedback. Although this output indication is only accurate to a few percent, it is corrected each time the controller drives the motor to one of its stops (0% or 100%). It avoids all the control problems associated with the feedback slidewire (wear, dirt, noise). When operating in this algorithm, the estimated "OUT" display is shown to the nearest percent (i.e. no decimal).

Accurate motor position In the event that an accurate and repeatable indication in motor position is required, Position Proportional model's slidewire input can be used to read the motor position and display it on the lower display as "POS" while still operating in the Three Position Step control mode.

Displaying the motor Table 5-22 list the procedure for displaying the motor position. posRlon

Table 5-22 b e d u r e for Displaying the 3PSTEP Motor Position


Action Step

1

Operation Press

Access the displays

Until you see:

The PV value Lower Display

POS = 3PStep motor position with slidewire connected or OUT = Estimated 3PStep motor position when no slidewire exists

Digital lnput Option (Remote Switching)

Introduction The Digital Input option detects the state of external contacts for either of two inputs. On contact closure, the controller will respond according to how each digital input is configured. Make your selection under Set Up group "OPTION, function group prompt "DIG INl" or "DIG IN2". See Section 3 - Configuration for details.

Action on closure Table 5-23 lists the configuration prompt selections, the "Action on Closure", and the display indication for each selection available.

Table 5-23 Digital Input Option Action on Contact Closure

'The Digital lnput Annunciator will always show the Digital lnput status.

Keyboard operation If a particular mode or parameter is selected by the contact closure, using the keyboard to select the same parameter will ensure that the selected mode will be maintained after the remote digital switch is re-opened.

Action on contact closure*

No Digital Input selection

Puts the controller into manual mode Contact open returns the controller to former mode unless [AUTOIMAN] key is pressed while digital input is active.

Puts the controller into local setpoint 1. When contact opens, the controller returns to former operation, local or remote setpoint, unless the [SETPOINTISELECT] key is pressed while digital input is active.

Puts the controller into local setpoint 2.

Selects direct controller action.

Suspends setpoint program or setpoint ramp. Contact open runs the program or ramp.

Selects PID2

Selects the PV to equal Input 2.

Starts a stopped SP Program.

Resets the Setpoint Program back to the beginning of the first segment in the program. The output goes to failsafe, manual mode.

Disable PID (I) Integral action.

Enables adaptive tune process.Opening contact aborts the current Adaptive Tune process.

Unit goes to Manual Mode, output goes to the Failsafe value.

DIG IN1 or DIG IN2 selections

None

To MAN

To LSP

To 2SP

To DIR

ToHOLD

ToPID2

PV 21N

To RUN

ToBEGN

STOP I

EN ADT

MANFS


Display lndicatbn

Dl 1 2 always off*

"MAN" blinks

"RSP BLOCK" blinks

None

"H" blinks

PID2 in lower display

"R" indicator blinks

Adaptive Tune (Accutuney

Introduction Adaptive Tune will continually adjust the Gain or Proportional Band (P), Rate (I), and Reset Time @) tuning constants in response to setpoint changes. Adaptive Tune handles all Local and Computer Setpoint changes.

Adaptive Tune uses time domain analysis, and the rule based expert system techniques to identify the two most dominant process lags plus any dead time. It then automatically readjusts the PID parameters as necessary. It does this while controlling to setpoint in automatic (closed loop) control mode. These calculated PID values can be changed, if desired, by disabling Adaptive Tune and entering different values.

Setpoint changes During start-up, or whenever the setpoint changes, Adaptive Tune employs time domain analysis to tune the process at any desired setpoint without any prior initialization or process knowledge.

Rules and regulations The following is a list of rules and regulations for Adaptive Tune. Adaptive Tune:

can tune on all Local or Computer setpoints will work only for algorithms PID-A or PID-B selections is done in automatic mode can be monitored or reconfigured over Honeywell's communication network can be disabled via Digital Inputs or Logic Gates.



Adaptive Tune (Accutuney, continued

Procedure

Before starting Adaptive Tune you must enable the Adaptive Tune feature set the minimum value of setpoint change in % of span that will result in re-tuning.

Use the procedure in Table 5-24 to configure these items. Table 5-24 Procedure for Configuring Adaptive Tune Parameters


lot92 UDC3000 Product Manual 103

Action

Until you see: [ t t r Display

=ET LIP

Lower Display

[RclFIPTl

You will see:

r p p e r y ! DISABLE,

Lower Display SP ONLY piEiiZ.1 DISABLE - Adaptive Tune disabled SP ONLY - Adaptive Tune will occur on

setpoint changes only

until the desired selection appears in the upper display.

until you see Upper Display

Flange: Lower Display k5 5%

-1 Of pv Wan

This is the minimum setpoint chanje value on which re-tuning will occur.

Example: If the range is 0 to 2000, and 5% is configured here, re-tuning will occur if the setpoint change is 100 or larger.

until the desired range appears in the upper display.

Press

Fl

i F]

Step

1

2

3

Operation

Select Adaptive Tune Set Up Group

Select the type of Adaptive Tune

Enter the setpoint change value

Adaptive Tune (AccutuneTM), Continued

Configuration, continued

Table 5-24 l?rocedure for Configuring Adaptive Tune Parameters, continued

Start-up mode At start-up, SP ADAPT tuning is used. The procedure for start-up is listed in Table 5-25. Table 5-25 Procedure for Using Adaptive Tune at Start-up

Actkn


Flange: Lower Display Oaol

I E I The Process Gain Value is normally a READ only value. It should only be changed if the controller fails to identify the process. In this case, set the value to the algebraic value of PV in percent, divided by output in percent, as displayed while in manual mode.

until the desired range appears in the upper display.

- Step

4


Step

1

2


Operation

Verify or change the process Gain value

Press

IRKm.I

t

Action

Until the MAN indicator is ON. YOU will see: Upper Display

the PV value

Lower Display

p7-EE-q to adjust the output value in the lower display, so that the PV lines out at least 10% of PV range and much lower than the normal setpoint setting.

Allow the PV to stabilize (stop changing). Depending on the response time of the process, you may have to wail a while for the PV value to line out. Watch the displays for a stable condition.

Operatbn

Put the controller into manual mode

Let PV stabilize

Press

1

A


Start-up mode, Table 5-25 Procedure for Using Adaptive Tune at Start-up, continued continued

SP ADAPT (after Start-up)

SP ADAPT will occur whenever the controller is in automatic mode and a setpoint change occurs which is greater than the previously configured minimum setpoint change value. The controller will delay using any setpoint changes for 30 seconds to enable it to calculate whether to "SP ADAPT" or not. But, if the controller is toggled between LSP1 and LSP2 or if any other key (such as LOWER/USPLAY) is pressed, the setpoint change is immediate. A bg:e "T' is displayed in the upper display whenever SP ADAPT mode is in progress.

Step 3

4


Operatbn Adjust the setpoint

Start SP ADAPT tuning

Press Actbn Until you see:

the PV value


A

Lower Display

m to adjust the setpoint value in the lower display to the desired setpoint at which you plan to operate after Adaptive Tune

The controller will switch to automatic mode and the process will stan to move toward the setpoint and will line out with the proper tuning constants. A large '7" appears on the left side of the upper display to indicate that (SP ADAPT) Adaptive tune is in progress. You will see: Upper Display

the PV value

Lower Display

the setpoint value


Re-Tun i ng The controller will evaluate current tuning as SP changes occur. When re- tuning is required, the controller operates in automatic mode controlling to new "intermediate" tuning constants until PV lines out within approximately 0.2% span of SP. At that point, the '"I"' disappears and "Final" tuning values are entered and used until re-tuning occurs again. The controller never goes into manual and does not bump the output to evaluate tuning requirements. Note that if re-tuning was not required, no changes will be made; but, the "T" will still occur to indicate that Adaptive Tune algorithm is measuring the process response.

Error code accessing When an error is detected in the Adaptive tune process, the message "AT procedure ABORT" will appear in the lower display.

Access function prompt "AT ERROR" to determine what is causing the error. This procedure is listed in Table 5-26.

Table 5-26 Procedure for Accessing Adaptive Tune Error Codes



Actbn

Until you see: UP^ Display, ST UP

Lower Display

pzEiiq You will see: / P W ~ D~sP$

An error code

Lower Display

-1 Table 5-27 lists all the Adaptive tune error codes and their definitions.

Press

Fl Step

1

2

Operatbn

Select Adaptive Tune Set Up Group

Go to Emr Code prompt

Adaptive Tune (Accutuney, Continued

Emr codes Table 5-27 lists the Adaptive Tune error codes and their definitions.

Table 5-27 Adaptive Tune E m Code Definitions

NONE

OUTUM

IDFAIL

ABORT


Code Definitbn

ADAPTIVE TUNE ERROR STATUS - When an error is detected in the Adaptive Tune process, an error prompt will appear.

NO ERRORS

OUTPUT GREATER OR LESS THAN OUTPUT LIMITS - Output set insufficiently to get Setpoint value.

IDENTlFlCATlON PROCESS FAILED - An illegal value for Gain, Rate, or Reset was calculated

CURRENT ADAPTIVE TUNE PROCESS ABORTED - caused by one of the following conditions: changing to manual mode Digital input detected In heat region of output and a cool output calculated or vice versa.


AT ERROR

Upper D m E m Code

Section 6 - Setpoint Ramp/Soak Programming Option

Overview

What is progmming? The term "programming" is used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required setpoint versus time profile (also called a program).

A segment is a ramp or soak function which together make up a setpoint program. Setpoint Ramp/Soak Programming lets you configure 6 ramp and 6 soak segments to be stored for use as one program or several small programs. You designate the beginning and end segments to determine where the program is to start and stop.

Review program data While the procedure for programming is straightforward, and aided by and wnflguration prompts, we suggest that you read "Program Contents" in this section as

well as "Section 3 - Conj?guration" before doing the setpoint programming.

Fill out the woksheet Draw a Ramp/Soak Profile on the worksheet provided and fill in the information for each segment. This will give you a record of how the program was developed.

What's in this sedbn The table below lists the topics that are covered in this section.


Topic

Program Contents

Drawing a RampISoak Profile Example Program Record Sheet

Entering the Setpoint Program Data Introduction General Procedure Alarms on setpoint programs Prompt Hierarchy and selections

Running the Program Introduction RunJMonitor Functions

Set the Local Setpoint Run State Hold State External Hold External Program Reset Viewing the present segment number and time Viewing cycles End Program

Power-up State

See Page

109

11 1 111 112

113 113 113 113 114

116 116 116 116 116 116 116 117 117 117 118 118

Program Contents

What you will configure Basically, you will configure all the data that is relevant to each ramp and soak segment for a given setpoint versus time profile. The controller will prompt you through the sequence of segments and associated functions.

Ramp segments A ramp segment is the time it will take to change the setpoint to the next setpoint value in the program. Ramps are odd number segments. Segment #1 will be the initial ramp time. Ramp time is determined in either:

TIME* - Hours:Minutes Range = 0-99hrs:59 min. or

RATE* - DegreesIMinute Range = 0 to 999 * This selection of time or rate is made at prompt "RAMP UNIT"

Set this prompt before entering any Ramp.

Entering "0" will imply an immediate step change in setpoint to the next soak.

Soak segments A soak segment is a combination of soak setpoint (value) and a soak duration (time). Soaks are even number segments. Segment 2 will be the initial soak value and soak time. The soak setpoint range value must be within the setpoint high and low range limits in engineering units. SOAK TIME is the duration of the soak and is determined in:

TIME - Hours:Minutes Range = 0-99hrs:59 min.

Stan segment number This designates the number of the first segment. Range = 1 to 11

End segment number This designates the number of the last segment. It must be a soak segment (even number).

Range = 2 to 12

Recycle number This number allows the program to recycle a specified number of times from beginning to end.

Range = 0 to 99



Program Contents, Continued

Guaranteed Soak Each soak segment can have a deviation value of from 0 to B which guarantees the value for that segment. Guaranteed soak segment values >O guarantee that the segments process variable is within the & deviation for the configured soak time. Whenever the f deviation is exceeded, soak timing is frozen. There are no guaranteed soaks whenever the deviation value is configured to 0, i.e., soak segments start timing soak duration as soon as the soak setpoint is first reached, regardless of where the process variable remains relative to the soak segment. The value is the number in engineering units, above or below the setpoint, outside of which the timer halts. The range is 0 to + 99. The decimal location corresponds to input 1 decimal selection.

Program state

- -- -

This selection determines the program state after completion. The selections are:

DISABL = Program is disabled HOLD = Program on hold

Program tenination This function determines the status of the controller upon completion. state The selections are:

LAST SP = controls to last setpoint and last control mode F SAFE = Manual mode, Failsafe Output

If power is lost during a program, upon power-up the controller will be in hold and the setpoint value will be the setpoint value prior to the beginning of the setpoint program. The program is placed in hold at the beginning.

amp unit This determines the engineering units for the ramp segments. The selections are:

TIME = H0urs:Minutes RATE = Degrees/Minutes


Drawing a RampfSoak Profile

Ramp/Soak Profile example

Before you do the actual configuration, we recommend that you draw a Rarnp/Soak profile in the space provided on the "Program Record Sheet' (Figure 6-2) and fill in the associated information. An example of a Ramp/Soak Profile is shown in figure 6-1.

Figure 6- 1 RarnpISoak Profile Example


- -


Prompt

STRTSEG

END SEG

RECYCLES

SOAK DEV

SEGl W P

SEG2 SP

SEG2llME

SEGBRAMP

SEG4 SP

SEG4llME

- SEGSRAMP

SEG6 SP

SEG6TIME

Prompt

SEG7RAMP

SEG8 SP

SEG8llME

SEGORAMP

SGlO SP

sG10 TIME

SG11RAMP

SG12 SP

SG12llME

STATE

PROG END

RAMP UNIT

Value

1

12

2

0

1 hr.

300

1 hr.:30 min.

1 hr.

400

1 hr.

1 hr.:30 min.

250

3hrs.:Omin.

Functbn

Ramp Time

Soak SP

Soak Time

Ramp Time

Soak SP

Soak Time

Ramp Time

Soak SP

Soak Time

Controller State at end

Controller Status

Engr. Unit for Ramp

Function

Start Seg.

End Seg.

Number of Recycles

Deviation Value

Ramp Time

Soak SP

Soak Time

Ramp Time

Soak SP

Soak Time

Ramp lime

Soak SP

Soak Time

Segment

1

2

2

3

4

4

5

6

6

Segment

7

8

8

9

10

10

11

12

12

Value

2hrs:30min.

500

Ohr.:30 rnin.

0

400

Ohr.:30 rnin.

3hrs:30min.

200

Ohr.:30 rnin.

LAST SP

HOLD

TIME

Drawing a Ramp/Soak Profile, C O W ~ U ~

Pmgrarn Record Sheet Draw your ramp/soak profile on the record sheet shown in Figure 6-2 and fill in the associated information in the blocks provided. This will give you a permanent record of your program and will assist you when entering the Setpoint data.

Figure 6-2 Program Record Sheet I

UDC3000 Product Manual 10/92

Entering the Setpoint Program Data

The procedure listed in table 6 1 tells you what keys to press and what prompts you will see when entering the setpoint program data. Follow the prompt hierarchy listed in table 6-2 when selecting the functions for setpoint programming.

Make sure SP RAMP and SP RATE are disabled first.

Table 6- 1 Setpoint Program Data Entry Procedure

Alarms on the Setpoint You can configure an event to go ON or OFF at the beginning or end of any Program segment. Refer to Section 3 - ConjTguration under "Alarms Parameters

Group" for details.


Result


Press Step Action

1

2

3

4

- 5

Select SP PROG Group

Select the functions

Change the value or selection of a function prompt

Enter Value or selection into memory

Exit configuration

Upper Display

until you see

FI

1

DWPUY

Display

EzEl This accesses the function prompts and enables Setpoint Programming.

-The current value for each prompt is shown

Lower Display

I ~ h e individual function prompts within the setpoint program group are shown.

Successive presses of the [FUNCTION] key will sequentially display all the functions and their values or selections. Follow the prompt hierarchy shown in table 6-2.

This changes the value or selection in the upper display. If the display blinks, you are trying to select an unacceptable value.

This enters the value or selection and goes to another prompt.

Repeat steps 3 and 4 for each function you want to change.

This exits from the configuration mode.

Entering the Setpoint Program Data, Contimed

Table 6-2 lists all the function prompts for Setpoint Program data configuration in the order of their appearance. Follow the procedure in table 6-1 to transfer the data from your setpoint Ramp1Soa.k profile into the controller. All parameters may be changed while the program is disabled or in HOLD. Table 6-2 Prompt Hierarchy and Available Selections

Continued on E t page

prompt

SP RRmP

SP RRTE

SP PROG

STRT SEC

End SEG

RECYCLES

SOAK dEU

SEC; I RRmP or

SEG I RRTE

SEC2 SP

SE[;ZT I l7E

SEG3RRl7P or

SEG3RRTE

SEW SP

SEWT I l7E


Definition

Setpoint Ramp selection

Setpoint Rate of Change

Setpoint RampISoak Programming

Start Segment Number

End Segment Number

Number of Program Recycles

Guaranteed Soak Deviation Value

Segment # l Ramp Time Segment # I Ramp Rate

Segment #t2 Soak Setpoint Value

Segment #t2 Soak Duration

Segment #3 Ramp Time Segment #3 Ramp Rate

Segment #4 Soak Setpoint Value

Segment #4 Soak Duration

1

Value or Selection (use A Or v) Selections: DISABLE SP RAMP must be disabled to allow Setpoint Programming.

Selections: DISABLE SP RATE must be disabled to allow Setpoint Programming.

Selections: ENABLE DISABLE

SP PROG must be enabled to view the remaining prompts.

Enter Value: 1 to 11

Enter Value: 2 to 12 Always end in a soak Segment (2,4 ,..... 12)

Enter Value: 0 to 99 recycles

Enter Value: 0 to ~f: 99 The number selected will be 0 to 99f: from setpoint.

Enter Value: Ramp Time = 0-99hrs:O-59min, or Ramp Rate = 0-999 degreeslmin Select HRS:MIN or DEGlMlN at prompt "RAMP UNIT". All ramps will use the same selection.

Enter Value: Within the Setpoint limits

Enter Value: 0-99hrs:O-59min

Enter Value: Ramp Time = 0-99hrs:O-59min, or Ramp Rate = 0-999 degreeslmin



Entering the Setpoint Program Data, COWW

Promp Hierarchy (continued)

Table 6-2 Prompt Hierarchy and Available Selections, continued


P m P t

SEC;SRAPIP or

SEGSRFITE

SEC6 SP

SEG6T I PIE

SEGlRRI7P or

SEG'IRRTE

SEG9 SP

SEGBT I PIE

SECSRRPIP or

SEGSRRTE

SG 1 0 SP

SG t OT I I7E

SC I I RFlmP or

SC I f RRTE

SC 1 2 SP

SC 1 ZT I I7E

STRTE

PROG End

RRllPUC1 t T

Definition










Segment #11 Ramp Time Segment # I 1 Ramp Rate



Program state at program end

Program Termination State

Engineering units for ramp segments

Value or Selection (use A Or v) Enter Value: Ramp Time = 0-99hrs:O-59min, or Ramp Rate = 0-999 degreeslmin












Selections: DISABLE HOLD(hold mode)

Selections: LAST SP - Hold at last setpoint in the program F SAFE - Manual mode1Failsafe output

Selections: TIME RATE

Run/Monitor the Program

Introduction Make sure all the "SP PROG function prompts under the Set Up group "SP RAMP" have been configured with the required data. An "H" will appear in the upper display indicating that the program is in the H O W state.

Run/Monitor functions Table 6-3 lists all the functions required to run and monitor the program.

Table 6-3 Run/Monitor Functions



Result

You will see Upper Display

I + , L - l Setpoint Lower Display Value

n To set the Local Setpoint value to where you want the program to start out.

Initiates the setpoint program.

An 'R" appears in the upper display indicating that the program is running.

Holds the setpoint program.

An 'H" appears in the upper display indicating that the program is in the HOLD state.

The setpoint holds at the current setpoint.

If Remote Switching (Digital Input Option) is present on your controller, contact closure places the controller in the HOLD state, if the setpoint program is running. The '94" in the upper display will blink.

The keyboard takes priority over external switch for the RUNIHOLD function.

Contact reopening runs program.

Functkn

Set the Local setpoint

Run State

Hold State

Extern81 Hold

Press

RunIMonitor the Program, Continued

RunNonitor functions (continued)

Table 6 3 Run/Monitor Functions, continued



~esuyt

If Remote Switching (Digital Input Option) is present on your controller, contact closure resets the SP Program back to the start of the first segment. Program cycle number is not affected.

Reopening the contact has no effect.

restarts the Setpoint Program

Function

External Program ~eset

press

Viewing the present rarnpor

Segment number and time

V M n g the number of cycles left In the

m-

until you see

until you see

'R" and the PV value

Lower Display

0 For Ramp segments: # RA XXXX

Ramp Time - Houn:Minutes or Ramp Rate - Degrees/Minute TT Indicates Ramp segment

Segment Number (odd only)

For Soak segments: # SK XXXX

remaining n segment in Hrs:Minutes including current partially completed minute

Indicates Soak segment

Segment umber (even only)

Upper Display

-'R" and the PV value

Lower Display

0 RECYC

I Remaining Cydes 0 to 99 This number includes the current partially completed cycle.

RunIMonitor the Program, c~nan~~ed

RurUMonitor functions (continued)

Table 6 3 RunNonitor Functions, continued

Power-up state The program will be placed in HOLD mode at the beginning of the program at the lkal Setpoint value prior to the beginning of the program.

Resul

When the final segment is completed, the 'R" in the upper display either changes to 'H" if configured HOLD state, or disappears if configured for disable of setpoint programming.

The controller operates at the last setpoint in the program in automatic or will be in manual mode at the failsafe output.

Function

~ n d Program


Press

Section 7 - lnput Calibration

Overview

lntroductlon This section describes the field calibration procedures for Input 1 and Input 2. Every UDC3000 controller contains all input actuation ranges fully factory calibrated and ready for configuration to range by the user. However these procedures can be implemented if the factory calibration of the desired range is not within specifications. Note that the field calibration will be lost if a change in input type configuration is implemented at a later time. The original factory calibration data remains available for later use after a field calibration is done.

What's In thls section This section contains the following topics:

Calibration steps

Topic - Minimum and maximum range values

Preliminary Information Disconnect the field wiring Equipment needed

Input 1 Set Up Wiring Thermocouple inputs using an ice bath Thermocouple inputs using a precision resistor RTD (Resistance Thermometer Device) inputs Radiamatic, Millivolts, or Volts except 0-1 0 Volts inputs 0 to 10 Volts input 4-20 Milliamps input

Input 1 Calibration Procedure

Input 2 Set Up Wiring 4-20 Milliamps input 1 to 5 Volts input

Input 2 Calibration Procedure C

Use the following steps when calibrating an input.

See Page

120

121 121 122

123 123 124 125 126 127 128

129

131 131 132

133


Step

1

2

3

4

Actbn

Find the minimum and maximum range values for your PV input range from Table 7-1.

Disconnect the field wiring and find out what equipment you will need to calibrate. DO NOT remove external resistor assemblies (if present).

Wire the calibrating device to your controller according to the Set Up wiring instructions for your particular input.

Follow the, calibration procedure given for lnput #1 or lnput #2.

Minimum and Maximum Range Values

Select the range values You should calibrate the controller for the minimum (0%) and Maximum (100%) range values of your particular sensor. If you have a two input controller, calibrate each input separately. Select the Voltage or Resistance equivalent for 0% and 100% range values from Table 7-1. Use these value when calibrating your controller.

Table 7-1 Voltage and Resistance Equivalents for 0% and 100% Range Values


Sensor Type

B Thermocouple

E Thermocouple

E(low)Thermocouple

J ~hermocouple

J (law) Thermocouple

KThermocouple

K( low)Therm~~~~ple

NINIMoly TK:

NlNlMoly (low) TIC

NIC hi-I NlsN TK:

R T h e r m ~ ~ ~ ~ p l e

S Thermocouple

T Thermocouple

T ( I o w ) T ~ ~ ~ I o c O U P ~ ~

W5W26 TIC

W W 2 6 (bw) TIC

Range

0%

-0.010 r n ~

-9.835 rnV

-6.471 mV

-0.885 rnV

-0.334 rnV

-0.692 rnV

-1.114 rnV

-0.001 rnV

-0.001 rnV

-0.461 mV

-0.089 mV

-0.092 rnV

-5.341 mV

-4.149 rnV

-0.234 mV

-0.234 mV

Values

100%

13.763 mV

76.358 rnV'

44.547 mV

50.059 mV

22.397 rnV

52.939 rnV

22.251 mV

71.330 rnV

31.820 rnV

47.502 mV

20.275 mV

17.993 rnV

19.095 rnV

12.572 mV

37.066 mV

22.277 mV

PV Input

" F

0 to 3300

-454 to 1832

-200 to 1100

0 to 1600

2 0 to 770

0 to 2400

-20to 1000

32 to 2500

32 to 1260

0 to 2372

0 to 3100

0 to 3100

-300 to 700

-200 to 500

0 to 4200

RTD (IECt0.00385)

100 Ohms 100 Ohms (bw)

500 Ohms

RadiamaUc (RH)

Milholts

volts

Range

" C

-1810 1815

-270 to 1000

-1 29 to 593

-18 to 871

-7 to 410

-18t0 1316

-29 to 538

0 to 1371

0 to 682

-18 to 1300

-18 to 1704

-1 8 to 1704

-1 84 to 371

-1 29 to 260

-18 to 2316

-1 8 to 1227

-300 to 1200 0 to 300

-300 to 1200

0 to 3400

-1 84 to 649 -18 to 149

-1 84 to 649

-18 to 1871

4 to 20 rnA

Oto 10 rnV

10 to 50 rnV

1 to 5 Volts

o to 10 VORS

25.18 Q 93.03 a

125.90 Q

0.000 rnV

329.16 5). 156.90 Q

1645.80 Q

57.12 rnV

4 rnA

0 rnV

10 rnV

1 volt

o VORS

20 mA

10 rnV

50 rnV

5 volts

10 V O ~ S

Preliminary Information

Disconnect the field MmJ

Depending on which input (#1 or #2) you are going to calibrate, tag and disconnect any field wiring connected to the input terminals on the rear of the controller.

Figure 7- 1 shows the wiring .terminal designations for Input #1 and Input #2.

Figure 7- 1 Input #1 and #2 Wiring Terminals



Preliminary Information, coainued

Equipment needed Table 7-2 lists the equipment you will need to calibrate the specific types of inputs that are listed in the table. You will need a screwdriver to connect these devices to your controller.

Table 7-2 Equipment Needed


lype of input

Thermocouple Inputs (Ice Bath)

Thermocouple Inputs (Precision Resistor)

RTD (Resistance Thermometer Device)

Milliampere, Millivolt, Volts, and Radiamatk

Equipment Needed

A calibrating device with +0.02% accuracy for use as a signal source such as a millivolt source.

Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input.

Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the precision calibrator.

Two containers of crushed ice.

A calibrating device with +0.02% accuracy for use as a signal source such as a millkott source.

Two insulated copper leads for connecting the calibrator to the controller.

A precision 500 ohm resistor +0.1% connected across input # I terminals 25(R) and 27(-) .

A decade box, with f 0.02% accuracy, capable of providing stepped resistance values over a minimum range of 0 to 1400 Ohms with a resolution of 0.1 ohm.

Three insulated copper leads for connecting the decade box to the controller.

A calibrating device with rt0.02% accuracy for use as a signal source.

Two insulated copper leads for connecting the calibrator to the controller.

Place current source at zero before switching ON.

Do not switch current sources OFFION while connected to the UDC3000 input.

lnput #I Set Up Wiring

Thermocouple Inputs Refer to Figure 7-2 and wire the controller according to the procedure given uslng an Ice bath in Table 7-3.

Table 7-3 Set Up Wiring Procedure for Thermocouple Inputs Using An Ice Bath

Figure 7-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath

Step

1

2

3

TIC Extension Wire

Actbn

Connect the copper leads to the calibrator.

Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points into the ice bath.

Connect the thermocouple extension wires to the terminals for lnput #l. See Figure 7-2.



Input #I Set Up Wiring, Continued

Thennocouple inputs using a pmclsion resistor

Refer to Figure 7-3 and wire the controller according to the procedure given in table 7-4.

Table 7-4 Set Up Wiring Procedure for Thermocouple Inputs Using a Precision Resistor

Figure 7-3 Wiring Comections for Thennocouple Inputs Using a Precision Resistor

Step

1

2

3

4


Action

Connect the copper leads to the calibrator.

Disconnect the cold junction resistor.

Install a 500 Ohm precision resistor across terminal 25(R) and terminal 27(-). See figure 7-3.

Subtract the millivolt value for 77OF (25°C) from the zero and span value for your range (see Table 7-1 for zero and span values) and use the adjusted value when calibrating.


RTD Inputs Use the copper leads and comect the calibrator to the rear terminals of Input # 1. See Figure 7-4.

Figure 7-4 Wiring Connections for RTD (Resistance Thermometer Device)

Copper Leads equal length

Cptinued on next page



Radiamatic, Mlllhrolts, or Use the comer leads and connect the calibrator to the rear terminals of volts (ex* 0 to 10 Input # 1. s e e Figure 7-5. volts) Inputs

Figure 7-5 Wiring Connections for Radiamatic, Millivolts, or Volts (except 0 to 10 Volts)

Copper Leads

Continued on neff page


Input #I Set Up Wiring, c ~ n t i ~ e d

0 to 10 V o l Inputs Use the copper leads and connect the calibrator to the rear terminals of Input # l . See Figure 7-6.

Figure 7-6 Wiring Connections far 0 to 10 Volt inputs


10192 UDC3000 Pmduct Manual 127

Input #I Set U

4 to 20 mA Inputs

D Wiring, Continued

Use the copper leads and connect the calibrator to the rear terminals of Input #l. See Figure 7-7.

Figure 7-7 Wiring Connections for 4 to 20 mA inputs r I

250n resistor assy

Copper Leads I

4 to 20 mA -+ Source I


Input #I Calibration Procedure

Introduction Apply power and allow the controller to warm up for 15 minutes before you calibrate. Please read "Set Up Wiring" before beginning the procedure. Make sure you have "LOCKOUT" set to "NONE." See Section 3 - Configuration.

[ For linear inputs, avoid step changes in inputs. Vary smoothly from initial value to final 100% value.

Procedure The Calibration procedure for Input #1 is listed in table 7-5. Table 7-5 Input #1 Calibration Procedure

Enter Calibration Mode

Step

until you see

Upper Display pcx-- ' j

Description

Lower Display

[ T I You will see: Upper Display

~~]

Press

Lower Display / CRL In: 1

Adbn

The calibration sequence is enabled and you will

Upper Display

Lower Display 1 At the completion of the sequence, the selection automatically reverts to disable.

Calibrate 0% You will see: Upper Display I rimy ]

Lower Display I :nl Z E R ~ ~

Adjust your calibration device to an output signal equal to the 0% range value for your particular input sensor. See Table 7-1 for Voltage or Resistance equivalents. Wait 30 seconds, then go to the next step.


lJI%3000 product Manual

Input #l Calibration Procedure, conawed

Table 7-5 Input #1 Calibration Procedure, continued

step ~escription mess I Adbn

Check the Cold Junction Temperature

3

The accuracy of the controller is directly affected by the accuracy of this value. Change this value only if the zero and span calibration procedures did not bring the controller within the specified

Calibrate 100 %

accuracy requirements.

I I I You will see:

I Lower Display

5

Adjust your calibration device to an output signal equal to the 100% range value for your particular input sensor. See Table 7-1 for Voltage or Resistance eauivalents.

Exit the Calibration Mode

Wait 30 secods, and

you are calibrating a Go to step 4

you are calibrating other Go to step 5

The calculations for zero and span are now stored and you will see: Upper Display I+ The cold junction

temperature at the h e r Dis,play rear terminals

-1 The value in the upper display is in the tenths of a degree. It is the current reading of the temperature as measured at the thermocouple terminals and recognized by the controller. You can change this value, if it is in error, using the A 0'- key.

when calibratina TIC inwts usina a precision resistor, calibrate the &ld jundtion as 7 f o ~ (25°C).

The controller will store the calibration constants and exit calibration mode.


Input #2 Set Up Wiring

4 to 20 mA input Use the copper leads and connect the calibrator to the rear terminals of Input #2. See Figure 7-8.

Figure 7-8 Wiring Connections for 4 to 20 mA input - Input #2

25m resistor assy

Copper Leads I

4 to 20 mA I + Source

- - -- - -



Input #2 Set Up Wiring, Continued

1 to 5 Volt inputs Use the copper leads and connect the calibrator to the rear terminals of Input #2. See Figure 7-9.

Figure 7-9 Wiring Connections for 1 to 5 Volt input - Input 2

I

Volt - + Source

Copper Leads


Input #2 Calibration Procedure

Apply power and allow the controller to warm up for 15 minutes before you calibrate. Please read "Set Up Wiring" before beginning the procedure. Make sure you have "LOCKOUT' set to "NONE." See Section 3 - Configuration.

Procedure The Calibration procedure for Input #2 is listed in table 7-6. Table 7-6 Input #2 Calibration Procedure


Calibrate 0%

Lower Display I until you see I I 1

I I ~ower Dis~lav


bEcrn 1 Lower Display I I CRL IW I

You will see Upper Display IAPRY 1 Lower Display

Adjust your calibration device to an output signal equal to the 0% range value for your particular input sensor. See Table 7-1 for Vottage or Resistance equivalents. Wait 30 seconds, then go to the next step.


1 13/92 UDC3000 Product Manual 133

Input #2 Calibration Procedure, Continued

Table 7-6 Input #2 Calibration Procedure, continued

134 UDC3000 Product Manual 1 0/92

Actbn

YOU will see

,U;=gi;@ay,

Lower Display 7 1 Adjust your calibration device to an output signal equal to the 100% range value for your particular input sensor. See Table 7-1 for Voltage or Resistance equivalents. Wait 30 seconds, then go to the next step.

The controller will store the calibration constants.

To store the calibration constants and exit the calibration mode.

Step

3

4

Desctiptbn

Calibrate 100 %


Press

Fl

/I Fl

DISPLAY

Section 8 - Output Calibration

Overview

Introduction This section describes the field calibration procedures for the following types of outputs:

Current Output Position Proportional and 3 Position Step Output Auxiliary Output

What's In thls seabn This section contains the following topics:

I Topk I See Page / Current Proportional Output Calibration

Introduction Equipment Needed How to Connect the Calibrator Calibration Procedure

Position Proportional and Three Position Step Output Calibration Position Proportional Control 3 Position Step Control Equipment Needed What connection to make Calibration Procedure


Auxiliary Output Calibration Introduction Equipment Needed How to Connect the Calibrator Calibration Procedure

142 142 142 142 143

Current Proportional Output Calibration

Calibrate the controller so that the output provides the proper amount of current over the desired range. The controller can provide an output current range of from 0 to 21 milliamperes and can be calibrated at 4 rnA for 0% of output and 20 rnA for 100% of outgut or any other values between 0 and 21 rnA.

Equipment needed You will need a standard shop type milliammeter, with whatever accuracy is required, capable of measuring 0 to 20 milliamps.

Calibrator connectbns Refer to Figure 8-1 and wire the controller according to the procedure given in table 8-1. Table 8-1 Set Up Wiring Procedure Current Proportional Output

Figure 8-1 Wiring Connections for Calibrating Current Proportional Output

Step

1

2

3

Milliammeter

Actbn

Apply power and allow the controller to warm up 15 minutes before you calibrate.

Tag and disconnect the field wiring, at the rear of the controller, from terminals 2(+) and 3(-). See Figure 8-1.

Connect a Milliammeter across these terminals.



Current Proportional Output, Continued

Procedure The procedure for calibrating the Current Proportional Output is listed in table 8-2. Make sure "LOCKOUT" in the Tuning Set Up group is set to "NONE." See Section 3 - Configuration.

Table 8-2 Current Proportional Output Calibration Procedure


Actbn

,U;pe;~~Ia~,

Lower Display

71 You will see: Upper Display

a value between 1 and 2048

Lower Display

-1 until the desired 0% output is read on the rnilliamrneter. Use the values shown below depending on the action of your controller.

0 rnA For 0 to 20 mA Direct Action* 20 rnA For 0 to 20 rnA Reverse Action 4 rnA For 4 to 20 rnA Direct Action 20 rnA For 4 to 20 rnA Reverse Action

This stores the OO/~value and, You will see:

Upper Display a value between 1 and 2048

Lower Display

pKq until the desired 100% output is read on the rnilliarnrneter. Use the values shown below depending on the action of your controller.

20 rnA For 0 to 20 mA Direct Action 0 rnA For 0 to 20 rnA Reverse Action* 20 rnA For 4 to 20 mA Direct Action 4 mA For 4 to 20 mA Reverse Action

The controller will store the span value.

To exit the calibration mode. When attempting to achieve 0 mA, always adjust the output to about 0.5 mA, and slowly decrease until the output just goes to zero. Further decrementing will not change the output current (since the circuit cannot produce negative current) but will affect the accuracy of the output by creating a dead zone where no current flows.

press

I] until you see

F m a 0

,XI

F W ~ ~ N 0

El

Fl piq

DISPLAY

Step

1

2

3

4

~escr~ption


Calibrate 0%

Calibrate 100%


Position Proportional and Three Position Step Output Calibration

Position Proportional When the UDC 3000 controller has a Position Proportional control output, contrd calibrate the controller so that the increase and decrease relays operate

properly with respect to the position of the external feedback slidewire.

Posltlon Step control Three Position Step Control Output models fi Motor Position Indication This model must have its output calibrated per the entire procedure to ensure the displayed output (slidewire position) agrees with the final control element position. Three Position Step Control Ourput models M&W& Motor Position Indication This model only requires that the "Motor Time" be entered as shown in the calibration procedure. FULL CALIBRATION IS NOT REQUIRED.

Equipment needed None

Connections Apply power and allow the controller to warm up 15 minutes before you calibrate. Leave all field wiring connected to the rear terminals.

Auto mode vs Manual There are two ways in which to calibrate Position Proportional or 3 Position mode Step control:

AUTO mode or MANUAL mode.

Rules for Auto mode vs The Auto-mode selection must be done at least once before the manual Manual mode mode will operate properly. Failure to use the Auto-mode procedure will

prevent the controller from going into automatic control mode.

Displayed values During the Auto-mode calibration procedure, the values being displayed are used only to indicate if the motor is still traveling. To view the actual calibration value, use the manual mode after the Auto- mode is completed. These values can be changed for purposes of tweaking the calibration.



Position Proportional and Three Position Step Output Calibration, Continued

Procedure The procedure for calibrating the Position Proportional output and 3 Position Step control output is listed in table 8-3.

Make sure "LOCKOUT" in Tuning Set Up group is set to "NONE." See Section 3 - Configuration.

For "Three Position Step Control Output models withow Motor Position Indication", do steps 1 and 2 only.

For "Position Proportional Output" and ''Three Position Step Control Output models Motor Position Indication" follow the entire calibration procedure.

Table 8-3 Position Proportional and 3 Position Step Output Calibration Procedure



Step

1

2

Press ~escrlption


Set Motor Traverse Time

Note: This is the time it takes the motor to travel from 0 to 100%.

.

Actbn

Lower Display until you see PROP 0


a value

Lower Display 1-1 until the proper motor stroke time is reached (see the motor specs or measure the time)

Range of setting = 5 to 1800 Seconds


Table 8-3 Position Proportional and 3 Position Step Output Calibration Procedure, continued



Actbn

until you see: Upper Display

p s q Lower Display

["os'"o'l You can calibrate the controller output manually or let the controller calibrate the output automatically. In the "Automatic Calibration Mode" (DO AUTO), the controller relays automatically move the motor in the proper direction. If desired, however, the motor may be manually positioned to 0% and 100% positions. Disconnect the relay wires. "DO MAN". In the "Manual Calibration Mode" (DO MAN) the motor does not move. Instead, the existing 0% and 100% values may be changed with the A OrV keys.

to select automatic or manual calibration. Upper Display r- DO AUTO

Lower Display or

DO MAN

Do A",, go to step 4 If you select DO MAN, go to step 6 Note: When calibration is terminated, this selection reverts to DISABL.

The decrement relay is turned on to move the motor to 0% position.

Upper Display counts of feedback

Lower Display slidewire (0 to 3000)

prizic" When the motor stops, the display should stop counting, then, go on to the next step.

The increment relay is turned on to move the motor to 100% position. Upper Display counts of feedback -slidewire (0 to 3000) Lower Display

piGEi1 When the motor stops, the display should stop counting, then, go on to step 8.

Press

F W ~ O N 0

El ~3 ~m(tmor~ 0

step

3

4

5

~escription

Select Automatic or Manual Calibration

- -

DO AUTO Set 0% value

Set 100% value


Table 8-3 Position Proportional and 3 Position Step Output Calibration Procedure, continued

Step

Set 100% value

Descrlptkn

DO MAN

8 1 Exit the Calibration

Press

Mode

Set 0% value You will see: Upper Display

The existing zero Lower Display calibration value

in counts. I ZERO UAL I

I I I I until the desired zero value is reached in the upper display. Upper Display

The desired zero value l p - l l - ,

The controller will store the 0% value and you will see: Upper Display

I-+ The existing span calibration value

until the desired span value is reached in the upper 1 mi 1 disP1aY- Upper Display

1- The desired span value

Lower Display

p%Gxq For manual calibration, the motor does not move from its position prior to the start of Position Proportional calibration.

The controller will store the 100% value.

To exit the calibration mode.


Auxiliary Output Calibration

Calibrate the controller so that the Auxiliary output provides the proper amount of current over the desired range. The controller can provide an auxiliary output current range of from 0 to 21 milliamperes and can be calibrated at 4 mA for 0% of output and 20 mA for 100% of output or any other values between 0 and 21 mA.

Equipment needed You will need a standard shop type rnilliammeter with whatever accuracy is required, capable of measuring 0 to 20 rnilliamps.

Calibrator connections Refer to figure 8-2 and wire the controller according to the procedure given in table 8-4

Table 8-4 Set Up Wiring Pmcedm for Auxiliary Output

Figure 8-2 Wiring Connections for Calibrating Auxiliary Output

step

1

2

3

Milliammeter

Actkn

Apply power and allow the controller to warm up 15 minutes before you calibrate.

Tag and disconnect the field wiring, at the rear of the controller, from terminals 16(+) and 17(-). See figure 8-2.

Connect a Milliammeter across these terminals.



Auxiliary Output Calibration, Continued

Procedure The procedure for calibrating the Auxiliary Output is listed in table 8-5. Make sure "LOCKOUT" in the Tuning Set Up group is set to "NONE." See Section 3 - Configuration.

1 1 Enter Calibration Mode F l l p j Table 8-5 Auxiliary Output Calibration Procedure

Calibrate OO/o

Calibrate 100%

Actbn

until you see

I 1

Press Step

Lower Display

I FlUX LXlT 1

~escrlption

- You will see:

I-+ a value

Lower Display

~zG-iZ-1

Lower Display

I/

until the desired 100% output is read on the rnilliarnrneter. Use the values shown below depending on the action of your controller.

until the desired 0% output is read on the rnilliarnrneter. Use the values shown below depending on the action of your controller.

0 mA For 0 to 20 mA Direct Action 20 rnA For 0 to 20 mA Reverse Action 4 rnA For 4 to 20 rnA Direct Action 20 rnA For 4 to 20 rnA Reverse Action

20 mA For 0 to 20 mA Direct Action 0 rnA For 0 to 20 rnA Reverse Action* 20 rnA For 4 to 20 mA Direct Action 4 rnA For 4 to 20 rnA Reverse Action

This stores the OO/~value and,

4 Exit the Calibration 1 Mode The controller will store the span value.

LOWER DISPLAY

0 r

To exit the calibration mode. * When attempting to achieve 0 mA, always adjust the

output to about 0.5 mA, and slowly decrease until the output just goes to zero. Further decrementing will not change the output current (since the circuit cannot produce negative current) but will affect the accuracy of the output by creating a dead zone where no current , flows.


Section 9 - Troubleshooting 1 Service

Overview

Instrument performance can be adversely affected by installation and application problems as well as hardware problems. We recommend that you investigate the problems in the following order,

Installation related problems Application related problems Hardware and software related problems

and use the information presented in this section to solve them. If a replacement of any part is required, follow the procedures listed under "Parts Replacement Procedures".

What's in this sectbn? The following topics are covered in this section.


ToPk

Overview

Troubleshooting Aids Overall Error Messages Controller Failure Symptoms Customer Support Determining the Software Version Number

Power-up Tests

Status Tests

Background Tests

Controller Failure Symptoms

Troubleshooting Procedures Power Failure Current Proportional Output Failure Position Proportional Output Failure Time Proportional Output Failure TimeJCurrent or CurrentfIime Proportional Output Failure Alarm Relay Output Failure Keyboard Failure Communications Failure

Parts Replacement Procedures How to remove the chassis How to replace the displaylkeyboard assembly How to remove the printed wiring boards from the chassis Printed wiring board identification 2nd input board replacement procedure Power input board replacement procedure Digital input board replacement procedure Aux.Out/communications board replacement procedure MCUIoutput board replacement procedure

Maintenance


See Page

144

146 146 147 147 147

148

149

151

153

154 154 155 156 157 158 159 160 161

162 163 164 165 166 167 168 169 170 171

172

Overview, Continued

Installation related Read the Installation section in this manual to make sure the UDC3000 has P-S been properly installed. The installation section provides information on

protection against electrical noise, connecting external equipment to the controller, and shielding and routing external wiring.

System noise induced into the controller will nsult in diagnostic error messages recurring. If the diagnostic error messages can be cleared, it indicates a "soft" failure and is probably noise related. If system noise is suspected, completely isolate the controller from all field wiring. Use calibration sources to simulate PV and check all controller functions; i.e. Gain, Rate, Reset, Output, Alarms, etc.

Application related Review the application of the controller, then, if necessary, direct your P-S questions to the local sales office.

Harclware and software Use the troubleshooting error message prompts and controller failure related problems symptoms to identify typical failures which may occur in the controller.

Follow the troubleshooting procedures to comct them.


Troubleshooting Akls

Overall error messages An error message can occur at power-up during continuous background tests while in normal operation when the Status Tests are requested

Table 9-1 lists all the error message prompts that you could see, the reason for the failure, and under what test group the prompt could appear. Refer to Tables 9-3 (Power-up), 9-5 (Status), and 9-6 (Background) for the particular test group indicated. Table 9- 1 Error Message Prompts



Error Message (l-dww)

CAL TEST

CONF ERR

CONFTEST

E E FAIL

FACT CRC

FAILSAFE

INPIFAIL

lNP2FAlL

INP1 RNG

INP2 RNG

PV LIMIT

RAM TEST

RV LIMIT

SW FAIL

CAL MTR

Test Group

Power-up or Status

Background

Power-up or Status

Background

Status

Power-up, Background, or Status

Background

Background

Background

Background

Background

Power-up or Status

Background

Background

Power-up

Reason for Failure

Calibration test failure

Low limit greater than high limit for PV, SP, Reset, or Output

Configuration test failure

Unable to write to non- volatile memory

Factory Calibration Cyclic Redundancy test

Controller in Failsafe

Two consecutive failures of lnput 1 integration

Two consecutive failures of lnput 2 integration

Input 1 Out of Range

Input 2 Out of Range

PV Out of Range

RAM test failed

Remote Variable Out of Range

Position Proportional slidewire input failure

Position Proportional or 3 Position Step control with motor position indication, Auto Cal never performed.

1

Refer to Table

9-3 9-5

9-6

9-3 9-5

9-6

9-5

9-3 9-5 9-6

9-6

9-6

9-6

9-6

9-6

9-3 9-5

9-6

9-6

9-3

Troubleshooting Aids, Continued

Controller faiium Other failures may occur that deal with the Power, Output, or Alarms. Refer SympOmS to the controller failure symptom in Table 9-7 to determine what is wrong

and the troubleshooting procedures to use to correct the problem.

check installation If a set of symptoms still persists, refer to Section 2 - Installation and ensure proper installation and proper use of the controller in the system.

Customer support If you cannot solve the problem using the troubleshooting procedures listed in this section; or get the model number and serial number from the label on the chassis molding (see Figure 9-I), and software version (see Table 9-2) then:

call Customer Support Phone Number 1-800-423-9883.

If it is determined that a hardware problem exists and the controller is still within the two year warranty, a replacement controller will be shipped with instructions for returning the defective unit.

Determining the Table 9-2 lists the procedure for identifying the software version number. mftwate version

Table 9-2 Procedure for Identifying the Software Version

Operatbn I Press I Actbn

Select STATUS Set Up Group

1 0/92 UDC3000 Product Manual 147

Read the software version

1 I

Lower Display

pimq Until you see: ;pper Display+

Software version

Lower Display

7 1 Number

Please give this number to the Customer Support person. It will indicate which version of UDC3000 you have and help them determine a solution to your problem.


I REW

Power-up Tests

Whathappensat When the controller is powered-up, three tests are run by the UDC3000 pOWer*P software to ensure memory integrity.

As the tests are run, the displays will appear as shown in Table 9-3.

Table 9-3 Power-up Tests

Test failums

-r Mspw

RAM TEST

CONFTEST

CAL TEST

If any of these three tests fail, "FAILED', will appear momentarily in the

Upper Display

PASSED or FAILED

PASSED or FAILED

PASSED or FAILED

upper display, then a display test is run, after which the controller will go into manual mode and you will see:

Upper Display )- PV value

Lower Display -1 (blinking)

Refer to "Status Tests" to determine which tests have failed and how to correct t h e n

Position propoctional or For controller configured for Position Proportional or 3 Position step 3 position step test control with motor position indication and Auto-cal has never been done, a failurn prompt "CAL M T R will appear suggesting that the controller be calibrated.


Status Tests

Intmdudion When required, the results of these tests can be checked to determine the reason the controller has gone to "Failsafe".

How to check the status The procedure in Table 9-4 tells you how to display the results of the status tests tests. Table 9-5 lists the tests, the reason for the failure, and how to correct

the problem.

Table 9-4 Procedure for Displaying the Status Tests Results

Step

1 Select 'STATUS Set Up Group

Read the status tests results


ECl Lower Display


-1 -IIE5 indicates a failure

Lower Display

I FR ILSRFE 1 Successive presses of the [FUNCTION] key will display the results of the status tests in the following order:

RAM TEST CONF TEST CAL TEST FACT CRC

Identify the problem and correct the failure as shown in Table 9-5.



Status Tests, Continued

Status Tests Table 9-5 lists the Status tests, the reason for their failure, and how to correct the failure.

Table 9-5 Status Tests


How to C o w the Failure

1. Step through the rest of the STATUS check to identify the particular failure.

Also see Table 9-6, Background tests

RAM test passed.

1. Power cycle to see if the error clears.

Configuration checksum passed.

1. Step through STATUS tests - the controller will recalculate the checksum.

2. Check all configuration prompts for accuracy. See Section 3 - Configuration

Working calibration checksum passed.

1. If the controller has not been field calibrated, see Section 3 - Configuration and change the input to a different type. Enter it, loop through the status tests, then return the input type to the original one.

2. If the controller has been field calibrated, recalibrate the controller.

Factory calibration cyclic redundancy test passed

1. Cycle through Status to clear the error.

2. Check the calibration. Make sure 0 and 100% are correct values.

3. Recalibrate if step 1 is unsatisfactory. Refer to Section 7 - Input Calibration.

Test (Lower Display)

FAILSAFE

RAM TEST

CONF TEST

CAL TEST

FACT CRC

Upper Display

NO

YES

PASS

FAIL

PASS

FAlL

PASS

FAlL

PASS

FAIL

DefinRlon

Failsafe Fault

RAM test run at power-up

Configuration Checksum

Working Calibration

Factory calibration test

Reason for Failure

No Failure

Burnout configured for none and input fails. -RAM TEST failed -CONFTEST failed -CALTEST failed

No Failure

RAM Failure

No Failure

Configuration data is in error.

No Failure

The working calibration constants in the controller are in error.

No Failure

Factory set input constants have been changed due to the change in input type.

Background Tests

The UDC3000 performs on-going background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed (blinking) in the lower display.

Background Tests In the case of more than one simultaneous malfunction, only the one with the highest priority will appear in the lower display. Table 9-6 lists these background tests, the reason for their failure, and how to correct the problem.

Table 9-6 Background Tests



How to Correct the Problem

1. Check the accuracy of the parameter and re- enter.

2. Try to change something in configuration. 3. Run through STATUS tests to re-write to

EEPROM.

1. Run through STATUS check to determine the reason for the failure.

2. Press the [SET UP] key until STATUS appears in the lower display.

3. Press the [FUNCTION] keyto see what tests Pass Or fail, then run through the STATUS codes a second time to see if the error cleared. Correct according to the recommendations given in table 9-5.

1. Make sure the actuation is configured correctly. See Section 3 - Configuration.

2. Make sure the input is correct. 3. Check for gross over-ranging. 4. Replace the cold junction assembly.

1. Make sure the actuation is configured correctly. See Section 3 - Configuration.

2. Make sure the input is correct. 3. Check for gross over-ranging.

1. Check motor slidewire connections.

2. Recalibrate the slidewire motor position. see the calibration section.

1. Check the configuration for each item and reconfigure if necessary.

Loww Display

EE FAIL

FAILSAFE

INP1 FAIL

INP2FAIL

SW FAIL

p-

CONF ERR

Reason for Failure

Unable to write to non-volatile memory. Anytime you change a parameter and it is accepted* you will see EE FAIL-

This error message shows whenever the controller goes into a failsafe mode of operation. This will happen if:

RAM test failed Configuration test failed Calibration test failed Burnout configured for none

and the input failed.

Two consecutive failures of input 1 integration. i.e., cannot make analog to digital conversion.

Two consecutive failures of input 2 integration. i.e., cannot make analog to digital conversion.

Position Proportional input slidewire failure

-- - PV low limit is > PV high limit SP low limit is > SP high limit Output low limit > Output high limit

Background Tests, coalued

Table 9-6 Background Tests, continued



1. Make sure the range and actuation are configured properly.

2. Check the input source.

3. Restore the factory calibration: a Disconnect the wiring from and place a jumper across terminals 26 and 27. The controller should read room temperature if it is configured for a thermocouple input. b. If it does not read room temperature, see Section 3-Configuration and change the IN1NP prompt in the INPUT 1 group to another type of thermocouple. c. After the change, press [FUNCTION] key, then the [LOWER DISPLAY] key. The controller should read the correct room temperature. If it does not, the unit has an input failure. d. Repeat step b. This time switch the IN1NP back to the originally selected thermocouple. e. Repeat step c. The controller is restored with factory calibration. f. Remove the jumper and reconnect the thermocouple.

4. Field calibrate. See Section 7 - lnput Calibration.

1. Make sure the range and actuation are configured properly.

2. Check the input source.

3. Field calibrate. See Section 7 - lnput Calibration.

1. Make sure the input signal is correct.

2. Make sure the Bias setting is correct

3. Recheck the calibration. Use Bias of 0.0

1. Make sure the input signal is correct.

2. Make sure the Ratio and Bias settings are correct.

3. Recheck the calibration. Use a Ratio of 1.0 and a Bias of 0.0.

Display

INP1 RNG

INP2 RNG

W LIMIT

RV LIMIT

Reason for Failurn

Input 1 out of range. The process input is outside the range limits.

If you have a linear input and the range goes outside the range limits, the controller will switch to Mama1 mode at the configured Failsafe output value.

Input 2 out of range. The remote input is outside the range limits.

PV out of range. PV = INP1 + INP1 BlAS

The result of the formula shown below is beyond the range of the remote variable.

RV = INP2 X RATIO + BlAS

Controller Failure Symptoms

In addition to the error message prompts, there are failure symptoms that can be identified by noting how the controller displays and indicators reacting.

SymptCrmS Compare your symptoms with those shown in Table 9-7 and refer to the troubleshooting procedure indicated to correct the problem.

Table 9-7 Controller Failure Symptoms

Other symptoms If a set of symptoms or prompts other than the one you started with appears while troubleshooting, re-evaluate the symptoms. This may lead to a different troubleshooting procedure. If the symptom still persists, refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system.


Trwbte shoatlng

Procedure

1

2

3

4

5

6

7

8

Upper D m m

Blank

OK

OK

OK

OK

OK

Controller Ocltput

None

Controller Output

disagrees - with Displayed

Output

External Alarm function does not operate

properly

Probable Cause

Power Failure

Current Proportional

Output

Position Proportional

Output

Time Proportional

Output

Cu rrentfrime Proportional

Output

Malfunction in alarm output

Display does not function when a key is pressed

Controller fails to go into "Slave" operation during communications

~ower Display

Blank

Displayed Output

disagrees

with Controller Output

OK

Keyboard Malfunction

Communicatio ns Failure

lndlcators

Off

OK

OK

OK

OK

OK

Troubleshooting Procedures

The troubleshooting procedures are listed in numerical order as they appear in Table 9-7. Each procedure lists what to do if you have that particular failure and how to do it or where to find the data needed to accomplish the task.

Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow:

DC Milliamrneter - mAdc Calibration sources -TIC, mV, Volt, etc. Voltmeter

Procedure #1 Table 9-8 explains how to troubleshoot power failure symptoms. Table 9-8 Troubleshooting Power Failure Symptoms



How to do it

Use a Voltmeter to measure the AC voltage across terminals L1 and L2 on the rear terminal panel of the controller.

Check the earth ground connection.

Withdraw the chassis and visually inspect the controller board and the inside of the case.

Refer to Section 2 - Installation.

Step

1

2

3

What to do

Check the AC line voltage.

Make sure the chassis plugs into the rear of the case properly.

Check the system for Brown- outs, heavy load switching, elc.; and conformance to installation instructions.

Troubleshooting Procedures, CM~W

Procedure #2 Table 9-9 explains how to troubleshoot Current Proportional Output failure symptoms. Table 9-9 Troubleshooting Current Proportional Output Failure



Haw to do tt

Make Set Up group prompt "ALGORTHM". Function prompt "OUT ALG" = selection "CURRNT" Refer to Section 3 - Configuration.

Output impedance must be less than or equal to 1000 Ohms.

Refer to Section 3 - Configuration to check all this data and how to reconfigure.

Put the controller into Manual mode and change the output from 0 to 100% (4-20 mA). Use a DC milliammeter at the rear teminals to verify the output.

Refer to Section 8 - Output Calibration for details.

Step

1

2

3

4

5

-

Whattodo

Make sure the controller is configured for Current output.

Check the field wiring.

Make sure all the configurable tuning constants, limits, and configuration data stored in the controller are correct. Reconfigure, if necessary.

Check the output.

Recalibrate the Current Proportional Output.

Troubleshooting Procedures, Continued

Procedure #3 Table 9- 10 explains how to troubleshoot Position Proportional Output failure symptoms. Table 9-10 Troubleshooting Position Proportional Output Failure

Step

1

2

3

Check the output voltage to the slidewire.

Check whether the motor drives in both directions. If it does go to step 6.

Check whether the motor drives in either direction. If the motor drives in one direction, check the slidewire. If the motor does not drive in either direction, check the motor.

Should equal from 1.3 to 1.0 volts. See wiring in the installation section for terminal designations. The feedback slidewire output voltage must vary with the valve position.

Whattodo

Make sure the controller is configured for Position Proportional output.


Check the output.

- --

See the Position Proportional calibration procedure in the Calibration Section for motor slidewire calibration.

Refer to the Motor instructions.

Make sure the output relays are actuating properly.

Haw to do It

Make Set Up group prompt "ALGORTHM". Function prompt "OUT ALG" = selection "POSITN" Refer to Section 3 - Configuration.

Refer to Section 2 - Installation for Position Proportional Wiring information.

Put the controller into Manual mode and change the output from 0 to 100%.

Recalibrate the controller.

Put the controller into Manual mode. Vary the output above and below the present value.Observe "OUT" indicator on the operator interface. If they are not working properly, check the field wiring, then go to step 5. If they are, go to step 8.

Refer to Section 8 - Output Calibration.



Troubleshooting Procedures, c m e d

Procedure #4 Table 9- 1 1 explains how to troubleshoot Time Proportional Output failure. Table 9- 1 1 Troubleshooting Time Proportional Output Failure


'1 0192 UDC3000 Product Manual 157

Hawtodoit

Make Set Up group prompt "ALGORTHM". Function prompt "OUT ALG" = selection "TIME" or "TIME D" Refer to Section 3 - Configuration.

Make sure the NO or NC contact wiring is correct at the rear terminals. Refer to Section 2 - installation for details.

Refer to Section 3- Configuration to check all this data and how to reconfigure.

Put the controller into Manual mode. Vary the output above and below the present value. Observe "OUT" indicator on the operator interface.

Step

1

2

3

4

Whattodo

Make sure the controller is configured for Time Proportional output.



Check the output.


Procedure #5 Table 9- 12 explains how to troubleshoot CurrenOirne or TimeICurrent Proportional Output failure. Table 9-12 Troubleshooting TimeICurrent or CurrentITirne Proportional

Output Failure



Hawtodolt

Make Set Up group prompt "ALGORTHM". Function prompt "OUT ALG" = selection ''TI CUR" or 'CUR TI" Refer to Section 3 - Configuration.

Make sure the NO or NC contact wiring is correct at the rear terminals. Refer to Section 2 - Installation for details.

Refer to Section 3 - Configuration to check all this data and how to reconfigure.

Put the controller into Manual mode. Vary the output above and below the present value. Observe "OUT" indicator on the operator interface.

Put the controller into Manual mode and change the output from 0 to 100% (4-20 mA). Use a DC milliammeter at the rear terminals to verify the output.

Refer to Section 8 - Output Calibration for details

Step

1

2

3

4

5

6

What to do

Make sure the controller is configured for TimeICurrent or Currentfrime Proportional output.



Check the relay output.

Check the Current Proportional Output.

Recalibrate the controller.


Procedure #6 Table 9- 13 explains how to troubleshoot Alarm Relay Output failure. Table 9- 13 Troubleshooting Alarm Relay Output Failure


Step

1

2

3


What todo

Check the alarm configuration data. If it is correct, check the field wiring.

Check that the applicable alarm relay actuates properly depending on what you have set at prompt "ALARM TYPE". If it does, check the field wiring.


How to do it

Reconfigure if necessary. Refer to Section 3 - Configuration for details.

If the alarm type is set for PV, place the controller in manual mode. Vary the input to raise and lower the PV around the setpoint. Listen for a click from the relay as the PV moves in either direction and note that the proper ALMA or ALM2 is lit.

If the alarm is set for output, put the controller into manual mode. Raise or lower the output above or below the value you have set as the alarm setpoint.

Make sure the NO or NC contact wiring is correct on the alarm output terminals. Refer to Section 2 - Installation for details.


Procedure #7 Table 9-14 explains how to troubleshoot a Keyboard failure.

Table 9-14 Troubleshooting a Keyboard Failure


step

1

2

3

4


Whattodo

Make sure the keyboard is connected properly to the MCUIoutput and powerlinput boards.

Controller Keyboard or specific keys may be "LOCKED OUT" via the security code.

Run the keyboard test.

Replace the displaylkeyboard if any keys are shorted out.

Hawtodolt

Wihdraw the chassis from the case and visually inspect the connection.

Use your 4 digit securlty code number to change the lockout level. Refer to Section 3 - Configuration.

Press the [SET UP] key and hold in, then press the [FUNCTION] key at the same time. The controller will run a display test. Then you will see:

Upper Display p E 7 - ] Lower Display

p E K q

Press each key. If it works, the key name will appear in the bwer display.

Refer to "Parts Replacement Procedures" in this section.

Troubleshooting Procedures, c o w e d

Procedure #8 Table 9-15 explains how to troubleshoot a Communications failure. Table 9-15 Troubleshooting a Communications Failure


HawtodoIt

Refer to the RS4221485 Manual or the Gateway Manual depending on the protocol used.

Withdraw the chassis from the case and inspect the board. See the exploded view (Figure 9-2) for location of the board. Return the chassis to the case.

Run the Local Loopback Test.

Press [SET UP] until you see: Upper Display pFF-1 Lower Display

Ezzl Press [FUNCTION] until you see:

Upper Display pi%q

Lower Display

pEcEF-I Press A Or v, you will see:

Upper Display j-EiGcq Lower Display

[ T E E G q

The test will run until the operator disables it here.

Step

1

2

3

Whattodo

Check the field wiring and termination resistor.

Make sure the Communications Printed Wiring Board is installed properly in the controller.

Determine if the Communications board is fauRy by running a LOCAL LOOPBACK TEST.

If the test fails, replace the board.

Parts Replacement Procedures

Introduction These procedures tell you how to access and replace the following printed wiring boards in your controller.

Display/Keyboard MCUIOutput PowerfInput 2nd Input Digital Input Awciliary Output DMCS Communications RS422/485 Communications

Equlpment needed To accomplish the procedures that follow, you will need the following equipment:

Phillips Head Screwdriver Flat Bladed Screwdriver Small Pliers



Parts Replacement Procedures, Continued

How to remove the Refer to Figure 9- 1 for steps and follow the procedure listed in Table 9- 16. drassis

Table 9- 16 How to remove the chassis

Figure 9- 1 Chassis Removal I i

Step

1

2

3

a Insert screwdriver / and pry forward

Adbn -

Loosen the screw on the front face.

Insert a flat-bladed screwdriver into the hole on the top of the case as shown in Figure 9-1 and pry chassis forward slightly until the chassis connectors separate from the back of the case.

Grasp the bezel and pull the chassis out of the case.

- -


1 Of92 UDC3000 Product Manual 163


How to replace the Refer to Figure 9-2 and follow the procedure listed in Table 9- 17. displaykeyboard -My

Table 9- 17 Display/Keyboard Assembly Replacement Procedure

Figure 9-2 Display/Keyboard Replacement

Step

1

2

3

4

5

6

7

8

Displaylkeyboard

Adbn

Remove the chassis from the case as shown in Figure 9-1.

Peel the rubber bezel and display window off the chassis assembly.

Separate the chassis frame at the four release points shown in Figure 9-2 and wiggle each printed wiring board out of its socket on the displaylkeyboard assembly. Pull out slightly.

Insert a small flat-bladed screwdriver into each of the displaylkeyboard release points (Figure 9-2) and pry out the board.

Install the new board, bottom end in first, and push in the top until it clicks into place.

Reinstall the printed wiring boards into the rear of the display board making sure that the boards click into their release points.

Replace the bezel and window assembly.

Reinstall chassis into case. Press in hard, then tighten the screw. 4




How to remove the To remove the printed wiring boards from the chassis, refer to Figure 9-3 ~ r l m w l r l n g boards and follow the procedure in Table 9-1 8. frrwn the cClassis

Table 9-18 Printed Wiring Board Removal from Chassis - -

Figure 9-3 Removing the Printed Wiring Boards

Step

1

2

Chassis assembly

and window

Action

Remove the chassis from the case as shown in Figure 9-1.

Separate the chassis frame at the release points shown in Figure 9-3 and wiggle each printed wiring board out of its socket on the displaylkeyboard assembly. Pull both boards out of the chassis assembly.


- - -



Prlnted wiring board Figure 9-4 identifies each of the printed wiring boards that can be replaced IdentMcation Refer to this drawing when following the replacement procedures for each

of the boards, since you have to remove all of them from the chassis to replace the one you want. In order to lay boards flat, remove the transformer lead from the Aux.Out/Communications board and the Digital Input board. Refer to the specific procedure table to remove the desired board.

2nd Input Board - Table 9- 19 Power Input Board - Table 9-20 Digital Input Board - Table 9-2 1 Aux.Out~Cornrnunications Board - Table 9-22 MCUIOutput Board - Table 9-23

Figure 9-4 Printed Wiring Board Identification

WG connector (current output models only)

communications

Note: the transformer connectors are polarized and will only go on one way - - -




2nd input board Follow the procedure listed in Table 9- 19 to replace the Second Input board-P/N 307567 15-501.

Table 9-19 Second Input Board Replacement Procedure


Step

1

2

3

4

5

6

7

8

9

10


Action

Remove the chassis from the case. See Figure 9-1.

Remove the printed wiring boards from the chassis. See Figure 9-3.

Lay the boards flat and identify the 2nd Input board. See Figure 9-4.

Remove the transformer plug from connector J14.

The 2nd Input board is attached to the Power Input board by three mounting posts. Locate these posts under the power input board.

Use a small pliers and squeeze the ends of each post together and push it up through the board. Remove 2nd lnput board.

Orient the new 2nd Input board onto the Power Input board and push the mounting posts down through the Power lnput board until they click into place.

Replace the transformer plug onto connector J14.

Slide the printed wiring boards back into the chassis. Make sure the connections to the displaykeyboard assembly are made and that the release points on the chassis snap into place on the printed wiring boards.

Reinstall the chassis into the case. Push in hard, then tighten screw.


Power lnput board Follow the procedure listed in Table 9-20 to replace the Power Input board-P/N 30756669-501.

Table 9-20 Power Input Board Replacement h e d u r e


Step

1

2

3

4

5

6

7

8

9

10

11


Actbn



Lay the boards flat and identify the Power Input board. See Figure 9-4.

Remove the 2nd Input board, if present. See procedure in Table 9-1 9.

Remove the transformer connections to the Digital Input board and Aux.Out/Communications board, if present.

Remove the connector from plug WG if present (current output models only). Slide a small screwdriver under the connector and lift the release.

Replace the Power Input board.

Reinstall WG connector and transformer connections to Digital lnput board and Aux.Out/Communications board, if present.

Reinstall the 2nd Input board. See procedure in Table 9-19.

Slide the printed wiring boards back into the chassis. Make sure the connections to the displaylkeyboard assembly are made and that the release points on the chassis snap into place on the printed wiring boards.

Reinstall the chassis into the case. Push in hard, then tighten screw.


Digital input board Follow the procedure listed in Table 9-21 to replace the Digital Input board-P/N 30756696-501.

Table 9-21 Digital Input Board Replacement Procedwe


Step

1

2

3

4

5

6

7

8

9

10


Actbn



Lay the boards flat and identify the Digital Input board. See Figure 9-4.


The Digital Input board is attached to the MCUIoutput board by three mounting posts. Locate these posts under the MCUloutput board.

Use small pliers and squeeze the ends of each post together and push it up through the board. Remove the Digital lnput board.

Orient the new Digital Input board onto the MCUIOutput board and push the mounting posts down through the MCUIOutput board until they click into place.


Slide the printed wiring boards back into the chassis. Make sure the connections to the displaykeyboard assembly are made and that the release points on the chassis snap into place on the printed wiring boards.

Reinstall the chassis into the case. Push in hard, then tighten the screw.

Parts Replacement Procedures, Cortinued

Aux.Out/ Follow the procedure listed in Table 9-22 to replace the following boards: communicatbns board * Auxiliary Output Board-P/N 30756687-501

DMCS Communications Board-P/N 30756690-501 RS4221485 Communications Boar&P/N 30756693-501

Table 9-22 Aw.Out/Communications Board Replacement Procedure


Step

1

2

3

4

5

6

7

8

9

10

170 UDC3000 Product Manual 1 Of92

Aabn



Lay the boards flat and identify the Auxiliary Output or the Communications board. See Figure 9-4.


The Aux.Out/ Communications board is attached to the MCUIOutput board by three mounting posts. Locate these posts under the MCUIOutput board.

Use small pliers and squeeze the ends of each post together and push it up through the board. Remove the Aux.Out/Communications board.

Orient the new Aux.Out/Communications board onto the MCUIOutput board and push the mounting posts down through the MCUIOutput board until they click into place.


Slide the printed wiring boards back into the chassis. Make sure the connections to the keyboard assembly are made and that the release points on the chassis snap into place on the printed wiring boards.



MCU/output board Follow the procedure listed in Table 9-23 to replace the following MCUloutput boards:

Current Output-P/N 307567 18-502 Relay Output-P/N 307567 18-503

Table 9-23 MCUIOutput Board Replacement Procedure


Step

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Action



Lay the boards flat and identify the MCUlOutput board. See Figure 9-4.

Each option board is held onto the MCUIOutput board with three posts.. Locate these posts under the MCUIOutput board.

Use small pliers and squeeze the ends of each post together and push it up through the board. Remove the option boards present.

Remove the transformer connections to the Digital Input board and the Aux.Out/Communications board, if present.

Remove the Digital Input Board, if present. See Table 9-21.

Remove the Aux.Out/Communications board, if present. See Table 9-22.

Remove the connector from plug WG. Slide a small screwdriver under the connector and lift the release.

Replace the MCUIOutput board.

Reinstall the Digital lnput board, if present, onto the new MCUlOutput board.

Reinstall the Aux.Out~Communications board, if present, onto the new MCUlOutput board.

Reinstall the WG connector and the transformer connectors to the Digital lnput board and Aux.Out/Communications board, if present.

Slide the printed wiring boards back into the chassis. Make sure the connections to the displaylkeyboard assembly are made and that the release points on the chassis snap into place on the printed wiring boards.


Maintenance

If you find it necessary to clean the elastomer bezel, use an alcohol solution or mild soapy water.


Section 10 - Parts List

Exploded View

Introduction Figure 10-1 is an exploded view of the UDC3000 Controller. Each part is labeled with a key number. The part numbers are listed by key number in Table 10- 1. There is a list of parts not shown in Table 10-2.

Figure 10- 1 UDC3000 Exploded View



Exploded View, Continued

Parts klentiflcatbn Table 10- 1 lists the part numbers for the key numbers shown in the exploded view. Table 10- 1 Parts Identification



Quantity

1

1

1

1

1

1

1

1

2

1

1

De-wbn

Front Ground Screw

Bezel Assembly

DisplaylKeyboard Printed Wiring Assembly

Chassis

Auxiliary Output Printed Wiring Board DMCS Communications Printed Wiring Board RS4221485 Communications Printed Wiring Board

Powerllnput Printed Wiring Board

2nd Input Printed Wiring Board

Current Output MCUIOutput Printed Wiring Board Relay Output MCUIOutput printed Wiring Board

Relay, Electromechanical Relay, Solid State 1 Amp Open Collector Output Printed Wiring Jumper

Digital Input Printed Wiring Board

Case Assembly

KeY Number

1

2

3

4

5

6

7

8

9

10

1 1

Part Number

30756708-001

30756667-001

30756672-501

30756663-001

30756687-501 30756690-501

30756693-501

30756669-501

3075671 5-501

3075671 8-502

3075671 8-503

30755306-001 30756725-001 30756679-501

30756696-501

30756721 -501

Exploded View, Continued

Partsnotshown Table 10-2 lists the part numbers of the parts not show in the exploded view. Table 10-2 Parts Not Shown


Part Number

30731996-006

30754465-001

30752441 -501 30752441 -502

30755050-001

30756746-001

30756764-001

30755223-002 30755223-003

30756774-401

30756775-401

30754499-006

3075601 8-003

30756682-501

30756683-001

Desctlptkn

4-20 mA Resistor Assembly, 250 Ohms

0-10 Volt Input Resistor Assembly, 100K Pair

Varistor, 120V Varistor, 240V

Mounting Kit

Snubber Assembly

Rear Cover Kit

DIN Adapter Kit, Blue DIN Adapter Kit, Gray

Adaptive Tune Prom Upgrade

Adaptive TuneISetpoint Programming Prom Upgrade

Cold Junction Resistor Kit

External Relay, Solid State 10 Amp

Adapter (New chassis to old case)

Gasket (Panel to case)

Quanttty

1

1

1

1

1

1

1

1

1

1

1

1

Section 11 - Appendix A - Manual Tuning

Overview

When you tune a controller, there are some things to consider: Process Characteristics - Gain, Time Constants, etc. Desired response - Minimal overshoot

Basically, controller tuning consists of determining the appropriate values for the Gain (PB), Rate (Derivative), and Reset (Integral) time tuning parameters (control constants) that will give the control you want. Depending on the characteristics of the deviation of the process variable from the setpoint, the tuning parameters interact to alter the controller's output and produce changes in the value of the process variable. Since each parameter responds to a specific characteristic of the deviation, you may not need a combination of all three. It depends on the process characteristics and the desired control response.

Tuning technique You can estimate a starting point and the tuning parameters required to give the desired controller response and with some experience become proficient with this method. An alternate approach is to rely on a tuning technique. In practice, tuning techniques usually do not give exactly the type of response desired; thus, some final adjustments to the tuning parameters must be made. However, you should at least obtain a reasonable starting point from which the desired response characteristics can be obtained.

Controller tuning There are three procedures for tuning the controller: procedur@s Time, Position, or Current Proportional simplex control,

Duplex Time or Current Proportional control, Two sets of tuning constants for single output operation.

The suggested procedures describe how to establish and store values of Gain(PB), Rate, and Reset time constants for your process. You must know the type of control and algorithm your controller has.

Tuning aids A graphic recorder (such as Honeywell model DPR, DR4500, or VP13 1) connected to the process variable will make it easier to determine when the oscillations are constant and also the time for one oscillation. If a recorder is not available, you can use a stop watch to time the oscillation of the process variable displayed on the controller.


Time, Position, or Current Proportional Simplex Control

Procedure The procedure listed in table 11-1 gives you the steps for manually tuning a controller with Time, Position, or Current proportional simplex control.

Table 1 1 - 1 Manual Tuning Procedure for Simplex Control


Step

1

2

3

4

5

6

7

8


Actbn

In Manual Mode, adjust the output to bring the PV (Process Variable) near the desired value.

Set the Rate time to 0 minutes and set the Reset time to the maximum value (50.00 minutes) or set repeatsfmin to the minimum value to minimize reset action

If applicable, set the CYCLE TIME to 4 seconds and DEADBAND to 0.5.

Increase GAlN (decrease PB) significantly. Try a factor of 10.

Adjust the local setpoint to equal PV and switch to Automatic control mode.

lncrease the setpoint by 5 or 10% and observe the process variable response.

If the PV oscillates, continue to step 7. If it does not oscillate, return to the original setpoint and increase GAlN (decrease PB) again by a factor of 2, and repeat step 5.

Compare the oscillations with the figure below:

j ! 4hb-Q - -- --- -

-*( Time for one cyde

I I I I I I I I I I I I I I I I I I I I Tm

If the oscillation matches pattern A, go to step 8.

If the oscillation matches pattern B, increase GAlN (decrease PB) by a factor of 2 and repeat steps 4 to 6.

If the oscillation matches pattern C, decrease GAlN (increase PB) by a factor of 0.8 and repeat steps 4 to 6

The amplitude of the cycle is immaterial, but all of the elements of the loop must be within the operating range (i.e., the valve must not go full open or closed).

Record the current value of GAlN (or PB) and measure and record the value of time for one completed oscillation of PV.

Time, Position, or Current Proportional Simplex Control, contimed

Procedure, continued Table 11-1 Manual Tuning Procedure for Simplex Control, continued

Manual tuning formulas Table 1 1-2 lists the formulas used in the procedure listed in table 11- 1.

Step

9

1 0

Table 1 1-2 Manual Tuning Formulas

Actbn

Select the proper set of formulas from Table 11 -2. Use the values of Gain (or PB) and time (in minutes) in the formulas to arrive at the controller's tuning parameters settings.

Enter the values of GAlN (or PB), RATE, and RESET in minutes (or repeats per minute) into the UDC3000 controller and verify that the PV response is adequate.

Make additional trimming adjustments, if necessary, to fine tune the controller per the guidelines shown below:

TO REDUCE OVERSHOOT Less Gain (more PB) perhaps a longer Rate time.

TO INCREASE OVERSHOOT OR INCREASE SPEED OR RESPONSE More Gain (less PB), perhaps shorter Rate time.


Proportional (P) only

Proportional + Reset (PI) (No Rate)

Proportional + Reset + Rate (PID)

Unb

GAIN and RESET TIME in Minutes

Repeat

GAIN = Measured Gain x 0.5 RESET TIME = 50.00 (minimum reset)

RATE = 0

GAIN = Measured Gain x 0.5 RESET TIME =

(M/R) 1.2

RATE = 0

GAIN = Measured Gain x 0.6 RESET TIME = Measured

2

RATE = Measused T i m 8

% PROPORTIONAL BAND and RESETACTION in ReDeats

Minutes

%PB = Measured PB x 2 RESET ACTION = 0.02 (repeatslminute)

RATE = 0

%PB = Measured PB x 2.2 RESET ACTION = 1 ? (m) Measured Time

RATE = 0

%PB = Measured PB x 1.7 RESET ACTION = 1 7

Measured Time

RATE = Measured Time 8

Time Proportional Duplex or Current Proportional Duplex Control

For HEATICOOL applications. Tune the controller with the output above 50% for Heat and below 50% for Cool.

HEATICOOL prompts The "TUNING'*\function prompts for HEAT/COOL are:

HEAT PB or GAIN RSETMIN or RSETRPM RATEMIN CYCSEC

Two Sets of Tuning Parameters for Single Output Operation

You can use two sets of tuning constants for single output types and tune each set separately.

TWO SETS prompts The "TUNING function prompts for two sets are:

PID SET 1 PID SET 2 PB or GAIN GAIN2 RSETMIN or RSETRPM RATEMIN CYCSEC


Section 12 - Appendix B

How to Apply Digital Instrumentation in Severe Electrical Noise Environments

Guideline ovewlew Products that incorporate digital technology provide recognized performance advantages over conventional analog instrumentation used for process control. These advantages can result in better product uniformity and greater overall efficiency when used correctly.

There are, however, certain guidelines regarding installation and wiring which must be carefilly followed in order to achieve this performance. In addition to the traditional precaution of the separation of signal and power wiring in separate conduits, other measures must be taken to minimize the effects of electromagnetic interference (EMI) and radio frequency interference (RFI) on the operation of the equipment. Otherwise, if high level, short duration, noise spikes are permitted to enter the digital equipment, the noise can be transfemd into the system's logic networks and can be misinterpreted as signal data, resulting in erroneous system operation and other unpredictable responses.

- -

What's in this seabn This section contains the following information:


Topic

Potential Noise Sources

Prevention Methods

Recommended Wiring Practices

Power Source Considerations

Noise Suppression at the Source

See Page

181

182

183

185

186

Potential Noise Sources

Overview Noise can enter electronic equipment via three methods of coupling, namely:

Capacitive (or electrostatic) Inductive (or magnetic) Impedance.

Capacitive and Capacitive and inductive coupling have the same essential effect - they inductive coupling couple current or voltage, without any actual connection of the two circuits.

Impedance coupling requires a connection between the two circuits. Typical noise-generating sources that could affect electronic equipment through capacitive and inductive coupling include:

Relay coils Solenoids AC power wires - particularly at or above 100 Vac

Current carrying cables Thyristor field exciters Radio frequency transmissions.

Impedance coupled Impedance-coupled noise may enter by way of the lines used to power the noise digital equipment or by way of improper grounding. Most power lines, at

typical industrial locations, are far from noise-free. The noise on them can be generated in many ways, but are nearly always associated with switching circuits of some nature.

These include:

Large relays Contactors Motor starters Business and industrial machines Power tools HID (high intensity discharge) lights Silicon controlled rectifiers (S CRs) that are phase-angled fired.


Prevention Methods

introduction There are three ways to prevent electrical noise from interfering with the operation of the electronic digital equipment.

Built-in noise rejection Separation of signal and power lines

Noise suppression at source

Built-in noise rejectbn The first method is to &sign the digital equipment with a high degree of noise rejection built-in. This includes housing the equipment in a case that will provide shielding, liberal use of noise rejection filters and opt* isolators, and the use of noise suppressors on potential noise sources within the equipment itself. This, of course, is the responsibility of the manufacer who usually performs extensive laboratory and field testing of newly designed digital equipment to insure the adequacy of its immunity to noise. As a minimum requirement, the equipment should be able to pass the tests outlined in the IEEE Standard 472-1974 (Surge Withstand Capacizy Tests).

Signal and power line The second method is to prevent noise from getting on the signal and power SeParatbn lines that are connected to the equipment. This is achieved by proper

separation and shielding of those lines. In some cases, separate power lines or special power l i e regulation or filtering may be required for satisfactory electronic digital equipment operation. It is the responsibility of the installer to follow good wiring practices.

Suppression at the The third prevention method is to suppress the noise at its source. This is source the most effective but also the most difficult because it is not easy to identify

all of the potential noise sources in a typical industrial installation. Therefore, "suppression" is usually a last resort for those extreme situations where the other methods are insufficient by themselves. See Noise Suppression at Source which follows.


Recommended Wiring Practices

General rules All wiring must conform to local codes and practices. Wires carrying similar types of signals (Table 12-1) may be bundled together, but bundles with different types of signals must be kept separated to prevent inductive or capacitive coupling.

Table 12-1 shows what wiring should be bundled together to prevent inductive or capacitive coupling.

Wire bundling

Table 12-1 External Wiring



Wire Functbn

Bundle No.

1

2

3

No.

1 2 3

4

5

6 7

Are Shielded Twisted Wlm

Recommended?

NO

YES

YES

TYW

HIGH VOLTAGE Line Power Earth Ground Line Voltage Digital I/O

ANALOG 110 Process Variable

RTD Thermocouple dc MillivoRs

Low level ( 4 00V) 4-20 mA dc 1-5 Vdc

DIGITAL VO Low Voltage (c100V) Computer Interface

Recommended Wiring Practices, Continued

Addttlonal rules Please observe these additional rules for wire bundling:

For distances over five (5) feet, and when shielding is recommended, use a separate metal tray or conduit for each bundle. Where conduits or trays are not practical, use twisted wires with a metal overbraid and provide physical separation of at least one foot.

Tray covers must be in continuous contact with the side rails of the trays.

When unlike signal levels must cross, either in trays or conduits, they should cross at a 90-degree angle and at a maximum spacing. Where it is not possible to provide spacing, a grounded steel barrier or grid should be placed between the unlike levels at the crossover points.

Trays containing low level wiring should have solid bottoms and sides. Tray covers must be used for complete shielding. Tray cover contact with side rails must be positive and continuous to avoid high reluctance air gaps, which impair shielding. Trays for low level cables should be metal and solidly grounded.

Wires containing low level signals should not be routed near any of the following: - Contactors - Motors - Generators - Radio transmitters - Wires carrying high current that is being switched on and off.

Use a 12-gage (or heavier) insulated stranded wire for the ground connection. Attach it firmly to a proven good earth ground such as a metal stake driven into the ground.

All shields should be grounded at one end only - preferably the instrument end.


Power Source Considerations

Operate wtthln llmtts The AC power for the digital electronic equipment must be within the voltage and frequency limits specified for that equipment. Attempts to operate outside the specified limits will result in no performance. For those installations where the supply voltage will not stay within the specified limits, a ferroresonant transformer, for voltage resolution, should be used.

Independent AC source

For protection against noise, the AC source for the digital electronic equipment should be independent of all other loads especially when switching loads are involved. For example, it should not provide power for air-conditioning, convenience outlets, lighting, motors, or similar noise- generating devices. To obtain electrical isolation (see Figure 12- 1) a separate transformer is required to supply power to the digital equipment. For additional noise and transient rejection, shielded primary and secondary windings may be required. And, if necessary, power line filters may be added to attenuate noise signals that have a higher frequency than the power line frequency.

TlFensformerfordigW Figure 12-1 is an illustration of a separate transformer required to supply equipment power to digital equipment.

Figure 12- 1 Transformer for Digital Equipment

r---------- 1 I I I

Power source To digital 1201240 Vac electronic single phase

I I I I I I

- -



Generally speaking, when good wiring practices are used with well- designed digital electronic equipment, no further noise protection is necessary. However, in some severe electrical environments, the magnitude of the electrical noise is so great that it must be suppressed at the source. In most control cabinets, the main sources of noise are motor starters, contactors, relays, and switching gear. For this reason, many manufacturers of these devices supply "surge suppressors" which mount directly on the noise source, (for example, on the coil of a control relay or motor starter).

For those devices that do not have accessory "surge suppressors," resistance-capacitance (RC) Gircuits and/or voltage limiters such as metal varistors may be added when and where needed. This can be broken down into two categories, namely inductive loads (for example, a relay switch in series with a relay coil) and contacts.

Metal Oxide Varistors (MOVs) are recommended for transient suppression in inductive coils. An MOV is connected in parallel with the coil and is as close as physically possible to the coil (see Figure 12-2). MOV devices (listed in Table 12-2) 9 recommended for general purpose applications.

Table 12-2 lists part numbers for recommended MOV devices.

Table 12-2 MOV Devices


Part Number

Maximum AC

Energy Pulse Rating

Supplier (General Electric)


30732481 -001 *

130V

10 Joules

V130LA1 OA

30732481 -002

275V

15 Joules

V275LA15A

Noise Suppression at the Source, ~ o r ~ ~ l e d

Inductive coils, continued

Figure 12-2 is an illustration of transient suppression in inductive coils.

Figure 12-2 Transient Suppression in Inductive Coils

Additional protection may be provided by adding an RC circuit in parallel with the MOV. This consists of a 220-ohm resistor in series with a 0.5 microfarad, lOOOV capacitor. The power rating of the resistor will depend on the voltage rating of the coil (see Table 12-3).

Table 12-3 Coil Voltage vs Resistor Voltage Rating


Coil Voltage

115V

230V

460V

55ov


Resistor Voltage Rating

1M Watt

1 Watt

3 Watt

5 Watt J

Noise Suppression at the Source, c o r n e d

When a contact interrupts an inductive load, a certain amount of energy is stored in the load. An MOV or RC circuit in parallel with the load provides a place where this energy may be dissipated. However, if there is no MOV or RC circuit, the energy may create a visible electrical arc across the open contacts. This, in turn, results in electrical noise as well as damage to the contacts.

One way to eliminate this arc is to connect a resistor and capacitor across the contacts (see Figure 12-3). A combination of 47 ohms and 0.1 microfarads (1000 Vdc) is recommended for circuits up to 3 amps and 300 Vac. For voltages above 2000 Vac, an MOV across the contact may be added for extra protection.

Figure 12-3 is an illustration of a resistor and capacitor connected across a contact to eliminate electrical noise.

Figure 12-3 Contact Noise Suppression

A.C. supply

For large load currents, a rule of thumb is to size the capacitor so that the number of microfarads equals the number of amperes in the load current, and the resistor has the same resistance value as the load. The objective is to eliminate the visible arc.

Either discreet resistors and capacitors or packaged RC networks may be used. An Rc network (47 ohms and 0.1 microfarad) is available from Honeywell as part number 3037 1852-001. Similar RC networks are available from Electrocube Inc. (part number RG1782-3) and from Industrial Condensor Corporation.



Noise Suppression at the Source, Continued

Contacts, continued In DC circuits, the power dissipation under steady state condition can be eliminated by placing a diode (in series with a resistor) in parallel with the load (see Figure 12-4). The value of R should be less than or equal to the DC resistance of the inductive load.

Figure 12-4 is an illustration of DC load noise suppression.

Figure 12-4 DC Load Noise Suppression r I

D.C. supply

l nductive load


Index

A +COW 51 +VIEW 51 ADAPTIVE TUNE 53,102 Adaptive Tune Error Codes 106 ADAPTIVE TUNE ERROR STATUS 54 Adaptive Tune Set Up Group 35,53 Alarm Setpoints 99 Alarms Set Up Gmup 44,75 Algorithm Data Set Up Group 36,55 Automatic Mode 88 AUTOMATIC SWITCHOVER VALUE 66 Aux.Out/Communications Board Replacement

Procedure 170 AUXILIARY OUTPUT 70 Auxiliary Output Board 170 Auxiliary Output Calibration 142 Auxiliary output connections 20 AUX OUTPUT HIGH SCALING FACTOR 71 AUX OUTPUT LOW SCALING FhCTOR 71

Background Tests 151 BAUD RATE 73 BIAS 62,66 BURNOUT PROTECTION 62

C CALIB 51 Calib Group 46 Capacitive and inductive coupling 181 Chassis Removal 163 Cleaning 172 Coil Voltage vs Resistor Voltage 187 COMMUNICATION UNITS 74 Communications Group 43 Communications option connections 22 COMMUNICATIONS SELECTION 73 Communications Set Up Group 73 COMMUNICATIONS STATION ADDRESS 73 Composite wiring diagram 11 Configuration 25 Configuration Procedure 30 Configuration Prompt Definitions 48 Configuration Prompts 26 Configuration Record Sheet 47 Configuration Tips 29 Contact Noise Suppression 188 CONTROL ALGORITHM 55 CONTROL OUTPUT DIRECTION 68 Control Parameters Set Up Group 40,65 CONTROLLER DROPOFF VALUE 68 Controller failure symptoms 147,153 Current output connections 18

Current Proportional Duplex 179 Current Proportional Output Calibration 136 CYCLE TIME 50 CYCLE TIME 2 50

D DC Load Noise Suppression 189 DEADBAND 68 DECIMAL POINT LOCATION 59 Diagnostic error messages 85 Digital Input Board Replacement FWcedure 169 DIGITAL INPUT COMBINATIONS 72 Digital Input Option 101 DIGITAL INPUT SELECTIONS 71 Digital inputs connections 21 Dimensions 7 DIRECT ACTING CONTROL 68 Displayjkeyboard assembly 164 Displays and indicators 2 DMCS Communications Board 170 DUPLEX 74

Electrical isolation 185 Electrical noise 9,180 Electromagnetic interference 180 Electromechanical Relay Output. 15 EMISSIVITY 62 End segment number 109 Error messages 146 EXTERNAL PROGRAM RESET 72.11 7

FAILSAFE OUTPUT VALUE 69 FILTER 62 FILTER FOR INPUT TWO 64 Function of keys 3

G GAIN 49 GAIN 2 50 Guaranteed Soak 110

HIGH OUTPUT LIMIT 68 HYSTERESIS 69

lot92 UDC3000 Product Manual 191

Impedance coupled noise 181 INPUT 1 ACTUATION TYPE 60 INPUT 1 HIGH RANGE VALUE 61 INPUT 1 LOW RANGE VALUE 62 Input 1 Parameters Set Up Group 37.59 INPUT 2 HlGH RANGE VALUE 64 INPUT 2 LOW RANGE VALUE 64 Input 2 Parameters Set Up Group 39 Input Calibration 119 Installation 4

K Keys 3

Line voltage wiring 12 Local Setpoint Change 90 local setpoint source 90 LOCKOUT 51 LOOPBACK 74 LOW OUTPUT LIMIT 68 Lower Display Key 84

Maintenance 172 Manual Mode 88 MANUAL RESET 50 Manual Tuning 176 Manual tuning formulas 178 Manual Tuning Procedure 177 MANUAL/AUTO KEY LOCKOUT 51 MCUIOutput Board Replacement Procedure 171 Minimum and Maximum Range Values 120 Model number 6 Model Number Interpretation 6 Monitoring Your Controller 83 Mounting

Overall dimensions 7 Mounting method 8 Mounting procedure 8

N Noise 180 Noise rejection 182 Noise Suppression at the Source 186

ONIOFF 55 Open Collector 0utput.Connections 17 Operating limits 5 Operating Modes 87 opemting parameters 84 Operation 79 Operator Interface 2 Options Set Up Group 42,70 Output algorithm 57 Output Calibration 135 OUTPUT CHANGE RATE 68 OUTPUT RATE DOWN VALUE 68 OUTPUT RATE UP VALUE 68 Overview 1

P,Q PARITY 73 Parts Identification 174 Parts List 173 Parts Replacement Procedures 162 PD WITH MANUAL RESET 56 Physical considerations 7 PID A 55 PID B 56 Position Proportional Backup mode 89 Position Proportional control output calibration, 138 Position proportional output connections 19 Potential Noise Sources 181 Power Input Board Replacement Procedure 168 POWER LINE FREQUENCY 62 Power Source Considerations 185 Power u p 80 POWER UP CONTROLLER MODE RECALL 67 POWER UP PRESET AUTOMATIC OUTPUT 69 POWER UP PRESET MANUAL OUTPUT 69 Power-up Tests 148 Precision Resistor 124,130 Printed wiring board identification 166 Printed Wiring Board Removal 165 PROCESS GAIN 53 Program Record Sheet 11 2 Program state 11 0 Program termination state 11 0 Prompt hierarchy 26 PROPORTIONAL BAND 49 PROPORTIONAL BAND 2 50 PROPORTIONAL BAND UNITS 69


Index

R Radio frequency interfetence 180 Ramp segments 109 Ramp unit 11 0 RampISoak Profile example 11 1 RATE 2 50 RATE action 49 RATE DOWN 52 RATE UP 52 RATIO 66 Recommended Wiring Practices 183 Recycle number 109 RELAY TYPE 58 REMOTE SETPOINT 66.91 Remote Switching 101 RESET 50 RESET 2 50 RESET UNITS 69 REVERSE ACTING CONTROL 68 RS4221485 Communications Board 1 70 RUN/HOLD KEY 51

S Second Input Board Replacement Pmedure 167 SECURITY CODE 51,82 SET POINT LOW LIMIT 67 SETPOINT HIGH LIMlT 67 Setpoint Program Data Entry Procedure 113 SETPOINT RAMP 52

Configuring 93 Running 94

SETPOINT RAMP FINAL SETPOINT 52 SETPOINT RAMP TIME 52 Setpoint RarnpISoak Programming Option 108 SETPOINT RATE 52,92 SETPOINT SELECT KEY LOCKOUT 51 Setpoint selection indication 92 SETPOINT SOURCE 66 SETPOINT TRACKING 67 Setpoints 90 SHED CONTROLLER MODE AND OUTPUT

LEVEL 74 Shed setpoint 74 SHED TIME 73 Signal and power line separation 182 Single Setpoint Ramp 93

Soak segments 109 Software version 147 Solid State Relay Output Connections. 16 SP RampProgram Set Up Group 34 Start segment number 109 Start Up 86 Status Group 46 Status Tests 149 Suppression at the source 182 Surge suppressors" 186 Switch-over value 97

TEMPERATURE UNITS 59 THREE POSITION STEP 56 Three Position Step Control Algorithm 100 Three Position Step Output Calibration 138 Time Proportional Duplex 179 Transformer for Digital Equipment 185 Transient Suppression in Inductive Coils 187 TRANSMITTER CHARACTERIZATION 61 Troubleshooting / Service 144 Troubleshooting Aids 146 Troubleshooting Procedures 154 TUNING PARAMETER SETS 65 Tuning Parameters Set Up Group 32,49 Two Sets of Tuning Parameters 179

UDC3000 Exploded View 173 Using Two Set of Tuning Constants 96

Wire bundling 183 Wiring 9

electrical noise precautions 9 wire bundling 9 wiring the controller 10

Wiring Diagrams I 1 Relay output 15

10192 UDC3000 Pmduct Manual 193

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Attention: Manager, Quality I - - - - - - - - - - - - - - - - - . . . - - - - - - - - - - - - - . I - -

FOLD F0I-0 I I I I I I I I I I 1 I

I : s l u a m q puoy~ppv I

Honeywell Industrial Automation and Control Honeywell Inc. 1100 Virginia Drive Fort Washington. PA 19034

- -

Helping You Control Your World

51.52.1047 Page 6

Lieci1MI 01 Range of Ssltiw rn rn ALARMS A1S1 VAL

AlS2 VAL A2Sl VAL A2S2 VAL

Value in Engineering Units (For SP Programming, Value = Segment Number)

NONE = No Aiarm IN 1 = input 1 IN 2 = input 2 PV = Process Variable DEV = Devlatlon OUTPUT = Output SHED = Commun~cations Shed EV ON = Event ON (SP Programmlng) EV OFF = Event OFF (SP Programmlng)

A lS l (H L) (EV) HI = High Aiarm (H L) AlS2 (H L) (EV) LO = Low Aiarm (H L) A2S1 (H L) (EV) BEGIN = Beginning of Segment (SP

Programming) (EV) A2S2 (H L) (EV) END = End of Segment (SP Programming)

(EV)

AL HYST 0 0 to 5 0% of span or full output - - -- - - -

CALIB USED FOR FIELD CALIBRATION -

STATUS VERSION Software Verslon Number

FAILSAFE Read Oniv ' YES or " N O

RAM TEST CONFTEST Read Only CAL TEST "PASS or "FAIL" FACT CRC

-

SP RAMP SP PROG ENABLE (must enable to allow prompts listed lSet Polnt below1 .-- ~ a m p i a a k DlSABL Programming) GnT 9r I trill

END SEG 2 to 12 (must be Soak Segment-even number) - -- -- --

RECYCLES-__ 01099 - - --

SOAK DEV - -- Ot099(+)

p-

SEG1 RAMP 0 to 99 hrs 59 mlnutes or 0 to 999 degreeslmlnute

SEG2 SP W ~ t h ~ n SP range lhmlts In Engineering Unlts

SEG2 TlME 0 to 99 h n 59 mlnutes

SEG3 RAMP 0 to 99 hrs:59 minutes or 0 to 999 degreeslminute

SEG4 SP

SEG4 TlME

SEG5 RAMP

SEG6 SP

SEG6 TIME

SEG7 RAMP

SEGB SP

SEGB TlME

SEG9 RAMP

SGlO SP

SGlO TlME

SG11 RAMP

SGl2 SP

SG12 TlME

STATE

Within SP range limits in Engineering Limits

0 to 99 hrs:59 minutes

0 to 99 hrs:59 minutes or 0 to 999 degreeslminute







Within SP range limits in Engineering Units

0 togs hrs:59 minutes


Within SP range limits in Engineering Units

0 to 99 hrs:59 minutes -- --

DISABL uni n

PROG END LAST SP = hold at the last set ~ o i n t in the program

FSAFE = Manual Mode, Fallsafe Output - - RAMP UNIT TIME = Hours Mlnute

RATE = DegreeslM~nute

UDC 3000 /Configuration Universal Digital Controller Prompts

Key lets you move from one set up group to another.

Key lets you call up the specific function prompts within each P group. I I 1 ;::let you make a selection or change the 1

Industrlai Aatomallm and Cmtml Mrlslon. 1100 Viqlnia m, F M Washingtm. PA 1935.1 Prlnted In U.S.A. O Copyright 1962 - Honeywell Inc

51~52~10.07 Page 3

- Seeon or knpe 01 @ @ - 50 PCT = Current Duplex Range (Spllt)

1W PCT = Current Duplex Range (Full) MECHAN - Eteclro mechanlcai reiay SOL ST = Solld state relay

- - - - XXXX = No dec~mal place XXX X = One declmal place XX XX = Two declmai places DEG F = "Fahrenheit DEG C = "Celsfus NONE See Upper Dtsplay Prompts to select actuation type Applicable for Lmear input Ranges only See Upper Display prompts to make selection

-9999t09999 -9999to9999 -9993109999 0 to 120 seconds NONE = No burnout UP = Upscale burnout DOWN = Downscale burnout 001 t 0 1 W 60 Hz 50 HZ

- - - - - - -- Available for Llnear Inputs only See Upper Dlsplay Prompts -9999 to 9999 -9999t09999 0 l o 120 seconds

- - - - - - -- - -

---

Selecter 8% of E m g @ @ -

- 5 0 to + 105 0% Of output Ttme proportional dupiex = -5 0 to 250% ON OFF dupiex = 0 0 to 25 0% Positlon proportional or 3 posltlon step = 0 5 t 0 5 0 % OOto50% of PVSpan Wlthln the range of output llmits

TUNING PROP BAND or GAlN RATE MIN

0.1 t o m ALGORTHM 4.20RNG (continued)

RLY TYPE

CONTROL DROWFF (continued) DEADBAND

0.08 to 10.0 minutes 0.02 to 50.W RSET MIN or

RSET RPM MAN RSET PROP BD2 or GAlN 2 RATEZMIN

-- - -

INPUT 1 DECIMAL OUT HYST FAILSAFE MAN OUT AUTO OUT 0 to 10.M) minutes

0.02 to 50.00 PB or GAlN PB PCT = Proportional band In per cent

GAlN = Ga~n MiN = Mlnuteslrepeat RPM = Repeatsim~nute

- - -- - - - DISABL = No auxlllafy output IN1 = Inout 1

MiN or RPM CYC SEC CYC2 SEC SECURITY LOCKOUT

1 to 120 seconds I to I20 seconds 1104095 NONE = No lockout CALlB = Calibration locked out. +CONF = Tuning, SP Ramp, and Autotune

are Readwrite; ail other groups Read only.

+VIEW = Tuning and Set Point Ramp are Readwrite onlv: all others cannot

- - - - OPTIONS AUX OUT

IN1 HI IN1 LO BiAS IN1 FiLTER 1 BURNOUT

IN2 = Input 2 W = Process Variable DEV = Deviation OUTPUT = Output SP = Set Point

4mA VAL Low scale value within the range of the selected variable to remesent 4 mA

be viewed. MAX = Tuning and Set Point Ramp

parameters are avaflabie for Read 20mA VAL High scale value within range of the selected

variable to represent 20 mA. EMlSSiV PWR FREQ DIG IN1 NONE

TO MAN = To manual TO LSP = To local set point TO SP2 = To set point two TO DlR = TO direct action TO HOLD = To hold set polnt ramp TO PID2

only ENABLE (Allows ManiAuto key lockout) DISABL ENABLE (Allows Set Point Select key lockout) DISABL ENABLE (Allows RunIHoid key lockout) DISABL

- - - - - - - - - - ENABLE (Allows slnqle set Dolnt ramp

AUTO MAN - - - INPUT 2 XMlTrER SP SEL

RUN HOLD IN2 HI IN2 LO FILTER 2

-- -- -- - CONTROL PlD SETS

PV 21N TO RUN TO BEGN STOP l EN ADT TO MAN FS Same as DIG IN1

-- - SP RAMP SP RAMP

prompts) DISABL (Must be disabled to permlt

"SP PROG Sat Point RamplSoak Programming)

1 ONLY = One set 2KEYBD = Two sets, keyboard selectable 2PV SW = Two sets, PV automatic DIG IN2

- -- - - -- Corn Corn STATE TIME MIN

FINAL SP SP RATE

switchover 0 to 255 minutes Within the Set Point Limits ENABLE (Set Point Rate selection) DISABL

2SP SW = Two sets SP automatic swltchover DMCS R y l Z DISABL

SW VALUE SP SOURCE

Value in Engineering Units ILOCAL = Local set point 2LOCAL = Twa local set poinls Com ADDR

SHEDTIME" PARITY'

1 to 99 0 to 255 sample periods (0 = no shed) ODD EVEN m

SP PROG ENABLE (See page 6 for Prompts) DISABL

- - - - -- - - - RSP SRC NONE = No remote SP

IN2 = input 2 is remote SP -20.W to 20.W - m i 0 9 9 9 9 NONE = No tracking PV = Local set point will track the PV

when in manual mode RSP = Local set point tracks remote set

point when in auto mode MANUAL = Manual, local set point A LSP = Automatic, local se! point A RSP = Automatic, remote set polnt AM SP = Last mode. last set polnt AM LSP = Last mode, last local set point 0 to 100% of Span in Engineering Units 0 to 1W% of span in Engineering Units DIRECT control ou:put REVRSE control outpur ENABLE (output change rate) DISABL - -59 to 7 105O2/o of output - 5.0 to + 105.OYb of output

ADAPTIVE ADAPTIVE DISABL SP only

RATIO BIAS SP TRACK

BAUD*

SP CHANG KPG AT ERROR

ALGORTHM CONT ALG

5 to 15% Span 0 01 to SOW (Process Ga~n) (READ ONLY)

- -- - - --

ON-OFF PID A DUPLEX'

LOOPBACK"

HALF = Half duplex FULL = FII duplex ENABLE DISABLE

POWER UP PID B PD + MR = PD wlth Manual Reset 3PSTEP = Three Position Step

INPUT 2

OUT ALG

ENABLE DISABL

SHEDMODE" LAST = Same mode as before shed TO MAN = To manual mode, bumpiess

,,,,+",'+ SP HiLiM SP LOLlM ACTION

TIME CURRNT POSiTN TIMED CUR D CUR TI

FSAFE = To manual mode, fallsafe output TO AUTO = To automatic mode

SHED SP" TO LSP = To local set point TO CSP = To last computer set polnt Current duplex

CurrenURelay Duplex (relay = OUT RATE

UNITS PERCNT = Percent ENG = Engineering Units

. . -- - --. -- - - - . - .. 'US422 only

"in DMCS only

Heat) Current/Relay Duplex (reiay = CWl)

Ti CUR

INDEX NO. 19

HIGH TEMPERATURE CUTOFF

Honeywell

UDC2000 Mini-Pro Universal Digital Controller

Limit Control Model

Product Manual





UDC 2000 is a trademark of Honeywell Inc.




ii UDC2000 Limit Controller Product Manual 1 /93

How this manual Is This Product Manual is divided into 9 sections numbered 1 through 9. organized These sections contain all the information you need to configure, operate,

monitor, and troubleshoot your controller. To find information quickly, use the comprensive Table of Contents in the front of the manual.

Wananty The device described herein has been manufactured and tested for correct operation and is warranted as follows:

The UDC2000 Universal Digital Controller carries a two year warranty. This warranty includes immediate technical assistance via a toll free telephone number and complete replacement of the controller or parts, if necessary.


1-800-423-9883 An engineer will discuss your problem with you. Please have your complete model number, serial number, and Software version available. The model and serial numbers can be found on the chassis nameplate. The software version can be viewed under Setup Group "Status." If it is determined that a hardware problem exists, a replacement controller or part will be shipped with instructions for returning the defective unit.

Do not return your controller until the replacement has been received.

UDC2000 Limit Controller Product Manual iii

UDC 2000 LIMIT CONTROLLER FOREWORD How This Manual Is Organized The UDC 2000 Mini-Pro Universal Digital Limit Controller Product Manual consists of 9 sections numbered 1 through 9 titled as shown below and appearing on each page. Page numbers include a section number prefix so you can readily access the described information.

4 , OVERVIEW b,0 0 0 0 0 0 0 0 0 0 0 SECTION 1

- OPERATION 000000000 SECTION4 - CALIBRATION 30000000 SECTIONS

L - SERVICE 3 0 0 O O O O SECTION6 - - PARTS LIST 3 0 O O O O SECTION 7 1

APPENDIX A 3 0 0 0 0 SECTION 8

APPENDIX B 0 0 0 0 SECTION 9

El~minating electrical noise

Defining the configuration prompts

Ordering replacement parts

L___----__ Troubleshooting 1 Service

Calibrating the Mini-Pro

I I L______ Operating tips and procedures

' I ' Configuring the Mini-Pro I I Installing the Mini- Pro

I Describing the Mini- Pro

Start Up Made Easy Pages 2 and 3 of this foreword contain "Start Up Made Easy" information. The page references listed under the model codes let you find the information you need to get your controller Installed, Configured, and Operating as quickly as possible.

START UP MADE EASY

1. Model Number Selection To use this procedure, copy the Model Number of your controller into the blocks below. Note:The model number is located on the side of the case or on the inside of the chassis.

Key No. Table I Table I1 Table 111 Table IV

2. Process Variable (PV) Input Type The UDC 2000 Limit Controller will accept Thermocouple (TIC), Res~stance Temperature Device (RTD), and Radiamatic PV sensor inputs. You must connect and configure the UDC 2000 input properly so that it matches the process sensor you are using in the system. Please refer to the the following Product Manual pages:

Configuration: Pages 2-1,2-3, and 3-5 Installation : Page 2-1,2-3

3. Model Number Breakdown Following is a model number breakdown that identifies the functional~ty and opt~ons that may have been provided with your controller. Refer to the model number that you have written in above and select the table codes that are pertinent to that model. For each table code, there is a product manual page reference(s) that gives you the following: Explanation: A functional description of the option Installation: The steps needed to wire and mount your controller Configuration: How to configure hardware jumpers and software prompts a. The Key Numbers are:

DC2OOH HIGH LlMlT CONTROLLER DC2OOL LOW LIMIT CONTROLLER

Go to Pages Explanation: 1-1, 2-2

Hardware Configuration: 2-3 Installation: 2-4 through 2-9

b. If Table 1 is:

0 NO ALARM RELAY No page reference required

1 1 ALARM RELAY Go to Pages

Explanation: 1 - 1, 8-6 Configuration: 3-7,4-4 Installation: 2-1,2-2,2-3 Wiring: 2-6

contrnued next page

51-52-99-05, Page 2 of 3

3. Mode l Number Breakdown (continued)

c. I f Table 11 is:

000 NO PV OUTPUT I NO EXTERNAL RESET (CONTACT INPUT) No page reference required

200 PV OUTPUT I EXTERNAL RESET (CONTACT INPUT) Go t o Pages

Explanation: 1-1, 8-5 lnstallation: 2- 1, 2-3, 2-7 Configuration: 3-6,4-3

d. If Table 111 is:

1 XXX00 120Vac (50160 Hz) 2XXXOO 240Vac (50160 Hz)

Go t o Pages Installation: 2-1

XOXXOO NO APPROVAL BODIES N o page reference required

XXOXOO NO EXTERNAL RELAY OPTIONS N o page reference required

XX1 X00 10 AMP SOLID STATE CONTROL RELAY OUTPUT KIT XX2XOO 2 AMP SOLID STATE CONTROL RELAY OUTPUT KIT

Go t o Pages Hardware Configuration: 2-3 Installation : 2 -8

XXXOOO NO CUSTOMER ID TAG XXXTOO CUSTOMERIDTAG

N o page reference required

XXXXOO CUSTOM CONFIGURATION N o page reference required

4. Enter Set Point Value and Reset Output Relay The f inal step when setting your controller is t o enter your Set Point value and reset t h e Outpu t Relay, if necessary. Af ter t he un i t has been reset t o unlatch t he ou tpu t relay, t h e controller will n o t display the Limit indication o n the lower display. When the set po in t value has been exceeded, t he latching relay will t r ip and the lower display will indicate Limit. Please refer t o t h e t h e fo l lowing Product Manual pages:

Go t o Pages Enter Set Point Value: 4-3 Reset Output Latching Relay: 4-3

5 1-52-99-05, Page 3 of 3

TABLE OF CONTENTS

CONTENTS

FOREWORD (5 r -52-99-051 How thrs Manual IS Orgarlrzed . . . . . . . . 1 Start-up Made Easy . . . . . . 2

OVERVIEW (5 1 52 02 06) O~~era t~ng Prlnclples I - 1 Foat~~res'Bcnef~ts 1 - 1 Optronal Features 1 - 1 Operator Inlerface Overvrew 1-2 Mvitel Nurnbel Interpretatloll 1-3 Coriderisetf Specrf~cal~orla 1-3

01x1 al~rlq Condrt~ons 1-3 Flcld SL loctable Input Acluat~ons 1-4 ACC~II acy 1-4 Power Rc:qulr ernorlts 1-4 lsolat~or I 1-4

INSTALLATlON (57 52 09 101 Ir \~pect for Darnage Model Nurnt)er ldentlflcatron P~cllrnrnar y Checks

Check Operatrny Volla e Selection Clieck tllc lrlput Type 8electlon Check I rrnrl Relay Contacl Actron Clieck Alarm Relay Contact Actrori Check PV Output or Contact Input Select~or~

L~ rn~ t Reldy Contact Informat~on Chart Ala~ rn Relay Contact lnformat~on Chart Locatlor) of Jumpers and DIP swltch Mountlng

Plly srcal Cons~deratrons Mount~ng Procedu~ e Mo~~ntrr~cj Accessories -

W~rrr~y 2-5 lilet,trly y o ~ ~ r Model Nurnbcr 2-5 W ~ r ~ n g the Controller 2-5 Tak~ny Electr~cal No~se Precaut~o~ls 2-5 L~ rn~ t Cor~t~ol le~ Wlrlrly Dlagram 2-6 External Interface Optlor1 Wlrlng D~ayrarrl 2-7 Solid State Relays Wlr~ny D~agrarn 2-8

Aldrrn and Control Relay Caut~on 2-9

CONFIGURATION i s I 52 lo 21) lntroduct~on 3- 1 Prornpts 3- 1 Key Etro~ 3- 1 How to Get Started 3- 1 Prompt H~crarchy 3-2 How to change a Conf~gurat~on Parameter 3-3

How to Select a Set-Up group 3-3 How to Select a F~~nctron 3-3 How to change a Value or Select~orl 3-3

Huw to Restore the Or~glnal Value 3-3 How to Enter a Value or Select~on 3-3 How to Exit Conf~guratlon Mode 3-3 Conhgurat~on Tlps 3-3

Scroll~llg 3-3 Changlny Values Quickly 3-3 T ~ r n ~ n Out from Set-Up 3-3

Prompt 8loups Lockout Parameters 3-4 Lrmlt Parameters 3-4 Input Parameters 3-5 Opt~on Parameters 3-6 Alarm Parameters 3- 7

Conf~gurat~on Record Sheet 3-9

UDC 2000 LIMIT CONTROLLER

CONTENTS

OPERATION (5 1-52-1 1 16) Operator Interface Overvrew 4- 1 Checklng the Conf~gurat~on 4-2 Powerrng the Controller 4-2 Operating Prlncrples 4-2 Mon~torlng the Controllel 4-2

The D~splays and I~idrcato~ s 4-2 The [DISP] D~splay Key 4-2 Tlmlng out from Lower D~splay 4-2 The [RAISE'LOWER] key 4-2 Key Error 4-3 D~agnostlc Error Messages 4-3

Operatrng the Controller 4-3 Enter a Set Po~nt Value 4-3 H~gh and Low Lrmlt Indrcatrorl 4-3 How to RESET the Latchlng Relay 4-3 Usrng the Contact Input (Exte~rldl Reset) C I ~ ~ I O ~ I 4-3 Changlng the Alarm Set Porrlts 4-4 Power UP Logrc 4-4

CALIBRATION (5 1-52 13 16) lntroduct~on Input Cal~bratlon

lntroduct~on Mlnlmum and Max~mum Range Values Table of Voltage vs Reslstance Equivalents Prellmrnary Procedures

Disconnect f~eld wlrlng Set the DIP swrtches for Input

Equrpment Needed Thermocouple Inputs RTD (Reslstance Therniorneter Dev~ce) Rad~amatlc (RH)

Set UD ~he rmocou~ le Inputs . .

RTD . . . . . . . . . . . . . .

Radiamatrc (RH) . . . . . . . . . 5-4 lnput Cal~brat~on Procedu~e . . . . . . . . 5-5

Output Cairbratron . . . . . . . . . . . . . . 5-6 Auxrl~ary (PV) Output . . . . . . . 5-6

Introduction . . . . . . . 5-6 Preliminary Procedures . . . . 5-6 Equrpment Needed . . . . . 5-6 Set Up . . . . . . . . . . . . . . . . . . . 5-6 Callbratlon Procedure . . . . . . . . . . 5-7

TROUBLE SHOOTINGlSERVICE(5 r 5 2 - 13 r 7 , lntroductron . . . . . . . . . . . . 6- 1

lnstallat~on Related P~oblerns . . 6- 1 Application Related Problems . . . . 6- 1 Hardware and Software Related Problerns 6- 1

Controller Failure lnd~catioris . . . . . . . . 6- I Error Messages . . . . . . . . . . . . . . 6- 1 Other Failure Symptoms . . . . . . . . . 6- 1 Check lnstallat~on . . . . . . . . . . . 6- 1

Customer Support . . . . . . . . 6- 1 Phone Number . . . . . . . . . . . . . . . . . 6- 1

Error Messages . . . . . . . . . . . . . . . 6-2 Background Tests Error Prornpts . . . . . . . 6-2 Status Test Error Prompts . . . . . . . . . . . . . . 6-4 Controller Failure Symptoms Chart . . . . . 6-5

Troubleshoot~ng Procedures . . . . . . . . . 6-6 Power Failure . . . . . . . . . . . . . . . . . . . . . . . . 6-6 latchin Relay Output Fallure . . . . . . . . . . . 6-6 Alarm ?3elay Output Failure . . . . . . . . . . . 6-6

LIMIT CONTROLLER TABLE OF CONTENTS

CONTENTS PAGE

PARTS LIST (51 -52-14-10) . . . . . . . Exploded View of the Llmit Controller 7-1

. . . . . . . . . . . . . . . . . . . . . . . . . . Parts List 7-2 . . . . . . . . . . . . . . . . . . . . Parts Kits not Shown 7-2

APPENDlX A - DEFINITIONS (51-52-19-18) . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 8-1

. . . . . . . . . . . Parameter Groups and PI-ornpts 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock 8-2

Lock L~ rn~ t

Low or Hlgh Power up Set Po~nt high Llmlt Set Point Low L~ rn~ t Default D~splay

Input . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Declmal Point Locat~on Temperature Un~ts lnput Actuation Type lnput High Range Value lnput Low Range Value B~as Filter Em~sslv~ty Frequency

Options . . . . . . . . . . . . . . . . . . . . . . . . --- 8-5 Contact Input(Externa1 Reset) Auxiliary Output Selection

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Alarrn Set Point Value Alarrn Set Polnt Type Alarin Set Polnt State

Calibrat~on . . . . . . . . . . . . . . . . . . . . 8-7 Status Test Data . . . . . . . . . . . . . . . 8-7

APPENDIX B - (5 1-52-19-19) "How to apply Digrtal Ir~slri~rnentation //I Severe Electrical Noise Enwroi~ments"

lntroduct~or~ . . . . . . . . . . . . . . . . 9-1 . . . . . . . . . . . . . . . . Potential No~se Sources 9-1

. . . . . . Recomrnerlded Wiring Practices 9-1 . . . . . . . . . . . . . . . . . . . . . Power Source 9-2

. . . . . . . . . . No~se Suppress~on at the Source 9-3

OVERVIEW SECTION 1

Operating Principles General UDC2000 Controllers accept input signals from any of several types of external sensors such as Thermo- couples (T C's) and Resistance Temperature Detectors (RTD's). It condrtrons these signals, as necessary, to derlve the equivalent Process Variable (PV) value that drives various circurts in the controller.

The equivalent PV signal is compared with the Llmit control set point and any error signal from the differentla1 anrplifier de-energizes the coil of an electromechan~cal, single-pole, single-throw (SPST) lrmrt output relay.

When de-energrzed, the output relay "Locks Out" and remains that way unt~l the PV lnput srgnal drops below the Hlgh Llmlt Set Pornt or goes above the Low Llmrt Set Pornt and the controller ts reset manually vra the keyboard or frorn a remote locatron (Contact Input Optlon).

You can select rlormally open (N.O.) or normally closed (N.C.) Llrnlt Relay Contacts s~mply by movlng a jumper.

Ttle contact ot the output relay termmates at the rear terniinal of the controller to which you make the appropriate held wlrrng connections.

A flashrng "LIMIT" In the lower display ~ndrcates that the output relay 1s de-energized.

High Limit Controller When the PV lnput signal is below the limit set point, the output relay energrzes. If the PV srgrlal exceeds the lrmrt set pornl, the output relay de-energizes and the flashlng "LIMIT" dlsplay is turned on.

When the PV signal returns to a value below the llmrt set pornt, the controller can be reset manually using the [RESET] key or Contact lnput Optron.

Low Limit Controller When the PV tnput signal is above the limit set point, the output relay energizes. If the PV srgnal falls below the limit set point, the output relay de-energizes and the flashlng "LIMIT" display is turned on.

When the PV srgnal returns to a value above the l~mit set pornt, the controller can be reset manually usrng the [RESET] key or Contact lnput Optron.

Remote Reset (Contact lnput Option) If you have thrs option, the controller can be reset from a remote location by manipulating a momentary-type swrtch. Thls remote reset switch is connected to rear terminals on the controller that are used rn parallel with the local [RESET] pushbutton circuit.

Easy to Configure - A brrght dedrcated confrguratron drsplay provrdes strarghtforward Engl~si~ prompts that allow easy set-up wrth mtnrmurn tlnle and effort.

Universal lnputs - Accepts 10 thermocouple types. Radramatic or RTD Inputs through srmple confrguratron

Set Point Limits - Confrgurable high or low set point Irmrts.

Power Up Logic - lets you select " output In alarrn at power up" or "output to state prior to power down".

Thermocouple Failsafe - Upscale burnoul for thermocouple actuations on Hrgh Lrmlt, downscale burnout on Low Lrmit.

High Noise Immunity - The Mrnl-Pro IS designed to provide relrable performance In industrral environments that often affect hlghly norse-sensrtlve dlgital equipment.

Decimal Point Location - Contrgurable for none, one, or two places.

Diagnosticlfailsafe Outputs - Continuous dragnostic routines detect farlure modes, trigger a farlsafe output value and ~dentify the failure to mlnrmrre troubleshoottng trme

Highly Secure - Non-volatile memory assures data integrity durrng loss of power. Keyboard securlty inhibits accidental or unauthorized changes to the process.

Moisture Resistant Front Panel - capable of meeting NEMA3 and IEC IP65 (i.e. hosedown) requirements.

Optional Features External Reset (Contact Input) - This feature resets the latchlng relay on contact closure.

PV (Auxiliary) Output - This process variable auxll~ary output can be scaled from 0 to 5 Volts or 1 to 5 Volts for 0 to 10O0/o for arly range desired

Alarm Selection - One non-latchrng alarm relay to actrvate external equrpment when preset Hryh Low set pornts are reached There 1s an lnd~cator for ~ t w alarrr~ on the operator interface. There IS a flxed Alarrn Rctld) Hysteresrs of 0.5O/0 of lnput (PV) span

Solid State Relay Output - Optional output rated at 1 Amp at 120i240V or 10 Amps at 120 240V. Minimum load 0.1 Amp.

LIMIT CONTROLLER OVERVIEW

FUNCTION

, OPERATOR INTERFACE OVERVIEW

DISPLAY

L I n / \

Honeywell

ALM 12

OUT /I '1 ll(]lI 9 5 t ~ ] l I l , , l < , $ 1 , 1 1 -

I LOWER DISPLAY - ~ll5l*lrly Is dc.tjlk dl~'t1 111 1 1 1

[If(>' c!55 ~dlldk)lC! 0 1 [I11111 A dedicated 6 d~glt 14 Sc1 Po111t clur ~ n t l ~ ( J I III,II segment lower dlsplay U f i L 1d11011 ~ I t t l al(t'l l l d l ~

III~UI m'illon tl~splayc 1 1 ~ l l r i I I I ' )

~u r l l ~ yu~a t~o r l during conf~yuratlon SL! PUIII~ UI PIUCCL:

SET UP V ~ I iablc. values rrl~i\ I>< "PV on demand, wrth ttie 5 l l 0 ~ 1 l C ) l l delndlld value In the upper d~splay

I

F = "Fahrerltie~t C = " Cels~us

' 1 ALM = Alarm condltlon exlsts I

RESET

FUNCTION E l

I I I

P

STATUS INDICATORS They provlde the status of the

Key Functions SIX keys enable complete conf~gurat~ori and operatlor1

alarm relay There IS also lndlcat~on to show the

temperatul e units

-

DISPLAY El

Selects functions w~thln each conflguratlon group

SET UP E l Allows vlewlrlg of the set po~nt Deact~vates tilt I ~ I L~ I I I I ~ or Process Vanable Returns relay except 111 Sct UII the controller to normal rnode Also. L I ~ C C ~ tu operat~on from SET UP mode restore or~g~nal vduc or

selection when I r ) SET UP mode

Not used

Decreases the set polnt or configuration values.

Not used

71 Increases the sul poll11

I I or conflgur atlull values.

F~gure 1 - 1 Opcralor lr~tcrface 1


MODEL NUMBER INTERPRETATION

I ( MODEL SELECTION DCZOOX - X - X X X - X X X X X X - 0

/ Key Number Limit Control Output Hlgh L~nlit (TIC and RTD inputs only) ' DC200H , Low Lirnlt (TIC and RTD inputs only) ' DC200L I

Table 7 Add~tional Relays None

I One Alarr~l Rclay

1 Table 2 External Interface None 0 - -

I Aux~l~ary Oulput or D~a~tal Input 2 - - Opt~onal Input None - 0-

I Software Optlons No~je - 0 I

Table 3 Power Conf~gurat~on i20Vdc (50 60 H L ) 1 - - - - - 240Vdc (50160 Hz) 2 - - - - -

Approval Body Approval Body Pcndlnq - o - - - - Solrd State Relay K ~ t s Externally Mounted No11c - - o - - -

10 AIII~ - - I - - -

2 Amp - - 2 - - - Customer I.D Tag None - - - o - -

Tau (1 l~ne 30 Ctidractcrs Max inc blanks) - - - T - - Custom Conf~gurat~on Corllacl Factory - - - - 0 0

Table 4 No Selection 0

+Available w l l h temperature ranges only

CONDENSED SPECIFICATIONS

1

Operating Conditions

I Reference Rated Operatrve Lrmrts TransPortatlon Condrtrons Condrtrons and Storage

Amb~ent Temperature 22 23°C 15 to 55°C 0 to 55°C -40 to 66 " C I

72 t 5 " F 58 to 131 "F 32 to 131°F -40 to 151°F

V~brat~on F r e q i ~ e ~ ~ y (Hz) 0 0 to 70 0 to 200 0 to 200 Accelerat~on (g) 0 0 1 0 5 0 5

Mechan~cal Shock Accelerat~on ( g ) 0 1 5 20

I Duration (rns) 0 30 30 30

, Voltage (Vac) 120 2 1 102 to 132 102 to 132 -- I 240 2 2 204 to 264 204 to 264 --

Frequency (Hz) 50 2 0 2 49 to 51 48 to 52 --

I 60 2 0 2 59 to 61 58 to 62 --


CONDENSED SPECIFICATIONS (CONTINUED)

5 1-52-02-06 Paae 1-4

Accuracy

2 0.50?,0 of span typ~cal ( + 1 d ~ g ~ t for dlsplay)

Power Requirements

120'240 Volts, 50 or 60 Hz

Isolation

Inputs and Outputs are not Isolated from each other

Field Selectable lnput Actuations

PV Input

Thermocouples B E E(Low) J J(Low) K K(Low) NlN~Moly (NNM) R S T T (Low) W5W26 NIC N~cros~l Nlsll

RTD 100 Ohm Pt 100 Ohrn Pt (Low)

Radiamatic (RH)

Range

'F " C

150 to 3300 66 to 1815 -100 to 1832 -73 to 1000 -100 to 1100 -73 to 593

0 to 1600 -18 to 871 0 to 900 -18 to 482 0 to 2400 -18 to 1316

-20 to 1000 -29 to 538 0 to 1371 32 to 2500

0 to 3100 -18 10 1704 0 10 3100 -18 10 1704

-300 to 700 -184 10 371 -80 to 500 -63 10 260

0 to 4200 - 18 to 2316 0 to 2372 -178 10 1300

-300 to 900 -184 to 482 0 to 300 -18 to 149

1400 to 3400 760 lo 1871

INSTALLATION SECTION 2

lnspect for Shipping Damage and Check for Accessories If the MI~I-Pro Lim~t Controller has not been removed from ~ t s shipplng carton, Inspect the carton for damage, and remove the MI~I-Pro. lnspect the MI~I-Pro for any obvlous shlpplng damage and report any damage due to translt to the carrier. Check that a bag contalnlng mountlng hardware is included in the carton with the Lirrrlt Controller.

Model Number Identification Make sure the model number shown on the nameplate on the outside of the case agrees wlth what you have ordered. The model number Interpretation is on page 1-3.

Preliminary Checks Before you install the Lim~t Controller make the following preliminary checks. The procedure IS shown on page 2-3.

ALL MODELS

CHECK OPERATING VOLTAGE SELECTION The Operating Voltage Jumper posit~on has been set at the factory (120Vac or 240Vac) depending on what you have specified in your model selection, so there should be no need to change it. If you want to change the voltage selectlon you will have to position the J1 connector on the 110 printed wlring board to the voltage required. See Flgure 2-1 for jumper placement. CAUTION: Operating a 120 Volt controller at 240 Volts will damage the unit.

CHECK THE INPUT TYPE SELECTION You must check an internal DIP swltch to make sure the switches are set for the correct input type. The swltches are located at position SW1 on the I0 pr~nted wlrlng board. Set the swltches for the Input des~red. See figure 2-1 .

Preliminary Checks (Continued)

CHECK LIMIT CONTROL RELAY ACTION Externally Mounted Solid State Relay

The jumper at W5 or W6 or] the i 0 pr~nted wrrrng board 1s set for (NC) Normally Closed at the factory. If you want to change to (NO) Nvrrnally Open contacts on the E T CONTROL RELAY see flgure 2-1 for locat~on of W5 W6 jumper and set accordingly . See Table 2-1 for contact li~for~natlon and figure 2-1 for jumper placement. See Control Relay Caution Note, page 2-9

CHECK ALARM RELAY ACTION The controller has been shipped wlth the ALARM relay configured for (NC)normally closed contacts. It you want to change to (NO) Normally Open contacts on the relay, position the jumper at J5 on the TransformerlOption Printed wiring board fur (NO) Normally Open J5 IS the ALARM RELAY # I contact selector.

See Table 2-2 for alarm corltact ~nformatlo~~ and figure 2-1 for jumper placement.

See Alarm Relay Caution Note, Page 2-9.

CHECK OPTIONAL PV OUTPUT OR CONTACT INPUT SELECTION

The controller has been has been shlpped with the External Interface selection conflyuted for PV OUTPUT (AUX OUT).

If you want to change the selectlon to CONTACT INPUT (DIG IN), poslt~on the jumper at J6 on tlre Transformer'Opt~on pr~nted wlrlng board to select DIG IN (Contact Input) .

See flgure 2-1 for jumper placement.

51 -52-09- 10. Page 2 1

LIMIT CONTROLLER INSTALLATION

Table 2-1 Limit Control Relay Contact Information Chart

NOTE: Limit control relays are designed to operate in a failsafe mode. This results in momentary (5 seconds Maximum) limit actuation when power is init~ally applred, until the unit completes self diagnostics. I f power i s lost to the unit, the Limit Relay will function.

UNIT POWER

I

Off

On

Table 2-2 Alarm Relay Contact Information Chart

NOTE: Alarm relays are designed to operate in a failsafe mode. 1.e. De-energized during alarm state. This results in alarm actuation when power is OFF or when initially applied, until the unit completes self diagnostics. If power is

lost to the unit, the alarms will function.

LIMIT CONTROL

RELAY JUMPER

N.O.

N.C.

N.O.

N.C.

'OWER

I

Off

On

.

51 -52-09- 10. Page 2-2

VARIABLE IN LIMIT STATE

RELAY CONTACT

Open

Closed

Open

Closed

VARIABLE NOT IN LIMIT STATE

ALARM RELAY

JUMPER

N.O.

N.C.

N.O.

N.C.

INDICATOR

Off

On

RELAY CONTACT

Open

Closed

Closed

Open

INDICATOR

Off

Off

VARIABLE NOT IN ALARM

. RELAY

CONTACT

Open

Closed

Closed

Open

VARIABLE IN ALARM STATE

INDICATORS

Off

Off

CONTACT RELAY

Open

Closed

Open

Closed

INDICATORS

Off

On


PROCEDURES Before you lnstall the controller, remove the chass~s and make any preliminary checks necessary. If necessary, pull the transformerioption board and the 110 Board out to make the adjustment to the power selection jumper. The figure below shows all the checks listed on page 2-1.

Alarm Relay

r - - - Transformer/Option Printed Wiring Board PV Output or Contact Input

DIG IN (Contact Input)

AUX OUT (PV Output)

110 Printed W~rrng Board

' Operating Voltage Selection

J1 LI~ov--------] 1 I

DIP Swrtches for Limit Control Relay Input Type Electromechanrcal Relay Output

External Sol~d State Relay Output

For Range Type Switch and Position 5 W6

Rad~arnat~c OFF OFF OFF

RTD ON OFF ON OFF

- r - - - - - - - - - - ' - - - - - - - - - - - - L - - - - - - ' - - - - - - - - - - - - - - -

I I Switch 3 Is For BURNOUT I

I I OFF for High hmrt ON for Low Lrmrt EITHER for Farlsafe I L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J

FI~IIIC 2 1 Prcllnilnary Chccks

5 1-52- 09- 10. Page 2 i


Mounting

Physical Considerations The Limit Controller can be mounted on e~ther a vertical or tilted panel using the mounting kit suppl~ed with the controller. Adequate access space must be available at the back of the panel for installation and servlclng actlvltles.

The overall d~mer~s~ons and panel cutout requirements for mountlng the L~mit Controller are shown on the dimens~on data drawlng in figure 2-2. The enclosure Into which the L~mit Controller is mounted must be grounded accordlng to CSA standard C22.2 No. 0.4 or Factory Mutual Class No. 3820 paragraph 6.1.5.

The front parlel IS molsture rated NEMA3 IP65 (IEC) when properly rr~stalled w~ th panel gasket.

Mounting Betore mounting the Lln11t Controller, refer to the nameplate on the outs~de of the case and rrtake a rlote of the model number. It w~l l help later wherl s t ! l t?ct~~r~l the proper wir~ng d~agra~rr. 1. Mark and cut out the Llrn~t Controller rr~ocrlltltlg I i o i~ ,

In the panel accordlng to tlle d~rrrerls~ons spr:c:~l~~!~! on the dimension drawing below.

2. Pull the chass~s out of the case. 3. Orrent the case properly and slide 11 I l lrot~gh the

panel hole from the front. 4. Remove the mountlng k ~ t from the sh~pp~rig

contalner and Install the k ~ t as follows: a.lnstal1 the screws Into tlle tlireaded Irolt!s 01 I l ~ r , clips. b. Insert the prongs of ttte c.l111> 11110 tlre IWO 11o1t:- In the top and bottorrt ol ttrtn r:ase c. T~ghten both screws to stlct~rt: the c;;tst! Ltga~risl the panel. d. Carefully sl~de the chassts assembly ~rtto tttca case, press to close.

5 1-52-09- 10, Page 2-4


Mounting (continued) Mounting Accessories In addition to the panel cutout described previously, other ards for mounting the L~mit Controller include the following supplemental accessories and kits:

A rear terminal cover kit, part no. 30756091 -001 An adapter kit for DIN 43700 Panel Cutout(5 43 in X 5 43 in.) to fit D~alatrol, Barber-Coleman 560. and Leeds and Northrup E Max V cutout, part no 30755223-001 An adaptor plate with hardware to cover UDC 300 or UDC 4000 Cutout (3.62 rn X 5 43 in ), part no 30755223-002

WIRING Identify your Model Number To determine the appropriate diagrams for wiring your Limit Controller:

Refer to the model number Interpretation showri on page 1-3. The model number of the Lirnit Controller contains selection codes that identify the lnput type, Alarm selection, and optional selections. The model number of your controller can be found on the outside of the case.

Wiring the Controller Us~ng the intormation contamed in the model number, select the appropriate wiring diagrams f ro l~ l the connection diagrams In figure 2-3. 2-4, and 2-5 and wlre the controller accordingly.

LIMIT CONTROLLER FIGURE 2-3

Taking Electrical Noise Precautions Electrical noise is unabated electrical signals which produce undesirable effects in measurement and control circuits. Digital equipment IS especially sens~tive to the effects of electrical noise. Your Mini-Pro Lirnit Controller has built-in circuits to reduce the effects of electrical noise from various sources. To further reduce these effects:

Separate External Wir~ng - separate connecting wires into bundles (see table 2-3), and route the individual bundles through separate conduits or metal trays;

Use Suppression Devices - for additional noise protection, you may want to add suppression devices at the external source. Appropriate suppression devices are commercially available.

Table 2-3 PERMISSIBLE WIRE BUNDLING Bundle No. W~re Funct~ons

1 a. Llne power wiring b. Earth ground wiring c. Control relay output wlrrng d. L~ne voltaqe alarm wirinq

2 Analog signal wire, s i ~ c h as a. lnput signal wire(T C. 4 20rnA.etc) b. 4-20mA output signal wirirly c. D i~ i ta l input siqnals

3 a. Low-voltage alarm relay output wiring

b. Low voltage wirrng to solid state type control circuits

EXTERNAL INTERFACE OPTIONS FIGURE 2-4

SOLID STATE RELAY OUTPUT FIGURE 2-5

51 -52-09-10, Page 2 5


LIMIT CONTROLLER WIRING DIAGRAM

Rear of Controller I I

lnput 1 Connections

See table 2-5

Limit

(NOTE 2)

NEUTRAL AC Line Voltage (Note 1) --a-

HOT

ALM

LIMIT RELAY

PV OUT CONTACT IN

Alarm 11 Relay

1

12

+ 1 3

-14

Internal power selection , I 120V or 240V ; Ground separately and directly

to earth Ground ustng 12 gauge stranded wlre

I

I

1 , I - - I AC Line Voltage must match-

I Table 2-5 lnput 1 Connections I

@--

0--

@ = I - \

Thermocouple RTD

& 8 + 1 I

External Interface Opt~ons PV (AUXJ OUTPUT or

CONTACT INPUT (EXTERNAL RESET)

S E E FIGURE 2-4

j instrument nameplate and

Radiamatic I

NOTE 1. External fast blow fuses or circuit breakers must be rated at 1 2 Amp. 250Vdc Before powerlng the unit, see "Preliminary Checks" In thls sect~on of the product rrrarlual bet DIP sw~tches for Input type. Check jumpers for operating voltage and relay contacts

I NOTE 2. L~mit relay IS sh~pped havlng N.C. contacts conflgured Alarm relay is shtpped w~l t l N C contat:ts conftgured. N.O. or N.C. contacts are selectable by means of a jumper on I t l c J I 0 and TransformeriOpt~on printed wlring boards See "Prellrn~nary Checks" In ths 5ectlori of tlre

I product manual for detalls. Each alarm IS a SPST relay, rated at 5 arrips at 120V. and 2 5 dirlpt I I

at 240 Vac.

I

/ Figure 2-3 L ~ r n ~ t Controller Wlrlng D~agram I

5 1-52-09-1 0, Page 2-6

LlMlT CONTROLLER INSTALLATION

LIMIT CONTROLLER WIRING DIAGRAM (EXTERNAL INTERFACE OPTIONS)

CONTACT INPUT

I \ I \ \

I I 1 1 Contact Input I I I I I I I I

\

1 -- Connect Shield to Ground at one end only

@ @j @ @j @

@

NOTE: Contact lnput and PV Output are mutually exclusive. Selection IS determined by jumper on the TransformeriOption Printed Wiring Board.

F~gure 2 -4 1 ~ r n l t Controller External Interface Opt~ons W~r tng D~agram *

0 @ @ @ @ 0--

@

@ @ @ @)

@) 0

PV OUTPUT

/ \ I I 1 \ +

a +

7- IN 1 l o

6R ALM 1

'+ LIMIT RELAY

4 - +13 PV OUT

L2 CONTACT IN -14

L1 + I 5

@ & - -I6

1 1

7- IN 1 l o

6R ALM 1

l 1

5+ l2 LIMIT

4 - RELAY 1

PV OUT L2 CONTACT IN -14

Ll + I 5

@ A - -I6

I I I L I I I I I I I I "'Its

or -

0 0 @ @ 0 0-- @ @

Auxiliary Load 2500 Ohms or Greater

@ - - Connect Shield to

Ground at one end only \ Requires Field Calibration


LIMIT CONTROLLER WIRING DIAGRAM (SOLID STATE RELAY OUTPUT WIRING)

I0 AMP SOLID STATE RELAY ASSEMBLY

REAR OF CONTROLLER

SOLID STATE

RELAY ASSEMBLY

GREEN

BLACK

2 AMP SOLID STATE RELAY ASSEMBLY

REAR OF CONTROLLER

r - - - - - -

I LOAD '- L - - - - - - J

L2/N

L 1

F~gure 2-5 External Sol~d Staic Relay Output Wwng

5 1-52-09- 10, Page 2-8


ALARM AND CONTROL RELAY CAUTION NOTE

The alarm and control relay output suppression (snubber) circuitry can be extremely critical when controlling processes and maintaining plant safety. The UDC 2000 Universal Digital Controller is shipped with a board-mounted R-C suppression circuit. Its purpose is to protect the relay contacts from arcing due to high energy spikes. These spikes could occur when driving highly inductive loads and fast cycle-time processes. However, in certain AC powered, external solid state relays with very high input impedance, an

. undesirable leakage current can flow in the R-C suppression circuit and cause a voltage across the external load. This prevents deactivation of your external device (such as a Solid State relay) even though our display and internal relay are functioning correctly.

The fix, as shown in the figure below, is to open the correct R-C circuit by cutting one of the capacitor leads. This is acceptable because if the above problem occurred, the suppression circuit was not needed. Opening the c~rcuit eliminates any leakage current flow and allows the external relay to function normally.

5 1-52-09- 10, Page 2-9

1. Remove the chassis from the case and pull the boards out of the chassis. 2. Open the desired circuit by cutting the capacitor lead (shown in the figure below). 3. Return the boards to the chassis and return it to the case.

r - - - TransformerlOption Printed Wiring Board

I I 1 m

I . u I

I rn 1 m 000b r------7

I INL' L. Alarm - - - - - - I J I I I I I I

rli O LI 0000 r

- ' ' I10 Printed Wiring Board .i 1 - r_ - - -_ - - -__

j UDC 2000 j rn 0

m 1 ----------- 1 . m m . 1

Ftyure 2-6 RC Clrcult Capacllors

CONFlGURATlON SECTION 3 SOFTWARE CONFlGURATlON

Introduction Sottware confrguratron is a dedrcated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent controller data best suited for your specific application.

Prompts To asslst you in this process, there are prompts which appear rn the upper and lower displays (see Figure 3-1). These prompts let you know what group of configuration data you are working with and also, the specific parameters associated with each group. Frgure 3-2 grves you an overview of these prompts. As you can see, the configuratiorl data is divided into 5 main Set-Up groups plus Callbratlon and Read.

LOCK LIMIT

INPUT 1 OPTIONS ALARM 1

Wrthrn each of these groups are function prompts of assoc~ated parameters. NOTE: This manual explains all the prompts that can appear in the Limit controller. Some of the prompts won't apply to your specific controller and therefore will not appear.

Key Error When a key is pressed and the prompt "KEY ERROR" appears in the lower drsplay, rt will be for either of the following reasons:

Parameter not available Not in Set-Up mode, press [SET UP] flrst.

How to Get Started Read the procedure (page 3-3) for accessrng the groups and the functron parameters wtth~n each group to become fam~lrar w~th the key sequences Read the "Conhguratron Trps" on page 3-3, then start to configure the l~mrt controller for your applrcation. The groups and parameters are all lrsted on page 3-4, along wrth the select~ons and range of settrng available for each. If you need a detarled explanatron of any Set-Up or Functron prompt lrsted In this section yo tu Sectton 8 - Appendrx A. Record your selectrons on the c:onfigurat~on record sheet (page 3-9) so you'll have a record of how you've configured the controller

Figure 3-1 is a view of the operator Interface with whlch you'll be working.

FUNCTION

Honeywell

DISPLAY

ALM

OUT

RESET

PV

51 -52-10-21, Page 3- 1

Z SET UP

k

F~gure 3-1 Operator Interface

LIMIT CONTROLLER CONFIGURATION

PROMPT HIERARCHY

FUNCTION Key lets you call up the spec~f~c funct~on prompts w ~ t h ~ n each group I' Keys let you make a select~on or change a value of a tunct~on key prompt

..... ....... V.........'"..................>...<................ . '"a. ..,..A ..... .,., ..................... ... .> ..,. <> ?,. ...*...... \ ........... \ ...... .................... ?%, >..,........, ........................ . 8 ' E : :- . . i . . 4 E X T R S T $-i A U X O U T 8-$ 0 P C T ;-$ ~ O O P C T ; r. > i .................. << *.-& . *.. .... . .

........:...... ,.iCQI.OiOiQOCx<<~K . . .+ L*K.<*<wi,:<.i.:i.i:. I.<<.- .Q.-.\x<..r ................ ;.*..... ...' :. : .: :.

F~gure 3-2 Prompt H~erarchy

i

51 -52- 10-2 1 Page 3-2

1-Y-l USED FOR FIELD CALIBRATION 1


SOFTWARE CONFIGURATION (continued) How to Call Up and Change a Configuration Parameter

A list of how the Limit Controller was configured at the factory "Factory Settingsnappears on page 3-9. If you want to change any of these selections or values, follow the procedure listed below. This procedure tells you what keys to press so you can effectively use the prompts to start conf~gurlng your Limit Controller.

How to Select a Set-Up Group - Press the [SET UP] key. You

will see SET in the upper d~splay to let you know you are In the Set-Up mode and a SET-UP group title is be~ng d~splayed In the lower d~splay. LOCK (Lockout) is f~rst. Successive presses of the [SET-UP] key w~ll sequentially display the other Set-Up groups as shown in the prompt hierarchy (page 3-2). Note 1: Stop at the group you want to configure then go to "How to Select a Function" for the parameters w~thin that group.

How to Select a Functron As shown In the prompt hrerarchy, each of the groups l~sted contain speclfic prompts which deal with functions that are pertrnent to that particular group Press the [FUNCTION] key, you w~ll see the ind~v~dual funchon prompts for each group and the current value or selectlon Successive presses of the [FUNCTION] key w~ll sequentially display all the functions and their values or selections for that group NOTE 2 Stop at the functlon you want to conf~gure, then go to "How to change a value or select~on"

How to Change Value or Selection Press the [RAISWLOWER] key to change the value or selectlon rn the upper dlsplay. If the display blinks, you are trying to select an unacceptable entry or the LOCK function set to "CONF" IS preventing changes.

How to Restore the Original Value or Selection When you change the value or selection of a parameter wh~le In SET UP mode and decide not to enter ~ t , press the [RESET] key once. The original value or selection will be recalled.

How to Enter a Value or Selection Press the [FUNCTION] , [SET UP], or [DISPLAY] key. The value or selectlon will be entered into memory.

Configuration Tips

Listed below are a few procedures that will help you to easily and qu~ckly accomplish the tasks at whlch you'll be working when you configure the L~mlt Controller.

Scrolling To get to a SET-UP group or FUNCTION parameter quickly, hold [SET UP] or [FUNCTION] key in. The display will scroll through the parameters.

Changing Values Quickly When you press the [RAISEILOWER] keys to change a number, the least srgniticant drgit Increments and decrements. However. 11 you momentarily press the oppos~te key wh~le holdlng one of these two keys, the next slgnif~cant dlg~t beg~ns to Increment and decrement and each add~tional tap of the "opposite Key" will move the scrolling dlg~t one more step to the left Remember - you must hold in one key while the other IS pressed

Timing Out from SET-UP If you are in SET-UP mode and don't press any keys for one minute, the controller will time out and revert to the mode and display that was being used prior to entry into SET-UP mode.

Refer to Appendix A for additional data about any prompt you're not sure how to configure.

How to Exit Configuration Press the [DISPLAY] key to exit from configurat~on and return lo norinal operation.

5 1-52- 10-2 1 Page 3- 3

LlMlT CONTROLLER CONFIGURATION

LOCKOUT PARAMETERS GROUP

I PRESS DISPLA YS AT SETTING REMARKS I 11, configlrr,it~oir n~ot l t : "Lock " 9rt111;

SET UP displayed.

LOCKOUT s t : / ~ ~ ~ : t i c ) i ~ s FUNCTION NONE 110 li)(;kc J ~ I !

CALhratior, I,), kt!tl CONFiyurat~~)r~ j)(jf,lnlc:fc:rs , I I L . I L . . I ~ ! or1ly

LlMlT PARAMETERS GROUP

PRESS

1 SETUP I

FUNCTION u FUNCTION I FUNCTION El FUNCTION n FUNCTION 17

DISPLAYS AV SETTING

... .... ... ....

...................

Se1ections:Lo

.......,..

Engineering Units

Engineering Units

REMARKS

TYPE OF LIMIT CONTROL HI = High Lirrtil Coirtrol LO = Low Linrlt Corltrol

POWER UP LOGIC RST = Cor~trc)ller I.~/c:trirrg rt:l<q will hdve to t )e rest!/ ,it pow t :~ i r j ) NORM = Cor,/rr,l lt~ will opt!r, j / tx rlormally i r t sdn~c rnc)de ,is t ) t : tor t~ power dowr~

--

HIGH SET POINT LIMIT The local st!/ po111t will ~ i i r t o ~ r ~ . ~ l ~ ~ . . ~ l l ) adlusl itsell to 1 ~ 1 w~lt~irr /t,is / i r r r r /

Maxm~irm you woultl ever w~iirt t t ) st3! the set p o i ~ ~ t

LOW S R POINT LlMlT The locdl sts/ ~ ) o ~ r i t will ' iulorr~,i / i , .i l l) adl l~st itself to he wrthir~ tlrls 11r r ) r t Mir~inic~m you wocrld ever w< j r~ / / , I

the set poirrt

DEFAULT DISPLAY PROC = P r o ~ o s s V, j r~,~hle SP = Sel Poirrt

5 1-52- 10-2 1 , Page 3-4


INPUT 1 PARAMETERS GROUP j PRESS DISPLAYS AV SETTING REMARKS I

111 collfrgural~or) inode. "INPUT 1" group d~splayed.

....

FUNCTION elections:8888 No Dec~mal pl,dce One Declmdl [~ lace Two Deci~nal places '

' call only he used w l ~ e ~ r P r o ~ , t > s s Vanable 1s hetweerl -99 and + 99.

I

Selections:F Degrees FAHRENHEIT ................................. ....... Degreecs CELSIUS

N o Selection NONE

-

Selections: b NNM* 1 0 0 ~ Select whrch ACTUATION TYPE you E H R RADI are golng to use for Input OIE.

See "InstaNation" to set DIP sw~tches for input type. J H T H

.... ... .... .... ... J L T L N~NlMoly Tht!~ri~oc:oi~ple

.:.>. " Nrcros~l Nisi/ Tt ,sr~~iococ~pl~:

K H W K L lOOH

- INPUT I HIGH RANGE VALUE - Not

conf~gurable

I

FUNCTION INPUT 1 LOW RANGE VALUE - Not

confrgurable -

INPUT 7 FILTER - A dlgltal soffware FUNCTION Range: 0 to 120 Seconds filter to smooth the Input S I ~ I I ~ / .

0 = No Fllter

1

BURNOUT For n C Actuations UPSCALE lor high 11mit DOWNSCALE for low 11m1t

i

Range: 0.01 to 1.0

I Continued Next Page

51-52-10-21, Page 3 5


INPUT 1 PARAMETERS (Continued)

PRESS DISPLAYS AT SETTING REMARKS I POWER FREQUENCY 60 Hertz 50 Hertz See "lnstallatron" lo se1ec:t /clirtper posrtion tor Operrltirry Voltdye.

S R UP uuts vou III rtext set-LID group FUNCTION st:leots tttt: hrst ~ ) ~ i i , i i t ~ ~ ~ l ~ ~ i

in the /text yrcvr/~ DISPLAY cxlts st:! i l l ) nlotjt'

OPTION PARAMETERS GROUP

PRESS DISPLAYS AV SETTING REMARKS

SET UP El FUNCTION El FUNCTION El

Irr corrf~yirr. i / ic)~~ ritoJi!. "OPTIONS" group cfrs~)l~~yt~cl

EXTERNAL RESET(Digrta1 Input) D / s = Dlsdf)/(!if ENAB - Ertat)lt:s .E xterrt,~l Re:st!t Corttact closiire resets ttrc: 1.1t~ t t~ity relay

AUXILIARY OUTPUT OPTION NO selccl~orr

PROCess Vdri.il )It:

FUNCTION E l FUNCTION 0

I LING FACTOR e in erlgirteerrr)y ortits

~- -

LIMITS OF INPUT 1

SET UP puts yvu 111 flex! st?! c i ~ ) yioi/ i 1

FUNCTION selects the first p'~r,iirtctt:i rn !he nexl group DISPLAY exris set-LIP n~ocje

51 -52- 10-2 1 , Page 3-6


ALARM PARAMETERS GROUP

1 PRESS DISPLAYS AV SETTING REMARKS

SET UP El FUNCTION El FUNCTION I FUNCTION I FUNCTION El FUNCTION I FUNCTION r-7

SET UP I

In configuratioi~ mode, "ALARMlW group displayed.

ALARM 1 SET POlNT 1 VALUE Enter N] e/,gl/,eerl/lg units Will not appear unless select1011 PROC or DEV is made at "Alarm Set Point Type"

Range: Within lnput 1 range

....... :.:.:.; .. ......> ...... ........... ............................................. .,:..:::2:s3:~8x:g~I~xs$f

Selections:NONE PROC DEV

ALARM 1 SET POlNT 2 VALUE Enter vdlue 111 er~y~rieerir)g cinits Will not appeal ut~less seIec11o11 PROC or DEV IS mdde at "Alarm Set Point Type"

ALARM 1 SET POlNT I TYPE

NO select~on PROCess vdri.~f)le DEV~atron

g:$~:~p<~z*<wexe,;+..3.::.*.:.: ....... .:s;r<s<* .:.:.;>.. :ye.:+ ...:<.:. s;: ALARM I SET POlNT 2 TYPE ............ 7<.:..2 ........... "C.......... ;;.: ....... .:.:.:.x?.:.: ...<. .. ....,... Selections:NONE

:.<.:.:.: ...... ~~,~:sz~~~2;miIXZ~4~e~ NO selectlor) ....... ...... ...,. 3 A 1 S 2 T Y $ PROCess var ld~lo ...... $$

DEV DEV~atron ::~<:$?~.*.*.:*<:~.:**:~.~ .........................................

ALARM 1 SET POINT 1 STATE Hlgh Alarm LOW Alarm

....................... .+:.;.x<.:.:.:.:.:. ALARM 1 SET POlNT 2 STATE

..... ..:<.>:.:<.:.::y.$ " '. .............. ..... <._ ..................... ....__.... .......... ..... High Alanr) ...... .............. >?: .....,. ..... ..... x-*>.:~<::.>:.:.:.:.:.w:...x.:...:.:.: .,.>> :.:.v<; ' ....... , ..,.....r,......v..., ..., > ......... <.,A<.< ................... LOW Ahrm ....... ....... ... :" .:.:.:. A l S 2 H L 2 .... ....... ....... <$.::.:.:.:.:>s..:.; :.x.> y..:.:.:.:,K.*.:x.<.: <><:;; :s ..................................................................

then DISPLAY El TO EXIT SET UP MODE

Note: There is a Fixed Alarm Relay Hysteresis of 0.556 of lnput Span.

51 -52- 16-2 1 . Page 3 7


CALIBRATION PARAMETERS GROUP

STATUS GROUP

USED FOR FIELD TROUBLESHOOTING SEE THE TROUBLESHOOTING SECTION

51-52-10-21, Page 3-8

LIMITCONTROLLER CONFIGURATION

LIMIT CONTROLLER CONFIGURATION RECORD SHEET

GROUP FUNCTION VALUE OR FACTORY DESCRIPTION DESCRIPTION SELECTION SETTING

I

I LOCK LOCK C AL

LIMIT Lo or HI

I POWRUP

1 HI RNG 1000

I LO RNG 0 DISPLY PROC

1 INPUT 1 DECMAL

I UNITS I INlTYP I IN1 HI

IN1 LO BIAS 1 FILTR1 BURNOT EMlSS FREQ

OPTIONS EXTRST

I AUXOUT I 0 PCT I 100 PCT

. 8888 NONE K H 2400

NONE' = I ALARMS AlSlVA 90

I A1 S2VA 10 A1 S1 TY PROC

I

I A1 S2TY PROC A1 S1 HL HI A1 S2HL LO

B Configured according to the model ordered

b according to the model ordered

, 'Appears only 11 model number allows.

51-52- 10-21, Page 3-9

SECTION 4

L I A

1 1

Honeywell

I t

OPERATOR INTERFACE OVERVIEW

"'" " plpJqq OUT

LOWER DISPLAY A dedicated 6 d ~ g ~ t charactel 14 segment 1 lower d~splay provldes gu~dance, through prompts, for the operator durlng conf~guratiorl SET UP Also Indicates "SP" or "PV" on demand, w~th value in upper d~splay

FUNCTION E l

F = " Fahrenhe~t C = 'Celsius

ALM =Alarm con

Key Functions SIX keys enable cornplete corif~gurat~ori arid operatcon

alarm relay There IS also ~ndicat~on to show the

temperature units

STATUS INDICATORS They prov~de the status of the

DISPLAY El

UPPER DISPLAY A 4 ilryll 9 seglnerll i lp la I

d~s l~ lay IS ded~c att,~l 10 t t h

p~oc ess var~able or 1 inlit Set Polnt dur~ng rlo~inal opelation w~th alterr~ate tnforrnatlon d~splayed ~LIIIIICJ

conl~gurat~on Set Polnt or Process Variable values rnay be shown on demand

Selects lur~c;t~ons w~ th~n each configurat~on group SET UP El Scrolls through the

conf~gurat~on yl u ~ ~ p s

Allows viewing of the set po~n' Deact~vates the latcli~ng or Process Vara~ble. Returns relay except in Set Up the controller to normal mode Also, used to operation from SET UP mode. restore onglrial value or

select~on when In SET UP mode.

Not used

Decreases the set polnt or conf~gurat~on values.

Not used

Increases the set polnt or conf~guratiori values.

ni~ahle LlM IT CONTROLLER OPERATION

CHECKING THE CONFIGURATION Make sure the Lim~t Controller has been configured to handle your process needs. Refer to "Configuration" Section 3 for prompts and parameters.

Input Parameters 8 Alarm Set Po~nts and type

L~mit control type - High or Low External Reset (Contact Input) - Enable or Disable Power up Logic - Reset (relay on) or Normal (same as before power down)

.- 8 Lockout select~on

POWERING THE CONTROLLER'" Apply Power The Limit Controller runs four background tests to determ~ne the status of the controller:

RAM TEST - checks Internal memory CONFIGURATION TEST - checks the controller's software configuration for ~nconsistenc~es CALIBRATION - check calibration of the controller's configured analog inputs (Input 1) and output (PV Output Voltage)

8 FACTORY CALIBRATION CHECKSUM - check factory set Input constants

If all these Background tests pass, the controller will functlon In a normal manner without any diagnostic message. However, if one or more of these tests fail, the controller will go to FAILSAFE ("FAILSF" blinking in the lower display). Refer to the "Troubleshooting" sectlon in th~s manual to identify and correct the problem.

OPERATING PRINCIPLES The L~mit Controller accepts signals from such sources as thermocouples (TICS), Resistance Temperature Detectors (RTDs), and Radiamatics. The equivalent PV signal is compared with the Limit set point. It above (Hi Limit) or below (Lo Limit) a l~mit output relay IS de-energ~zed. When de-energized, the output relay locks out and remains in this state until the PV Input signal drops below the high limit set polnt or rises above the low limit set point, and the controller is reset manually from the front of the controller or through an optional external switch.

MONITORING THE CONTROLLER The Displays and lndicators The displays and indrcators on the operator interface as shown in figure 4-1 let you see what is happening to your process and how the Limit Controller is responding.

Displays The Limit controller is a single line display device except when in the SET-UP mode or [DISPLAY] key IS pressed or limit has been reached.

MONITORING THE CONTROLLER(cont..) The UPPER d~splay area has 4 d~g~ts ded~cated to the value of the process var~able or llnl~t set point dur~ng normal operatlor1 w~th alternate ~nformat~on dlsplayed on demand durlng conf~gurat~on. Set Po~nt or PV values can also be shown on demand using [DISPLAY] key

The LOWER d~splay area has 6 d~g~ts wtl~ch art1 normally blank but ~nd~cates when llrnrt set point IS be~ng dlsplayed upon request. It also prov~des alpha-numer~c prompts dur~ng collfrgurat~o~~ as well as d~agnost~c and error messages wtwn appropnate.

Indicators The annunc~ator d~splays, as show11 111

f~gure 4-1, give the tollow~r~g ~nd~cat~or~s

ALM 1 = Alarm Relay ON OFF status F or C = Temperature U111ts ( ' F or ' C)

The [DISPLAY] key Press the [DISPLAY] to show the set p o ~ ~ ~ t L I I PV 111

the upper d~splay, depend~ng O I I wt11c:tl has bet:() conf~gured as the default dlsplay.

You can press the only the Set Point

[RAISE/LOWER] k value shown In the

Timing out from Upper Dlsplay If ~t conf~gured as the detault d~splay var~able, the normal Process Var~able d~splay w~ll auton~at~cally return In the upper d~splay 11 the [DISPLAY] key 1s not pressed for 60 seconds.

The [DISPLAY] key IS also used l o return to llorrnal control from SET-UP mode.

The [RAISEILOWER] key When you press the [RAISULOWER] keys to change a number, the least slgr~~l~cant d ~ g ~ t Increments or decrements. However. 11 you momentar~ly press the oppos~te key wh~le hold~ng one of these two keys, the next s~gil~f~cant d ~ g ~ t beg~r~s tu Increment or decrement and each addit~onal tap of the "oppos~te Key" w~ll move the scrolling d ~ g ~ t one more step to the left. Remember - you must hold ln one key whlle the other IS pressed.

5 1-52- 1 1 - 16, Page 4-2

LIMIT CONTROLLER OPERATION

MONITORING THE CONTROLLER(cont..)

Key Error When a key is pressed and the prompt "KEY ERR" appears in the lower display. it will be for one of the following reasons:

Parameter not available Not in SET-UP mode. Press [SET UP] key first.

Diagnostic Error Messages The Limit controller performs additional background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed. In the case of more than one, the one with the highest prior~ty will appear on the lower display.

LOWER DISPLAY CONDITION PROMPT

E FAIL Unable to write to non-volatile memory

FAILSF Failsafe

IN1 FL Two consecutive fa~lures of Input 1 lntegratron

IN1 RNG Input 1 out-of-range

PV LIM PV 2 10°/~ out-of-range

IF ANY OF THESE ERROR MESSAGES OCCUR, REFER TO THE TROUBLESHOOTING SECTION IN THIS MANUAL.

OPERATING THE CONTROLLER Enter a Set Point Value

Press the [DISPLAY] key, if requ~red, until you see

OPERATING THE CONTROLLER (continued)

High and Low Limit Indication When the h~gh or low limit IS exceeded, the lower display indicates the word "LIMIT" (blinking). This will continue until you reset the latching relay using the [RESET] key or through the Optional External Reset feature.

How to Reset the Latching Relay

NOTE: The latching relay cannot be reset untll the PV input signal drops below the high set po~nt (H~gh Limit) or rises above the low set point (Low Limit) value. Press [RESET] key or make contact closure of an external switch if the Contact lnput option IS present

Using Contact lnput Option (External Reset)

The Contact lnput Option detects the state of external contacts. On contact closure, the controller w~ll reset the latching relay if the controller has External Reset enabled. To allow External Reset (Contact Input):

Press the [SET UP] key until you see

Press the [FUNC] key unt~l you see ,.;... .. ;., . *+&.<..ir

z..$# $$pC$ ....... Selection: DIS ..p....

~ ~ ~ ~ ~ t y i t . ~ w Z C Y . ~ ENAB ...... $3 E X T R S T ...... Press the [RAISVLOWER] keys to adjust the Set z:i:z: ..... %.%%:: s:yz: =**% i$ ......................................

Po~nt to the value vou want. The d~splay "BLINKS* if you attempt to enter a set Press the [RAISULOWER] keys to select ENAB ~n po~nt value beyond the high and low set point range the upper display. I11mts. Return to PV Display Press the [DISPLAY] key. You will see

or

Whatever has been configured as the default display

5 1-52-1 1 - 16, Page 4-3

LIMIT CONTROLLER OPERATION

OPERATING THE CONTROLLER(CONT..) Changing the Alarm Set Points The Alarm Set Point Values can be changed for each of the two alarm set points.


Press the [FUNCTION] key until you see

Appears only if "A1 S1 TY" is PROC or DEV

This is the Alarm 1 Set Point 1 Value. Press the [RAISULOWER] keys to change the value in the upper display.

Press the [FUNCTION] key 1 more time and repeat the procedure to set the other alarm set point value.

REFER TO THE CONFIGURATION SECTION OF THIS MANUAL TO DISPLAY OR CHANGE THESE ASSOCIATED ALARM PARAMETERS

SET UP GROUP PROMPT

ALARMS

A jumper selection configures the relay contacts for Normally Open (open wrth power off) or Normally Closed. Refer to the Installation Section under "Preliminary Checks" for Alarm relay contact information chart and jumper placement.

FUNCTION PROMPT

A1 Sl HL A1 S2HL

OPERATING THE CONTROLLER(CONT..)

PARAMETER

AlSlTY A1 S2TY

Alarm Set Point State - High or Low

Power Up Logic Configurable Power Up Logic lets you select the latching output relay to require "RESET" or to provide normal operation at power up. If power to the Limit Controller fails and power IS reapplied, the controller goes through power up tests then starts in one of the following configurabnle conditions: If you configured

Alarm Set Point type

A t Set Up group "LIMIT"

The lower display will blink "LIMIT" at power up. This will require reset via the [RESET] key or external switch to obta~n normal operation.

If you configured

At Set Up group "LIMIT"

The display and Lim~t Controller will function normally at power up, i.e. no reset of the latch~ng relay is required unless a limit has been exceeded. If the limit was latched when power went down, the unit wrll be rn Irrnif at power up.

Refer to Configuration section under SET UP prompt "LIMIT" and make your select~on at FllNCTlON prompt "POWRUP".

Press the [DISPLAY] key to return to normal control.

CALIBRATION This section has two parts, lnput Calibration and Output Calibration Each part has the following sub-headings:

Introduction - when calibration is required. Preliminary Procedures - d~sconnecting the field

wiring, setting internal DIP switches, etc. Equipment Needed - what you need to do the

calibration. Set Up - how to set-up the controller for the

calibration procedure, i.e. terminal connections, etc. L Calibration Procedures - how to do the

calibrat~on.

INPUT CALlBRATlOff - describes the field calibration procedures for lnput 1.

lnput 1 - can be calibrated for a variety of thermocouples, RTD, and Radiamatic ranges. You select which type of input you will be calibrat~ng by SETTING A DIP SWITCH inside the chassis on the Main Printed Wiring board, then connect a calibrating device as described in SET UP and following the PROCEDURE for lnput 1.

OUTPUT CALlBRATlON - describes the field calibration procedures for PV (Auxiliary) Output.

SECTION 5 INPUT CALIBRATION

Introduction This part describes the field calibrat~on procedures for input 1. However, this procedure should only be implemented if the factory calibration of the desired input range is not w~thin specifications. Note that every Llmit Controller contains all input ranges fully factory calibrated and ready for configuration to the range by the user. It should not be necessary to recalibrate the controller.

Note also, that the field calibration will be lost if a change in input type configuration is implemented at a later time. The input will revert to the factory calibration.

Minimum and Maximum Range Values Calibrate the Limit Controller to the min~mum (000) and maximum (100°~~) range values for your particular sensor. Select the voltage or resistance equivalent tor 090 and 100°/b range values from Table 5-1 on page 5-2. Use these values when calibrating the input.

PV (Auxiliary) Output - can be calibrated tor a range of 0 to 5 Volts or 1 to 5 Volts by connecting a calibrating device as described in SET UP and follow~ng the PROCEDURE.

51-52-13-16, Page 5-1

LIMIT CONTROLLER CALIBRATION

TABLE 5-1 -- Voltage and Resistance Equivalents for 0% and 100°/~ Range Values

I I PV Input Range I Range Value I

5 1-52- 13- 16, Page 5-2

Sensor Type I

B TIC

E T/C

E (low) T!C

J (TIC)

J (low) TIC

K T,C

K (low) T i c

NNM NiNiMoly T/C

R TIC

S TIC

T T!C

T (low) T/C

W5W2, T:C

NIC Nicrosil Nisil TIC

RTD IEC alpha = 0.00385

100 ohms

Radiamatic RH

OF

150 to 3300

-100 to 1832

-1 00 to 1 100

0 to 1600

0 to 900

0 to 2400

-20 to 1000

32 to 2500

0 to 3100

0 to 3100

-300 to 700

-80 to 500

0 to 4200

0 to 2372

-300 to 900

0 to 300

1400 to 3400

0%

0.009 mV

-3.976 mV

-3.976 mV

-0.885 mV

-0.885 mV

-0.692 mV

-1.114 mV

-0.001 mV

-0.089 mV

-0.092 mV

-5.341 mV

-2.225 mV

-0.234 mV

-0.461 mV

25.18 ohms

93.03 ohms

0.99 mV

"C

66 to 1815

-73 to 1000

-73 to 593

-18 to 871

-1 8 to 482

-18 to 1316

-29 to 538

0 to 1371

-18 to 1704

-18 to 1704

-1 84 to 371

-63 to 260

-1 8 to 231 6

-17.8 to 1300

-1 84 to 482

-18 to 149

760 to 1871

1 00 O/b

1

13.763 mV

76.358 mV

44.547 mV

50.059 ~ I V

26.396 ~ I V

52.939 rr~V

22.251 nlV

71.330 nlV

20.275 rrlV

17.993 rrlV

19.095 rrlV

12.572 mV

37.066 mV

47.502 mV

274.96 ohrr~s

156.90 ohlrls I

57.12 mV


INPUT CALIBRATION (continued)

Preliminary Procedures

Disconnect Field Wiring Tag and drsconnect any field wiring connected to the input terminals on the rear of the controller. (See Flgure 5-1 )

Set the DIP Switches for the lnput Before you calibrate the Input, you must check an internal DIP swltch to make sure the switches are set for the correct lnput type;

Thermocouples, RTD,

Rad~amatic

Procedure 1. Loosen the screw on the front

of the controller and pull the chassls out of the case.

2. The switches are located at position SW1 on the 1/0 printed wiring board assembly. (See Flgure 5-2)

3. Set the switches for the range type des~red according to the table In figure 5-2.

REAR OF CONTROLLER

0

; INPUT 0 I TERMINALS 1 L ------------ .I 0

0 0 -

Figure 5-1 lnput Connections

--

=- I10 Printed Wiring Board

0 m m m m 00

1 2 3 4 5

1 L For Range Type Switch and Position

1 2 3 4 5

TIC ON OFF - X--I OFF OFF

Radiamatic ON OFF OFF! OFF OFF

RTD ON OFF OFF: ON OFF I I I i

r - - - - - - - - - - - - - -7 I

I SW3 IS FOR BURNOUT I

OFF for High Limit I

I . ON tor LOW L~rnit I I

I EITHER for Failsate ( - - - - I L _ _ _ _ _ _ _ - - _ - - _ _ 2

Figure 5-2 DIP Switch Positions


INPUT CALIBRATION (continued) Equipment Needed

Screwdriver THERMOCOUPLE INPUTS

A calibrating device with + 0.02% accuracy for use as a signal source. Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input.

If you are using an Ice Bath Two insulated copper leads for

= connecting the thermocouple extens~on wire from the ice baths to the mV source. Two containers of crushed ice.

RTD (RESISTANCE THERMOMETER DEVICE)

A Decade Box, with + 0.02O/0 accuracy, capable of providing stepped resolution of .O1 ohm. Three insulated copper leads of equal length for connecting the Decade Box to the controller.

RADlAMATlC A calibrating device with 2 0.02% accuracy for use as a signal source. Two insulated copper leads for connecting the calibrator to the controller.

Set-Up (SEE FIGURE 5-3) THERMOCOUPLE INPUTS (Ice Bath)

Connect the copper leads to the calibrator. Connect a length of thermocouple wire to the end of each copper wire and insert each junction point into an ice bath. Connect the thermocouple extension wire to the terminals for input 1.

THERMOCOUPLE INPUTS (TIC Source) Connect the thermocouple extension wire to the terminals for input 1.

RTD or RADlAMATlC Connect the copper leads from the calibrator to the input 1 terminals as shown in'figure 5-3.

Place current source at zero before switching on. Do not switch current sources on~off whlle connected to the Limlt Controller Input.

NOTE For Radramatrc Inputs only set Emrssrvrly value to 1.0 See Set Up Prompt "INPUT 1"

Functron Prompt "EMISS".

I

51 -52- 13- 16, Page 5-4

REAR OF CONTROLLER

H

TD)

F~gure 5-3 Calibration Equipment Connections

!

I - - - - - - - - - - - - 0 0 0 0 0 0 0

THERMOCOUPLES USING AN ICE BATH

T'C EXTENSION

COPPER WlRE

WIRE

I + - mV

SOURCE

- INPUT /

BATHS

8 +

7 -

6 R

TERMINALS ; L _ - - - -

THERMOCOUPLES WITHOUT AN ICE BAT1

WIRE

RESISTANCE THERMOMETER DEVICE (R

COPPER

DECADE RESISTANCE

RADlAMATlC

I - + - mV

+- 8 +

SOURCE 0 - ~OPPER

7 -

6 R



INPUT CALIBRATION PROCEDURE

Apply power and let the controller warm up for 15 minutes before you calibrate.

Please read "SET UP" on previous page before beginning the procedure.

See Table 5-1 on page 5-2 for Voltage vs Resistance equivalent.

Make sure Set Up configuration prompt "LOCK" is set to "NONE".

1

PROCEDURE = '

PRESS DISPLAYS ACTION

, Enter Calibration Go to next key press. Mode

FUNCTION Go to next key press to enable INPUT 1

calibrat~on. r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

I Note. After completion ot t l~ t : ca11brirli~)rt I I

I sequence, the confrollef dc~lof l~cr l~cal l~ reit:rls 10 I : d~sabie. 1 I

L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J

This beglns the cal~bratlon proced~lre, Go

............... to next step.

.. .... .......... Calibrate O0Io "'.....<... !!G;::<ss <<* m s w.':<<c*:.:.$s.>

>.?>>. f@@$ A P L Y @ Adjust your calibrating device to an out-

FUNCTION . .*>....+ XW+~?$.. ..:.&...* , ,

>Y" av'.:., put signal equal to the OOtb range value for .....

2 ~ > . 1x3 your particular input sensor. (table 5-1 ..-. I N 1

R 0 $$ $3 Wait 30 seconds, then go to next step. ...SZX ... ..;k::*;. . ..<.. .............. *.*s :fi. 2.22?.> . , . .<$$$.::~:?x~~.$

.. :.:.: ... x.:.:::<.:. ..x~.:+,~<.:< :,.:.:.:.:.:.:.: Calibrate 100% ?src::'r::F.3s :zx4rssj $F A p L y % >>..

Adjust your cal~brat~ng devlce to an out- ....

$&; m l ~ a ~ ? s @ E l put signal equal to the 10090 range vali~t r

&$ for your particular Input sensor. $$. ! IN lSPNg$ :< ; ..:,> ,... ?. ........ ..- .;,

I .a >.... ??i%>w,,>.:<, .*:>si::.:.@ Wait 30 seconds, then go to next step if

, the input rs configured for thermocouple; otherwise, go to "Exit Calibration Mode".

I

I Check the Compare the measured value to the value Cold Junction FUNCTION in the upper display which is in tenths of

I Temperature a degree. It is the current read~ng of the I temperature as measured at the

thermocouple terminals and recognized I by the controller. You can change this

value, if it is in error, using Av keys.

Exit Calibration Mode

This stores the calibration constants and exits the calibration mode.

i

1

5 1-52- 13- 16, Page 5- 5


OUTPUT CALIBRATION PROCEDURE

PV (AUXILIARY) OUTPUT

Introduction Calibrate the controller so that the output provides the proper amount of voltage over the desired range. The controller can provide a Voltage output range of from 0 to 5 Volts and can be calibrated at 0 Volt for 0% of output and 5 Volts - for 100% of output or any other values between 0 and 5 Volts.

Preliminary Procedures Tag and disconnect the field wiring at the rear of the controller from termlnals 13 and 14. (See Figure 5-4.) Check that jumper J6 is positioned for (AUXOUT) per figure 2- 1.

Equipment needed A calibrating devrce w~th whatever accuracy is necessary, capable of measuring 0 to 5 Volts dc.

Set-Up Connect a calibrating device across termlnals 13 and 14 (see Figure 5-4). Apply the power and allow the controller to warm up for 15 minutes before you calibrate.

Follow the procedure on the next page.

DC VOLTMETER CALIBRATING DEVICE

*+ *-

*

REAR OF CONTROLLER

0 0 0 0

13+ 0 1

F~gure 5-4 Calibrat~on Equipment Connect~ons

5 1-52- 13- 16. Page 5-6

LIMIT CONTROLLER CALI BRATION

OUTPUT CALIBRATION (continued)

AUXILIARY OUTPUT CALIBRATION PROCEDURE

Make sure

Set Up configuration prompt "LOCK" is set to 'NONE". Function prompt AUXOUT" under Set Up prompt "OPTONS" is set to 'PROC"

External Reset is d~sabled.

! PROCEDURE PRESS DISPLAYS ACTION I - 1 I Enter Calibration Go to next step.

I i

Mode

I I

/ Calibrate 0% 1 I

I

I Calibrate 100%

SET UP n FUNCTION n Go to next step.

until

the desired 0% output is read on the voltmeter.

FUNCTION n This stores the min~mum value and gives you the display shown. Go to the next key press.

Exit Calibration Mode

This stores the span value and exlts the calibration mode.

51 -52-1 3- 16, Page 5-7

TROUBLESHOOTINGISERVICE SECTION 6

INTRODUCTION Instrument performance can be adversely affected by installation and application problems as well as hardware problems. We recommend that you investigate the problems in the following order:

lnstallation Related Problems - Read the lnstallation Section in this manual to make sure the Limit Controller has been properly installed. The lnstallation sectlon provldes information on protection against electrtcal nose, connecting external equipment to the controller, and shielding and routlng external wiring. IMPORTANT: System noise Induced into the controller will result in diagnostic error messages recurring. If the diagnostic error message can be cleared, it Indicates a "soft" fallure and is probably nolse related If system noise is suspected, completely Isolate the controller from all field wiring. Use calrbratron sources to simulate PV and check all controller functions 1.e. Output, Alarms, etc

Application Related Problems - Review the applicatron of the Limit Controller; then, i f necessary, direct your questions to the local sales office.

Hardware and Software Related Problems Use the troubleshoot~ng error message prompts and controller failure symptoms to identify typical failures which may occur in the Llmit Controller. Follow the troubleshooting procedures to correct them.

MAINTENANCE

CONTROLLER FAILURE INDICATIONS Error Messages The Limit Controller runs background tests during normal operation. If a problem with the Background tests occurs, an error message will be displayed on the operator interface. Table 6-1 shows you the error message, what the failure IS, and how to correct the problem.

Other Failure Symptoms Other fa~lure symptoms may occur that deal with the Power, Output, or Alarm. Refer to the controller fa~lure symptoms in table 6-3 to determine what IS

wrong and the troubleshoot~ng procedure to use to correct the problem.

Check lnstallation If a set of symptoms still pers~sts, reter to the lnstallation sectlon of this manual and ensure proper lnstallation and proper use of the controller in the system.

CUSTOMER SUPPORT If you cannot solve the problem using the troubleshooting procedures listed in thts section, get ~riodel and serial number and

Call Customer Supporl Phone Number

If the Elastomer Bezel,Display lens requires cleaning, use a soft cloth with alchohol or a mild solut~on of soapy water.

LIMIT CONTROLLER TROUBLESHOOTINGISERVICE

ERROR MESSAGES The Limit Controller performs on-going background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed (blrnklng) in the lower display. In the case of rnore than one simultaneous malfunct~on, only the one w~th the h~ghest priority will appear in the lower display.

Table 6-1 below shows these error messages, the reason for the failure, and how to correct the problem.

TABLE 6-1 BACKGROUND TESTS ERROR PROMPTS

Lower Display Reason For Failure Prompt


E FAIL Unable to write to non-volatlle memory. 1. Check the accuracy of ttie pararricter arlcl Anytime you change a parameter and ~t is not re-enter. accepted, you will see E FAIL.

FAILSF This error message shows whenever the 1. Run through STATUS clleck t o t lett!rrrir~~~. controller goes into failsafe mode of the reason for the fa~l i~re: operation. This will happen if: Press [SET UP] unbl READ aypt?ars 111 I I I ~

RAM Test failed lower d~splay. Configuration Test Faded Press [FUNCTION] to see wtlrcll tt:sts Calibration Test Failed Pass or Fall. Factory Calibrat~on Checksum Failed RAMTST CFGTST CALTST FACTST

2. Correct according 1 0 the recorrlrr1t!1ltl311o1is glven for a particular fa~lirre 111 Tat~l t : 6-2

IN1 FAIL Two consecutive ta~lures of lnput one 1. Make sure the actuatru~> IS cor~l~yurcd lntegrat~on, 1.e. cannot make analog to drg~tal correctly. See Cont~qc~ral~on St?ct~orl 3 conversion 2. Make sure the input 15 correct

3. Check for gross overranylng

continued next page


ERROR MESSAGES (continued)

TABLE 6-1 BACKGROUND TESTS ERROR PROMPTS (continued)

Lower Display Reason For Failure Prompt


INIRNG Input 1 - out of range. The process is 1. Make sure the range and actuation are outs~de the range Ilmlts. configured properly.

2. Check the Input source. NOTE. If lltc rangc goes Outs~dc ltlc crllcrla lislcd above, 3, Restore the factory caJlbratlon: l l ~ c cc~nl~ollcr w ~ l l go lo tllc la~lsalc o ~ t p t ~ l valt~c a. Disconnect the wir~ng from and place a

jumper across terminals 7 and 8. The controller should read room temperature if it is configured for a thermocouple input. b. If it does not read room temperature, see Section 3 - Configuration, and change INlTYP prornpt In the INPUT 1 group to another type of thermocouple. c. After the change, press [FUNCTION] key, then press the ILOWER DISPLAY] key. The controller should read roorn temperature. If it does not, the unlt has an Input failure. .

d. Repeat step b. Thls time swltch the INlTYP back to the originally selected thermocouple. e. Repeat step c. The controller IS restored with factory calibration. f. Remove the jumper and reconnect the thermocouple.

4. Check the lnput type switch placement. Refer to "Prellmlnary Checks" in Installation Section 2.

5. Field calibrate - See Calibration sectlon 5.

PV LIM PV Out-of-Range 1. Make sure the Input slgnal rs correct. The result of the formula shown below is 2. Make sure the B~as settrng IS correct. beyond the range of the PV 3. To recheck the cal~brat~on, use Ratlo 1.0

PV = IN1 + IN1 BIAS and Bias 0.0

LIMIT CONTROLLER TROUBLESHOOTlNGISERVlCE

STATUSTESTS When required, the results of these STATUS tests can Press the [SET UP ] key urltll

be checked to determine the reason the controller has you see gone to failsafe.

...... .. .... .,. . . . . . ........ .. Press until ::i:<X.:: ..... NO or yes

you see ...... . ... .. . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;..i r......;........... -..: .,... : ....... . .,.......... .

.. F A I L S F :

... :.::.; .: :.:..- .... . - . - : . . .. . . .

TABLE 6-2 STATUS TESTS

Lower Upper Display Definition Display Reason for Failure How to Correct the Problem Prompt Prompt

FAILSF Fallsafe NO No Failure Fault YES Burnout configured for 1. Step through ttlu rest of the STATCIS

none and input falls check to lderllity the partlci~lar ta~liirt: RAMTST failed Press [FUNCTION] key. CFGTST failed CALTST failed FACTST failed

RAMTST RAM Test PASS No Failure FAIL RAM Failure 1. Power cycle to see 11 the error clears

CFGTST Contlguratlon PASS No Fallure Checksum FAIL Configuration data In the 1 Step throuyt~ the STATUS tests the

controller ~n error controller will calr:ulate the checksurn 2 Check all the corlf~gural~on prompts tor

accuracy See Conf~< jura t~o~~ Sc?c.t~orr 3

CALTST Worklng PASS No Farlure Calrbratlon FAIL Worklng callbratlon 1 If the controller has not beer) Ileld Checksum constants In the controller calibrated, see t t~e conflguratlon sectlo11

~n error. and change the 111put type to a dlflerer~t type Enter I t , loc)p through all the STATUS tests then return Input typtl to the orlglnal

2. If the controller has been held callbrated, recallbrale the corltroller

FACTST Factory PASS No Failure Calibrat~on FAIL Factory set input 1. Cycle through STATUS to clear the Checksum constants in the controller error.

are in error. 2. Check the cal~brat~on - make sure 0 and 100% are the correct values. See Calibratlon Sectlon 5.

3. Recalibrate. If step 1 IS unsatisfactory. always do step 3 - See Cal~bratlorl Sectlon 5.

5 1-52- 13- 17, Page 6-4

LIMIT CONTROLLERTROUBLESHOOTlNG/SERVlCE

CONTROLLER FAILURE SYMPTOMS EQUIPMENT NEEDED TO FOLLOW In addition to the error message prompts there are TROUBLESHOOTINGPROCEDURES failure symptoms that can be identified by notlng how the controller's displays, indicators, and controller Calibration Sources - T!C. RTD. functions are reacting. Voltmeter Compare your symptoms with those shown in Table 6-3 and refer to the troubleshooting procedure The troubleshooting procedures begln on the next indicated to correct the problem. Page.

If a set of symptoms or prompts other than the one you started with appears while troubleshooting, re- evaluate the symptoms. Thls may lead to a d~fferent troubleshooting procedure. If the symptoms still perslst, refer to the lnstallat~on Sectjon in thls manual to ensure proper installation and proper use of the controller in your system.

TABLE 6-3 CONTROLLER FAILURE SYMPTOMS r

I Upper Display

Blank I

I I I OK I

I

I

t

I

I

OK

I

Lower Display

Blank

Lower D~splay

Disagrees w i t h

Latch~ng Outpu t Relay

Funct~on

OK

Indicators

Off

OK

OK

Controller Output

None

Latching Output Relay

Funct~on Disagrees

w i th Lower Display

External Alarm

Function Does Not Operate Properly

Probable Cause

Power Failure

Latching Output Relay

Malfunction in Alarm Output

Troubleshooting Procedure

1

2

3


CONTROLLER FAILURE SYMPTOMS TROUBLESHOOTING PROCEDURES

PROCEDURE I : TROUBLESHOOTING POWER FAILURE

PROCEDURE 2: TROUBLESHOOTING LATCHING OUTPUT RELAY FAILURE

What to Do

1 . Check the AC line Voltage.

2. Make sure the chassis plugs into the rear of the case proper1 y.

3. Check the Voltage selection.

4. Check the system for brown-outs, heavy load switching, etc.; and conformance to installation instructions.

How to do it or where to find the Data

1. Use a Voltmeter to measure the AC Voltage across terminals L1 and L2 on the rear terminal panel o f the controller.

2. Withdrawl the chassis from the case and visually inspect the main printed wiring board for damage

3. See i f the J1 connector on the I10 printed wiring board i s in the proper posit~on for the voltage being used. See "Preliminary Checks" in the Installation Section.

4. Refer to the Installation Section.

PROCEDURE 3: TROUBLESHOOTING ALARM RELAY OUTPUT FAILURE

What to Do

1 . Make sure all the configurable data for the Limit Controller is correct

2. Check that the latching relay actuates properly

3. Check the latching output relay jumper position (NO or NC)


1 . See the Configuration Section in this manual to check the configuration data and to reconfigure ~f necessary.

2. Move the set point above or below the PV value depending on the type of Limit control configured Listen for the click of the relay as the set point IS

moved above or below the PV

3. See the Installation section for Relay contact information.

5 1-52- 13- 17, Page 6-6

What to Do

1. Check the alarm configuration data. If it is correct, check the field wiring. Reconfigure if necessary.

2. Check the alarm relay jumper position.

3. Check that the applicable alarm relay actuates properly depending on what you have set at "ALARMS" group prompt "AxSxTY". If it does, check the field wiring.

How to do it or where to find the Data I

1. See the Configuration Section.

2. See the Installation Section for jumper placement and contact information.

3. If the alarm type i s set for PROC (process varaible), press [DISP] t o display SP. Vary the alarm set point around the PV creating a deviation value and l~sten for a click from the relay as the SP moves ~n either direction and note that the indicator ALM1 l~ghts

PARTS LIST SECTION 7

I I I

I

I Fiyurc 7-1 Exploded vlew of the L~rn~t Controller

LIMIT CONTROLLER PARTS LIST

Limit Controller Exploded View Parts List

PARTS KITS NOT SHOWN

-

5 I -57- 14- 10 Paoe 7-2

QUANTITY

I

1

1

1

1

1

KEY NO.

1

2

3

4

5

PART NUMBER

30757023-50 1

30757032-501 30757032-503

30755306-501

307541 42-003

3075609 1-001 + L

DESCRIPTION

DisplayiKeyboard Printed Wiring Board

Transformer Printed Wiring Board TransformeriOption Printed Wi r~ng

Board

Electromechanical Relay - 5 Amps

Terminal Strip

Rear Terminal Cover Kit

APPENDIX A

lNTRODUCTlON This Append~x provides information for all the user conf~gurable parameters listed in the configuration section. If you aren't familiar with these parameters, this appendix gives you a definition of how each parameter setting affects controller performance. It will also refer you to any other prompts that m~ght be affected by your selection.

PARAMETER GROUPS AND PROMPTS As shown In the Table of Contents, the ~nformat~on IS

d~v~ded Into 5 configurat~on groups which are accessed by pressing the [SET UP] key.

Each of these groups contain prompts, v~ewed In the lower drsplay, wh~ch deal with funct~ons that are pertinent to that particular group These are accessed by pressing the [FUNCTION] key

The select~ons or values are listed in the upper display Refer to the Conf~gurat~on sect~on for step by step instructions.

SECTION 8

TABLE OF CONTENTS Group Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . Lockout 8-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 8-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Input 1 8-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Options 8-5

Alarm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

. . . . . . . . . . . . . . . . . . . . . . . . . . Cal~brat~on 8-7

. . . . . . . . . . . . . . . . . . . . . Status Test Data 8-7

LIMIT CONTROLLER APPENDIX A

LOCK Three levels of keyboard security protect Configuration and Calibration data.

LOCK LOCKOUT applles to one of the functional groups: Configurat~on and calibration. DO NOT CONFlGURE THIS UNTIL ALL CONFIGURATION IS COMPLETE.

NONE No Lockout - - all groups read:write.

CAL Callbratlon IS deleted from the SETUP list.

CONF Lockout 1s read wrrte. All other groups are read only.

5 1-52- 19- 18, Page 8-2


LIMIT This data deals w~th the type of Limit Control you want, power up Logic, set point high and low Iim~ts, and the default display.

Lo or HI Lo LOW LIMIT CONTROL - latching relay de- energizes when PV goes below configured set po~nt. Cannot be reset until PV rises above configured set potnt and Reset key is pressed.

Hi HlGH LlMlT CONTROL - latch~ng relay de- energizes when PV goes above configured set po~nt. Cannot be reset until PV drops below configured set potnt and Reset key is pressed.

POWRUP RST RESET - atter power down, controller latchtng relay will have to be reset.

NORM NORMAL - after power down, controller will operate normally in same mode as before power was removed unless a limit has been exceeded. If the limit was latched at power down, the unrt wrll be in "LIMIT" at power up and have to be reset..

HI RNG SET POINT HlGH LlMlT - this selection prevents the set point from going above the value selected here. The setting must be equal to or less than the upper range of the Input .

Range 0 to 100?/0 of Input In engineering units

LO RNG SET POINT LOW LlMlT - th~s selection prevents the set po~nt from going below the value selected here. The setting must be equal to or greater than the lower range of the Input .

Range 0 to 100% of input in engineer~ng units

DISPLY SP-If conf~gured, the Set Po~nt will be displayed in the upper display. "SP" will appear in the lower drsplay.

PROC - PV will be displayed in the upper display.


INPUT7 These are the parameters required for input 1; temperature units, decrmal location, actuation, hlgh and low range values In engtneering units, bias, filter.

DECMAL DECIMAL POINT LOCATION -- This selectlon determines where the dectmal point appears In the dlsplay.

None One Place Two Places ' ' can only be used when Process Var~able 1s between -99 and + 99.

UNITS TEMPERATURE UNITS -- This selectlon will atfect the lndlcator. What display of temperature do you want.

F = Degrees Fahrenheit C = Degrees Celsius None = None

IN1TYP INPUT 1 ACTUATION TYPE -- This selection determines what actuation you are going to use for Input one.

b E H E L J H J L K H K L NNM R S T H T L W RADl NIC 1 OOH 1 OOL

B thermocouple

E thermocouple high E thermocouple low J thermocouple hlgh J thermocouple low K thermocouple hlgh K thermocouple low NI Ni Moly thermocouple R thermocouple S thermocouple T thermocouple high T thermocouple low W thermocouple Radtamatic RH Nicrosil Nisil Thermocouple 100 ohm RTD high 100 ohm RTD low

BIAS 1 BIAS,ON INPUT 1 - - Select ttie has val~~r: yocr want on lnput one.

RANGE

-10 to + 10

FILTER FOR INPUT ONE - - A sottware d~<j t [~ l l fllter IS provlded tor Input 1 to smooth the 1r)p~11 slgnal. You car) configure ttie first order lay t l r l l c 2

constant from 0 to 120 seco~ids If yo^^ ( i c t r \ ' t W:IIII

filtering, enter 0.

BURNOUT NOTE: On all thermocouple ac:tuarloris. Upscale burnout IS provided for hlgh limit control; Dowr~scalr~ burnout IS provlded for low lln~tt control.

EMlSSlVlTY EMlSSlVlTY FOR RADlAMATlC (RH) INPUTS A radlamatlc pyrometer converts radlant erlergy emltted by a target Into electrical energy. Err~lss~v~ty IS a correction factor applled to the radlatr)at~c irlpt11 slgnal that is the ratlo of the actual energy e~rilttt!ci from the target to the energy w t ~ ~ c l ~ would bt? em~tted if the target were a perfect rad~alor Range: 0.01 to 1.0

FREQ POWER LINE FREQUENCY - Select wtictlier y o ~ ~ r controller IS operating at 60 t - 1 ~ or 50 H r .

60 Hertz 50 Hertz

IN1 HI IN1 LO

These prompts appear and represent the Hi and Lo values of the Input type selected and are not conflgurable.

5 1-52- 19- 18, Page 8-4


OPTONS Two optional features are available: External Reset (Contact Input) and PV(Auxiliary) Output.

EXTRST EXTERNAL RESET (CONTACT INPUT) resets the latching relay on contact closure.

DIS Disable the external reset option

ENAB Enables the exterrlal reset option. Contact closure resets the latching relay.

AUXOUT PV (AUXILIARY OUTPUT) SELECTION provides a voltage output representing the process variable. The display for auxiliary output viewlng w~ll be in engineering units.

Other prompts affected by th~s select~on: "OPCT" and " 100PCT. "

NONE No auxiliary output

PROC PROCESS VARIABLE -- Represents the value of the Process Vanable.

0 PCT PV (AUXILIARY) OUTPUT LOW SCALING FACTOR -- Use a value ~n eng~neering units for Process Variable.

100 PCT PV (AUXILIARY) OUTPUT HIGH SCALING FACTOR -- Use a value ~n engineering un~ts for Process Varrable.


ALARMS An alarm is an indication that an event that you have configured (for example--Process Var~able) has exceeded one or more alarm limits. There are two set points. You can configure each of these two set points to alarm on the process variable. There are two alarm output selections, High and Low. You can configure each set point to alarm either on High or Low. These are called single alarms. You can also configure the two set points to alarm on the same event and to alarm both high and low. There is a Fixed Alarm Relay Hysteresis of 0.5% of Input (PV) span.

A l S l V A ALARM 1 SET POlNT 1 VALUE -- This is the value at which you want the alarm type chosen in Prompt "A1 S1 TY' to actuate. The value depends on what the alarm set point has been configured to represent.

ALARM 1 SET POlNT 2 VALUE -- This is the value at whbch you want the alarm type chosen In Prompt "AlS2TY" to actuate. The value depends on what the alarm set point has been configured to represent.

ALARM 1 SET POlNT 1 TYPE -- Select if you want set point 1 of alarm I to represent the process variable or dev~ation.

NONE No alarm

PROC Process Vanable

DEV Deviat~on

ALARM 1 SET POINT 2 TYPE -- Select what you want set point 2 of alarm 1 to represent. The select~ons are the same as A1 SlTY.

ALARM 1 SET POlNT 1 STATE -- Select whether you want the alarm type chosen in Prompt "A1 SlTY" to alarm HlGH or LOW.

HI High alarm

LO Low alarm

A1S2HL ALARM 1 SET POlNT 2 STATE -- Select whether you want the alarm type chosen in Prompt "AlS2TY" to alarm HlGH or LOW.

HI High alarm

LO Low alarm

5 1-52- 19- 18, Page 8-6


CAL The prompts used here are for field calibration purposes. Refer to the Calibration section in this manual for complete information.

READ The prompts used here are for determining the reason for a controller failure. Refer to the Troubleshooting section in this manual for complete information.

APPENDIX B SECTION 9

HOW TO APPLY DIGITAL INSTRUMENTATION IN SEVERE ELECTRICAL NOISE ENVIRONMENTS

Introduction Products which incorporate digital technology provide recognized performance advantages over conventional analog instrumentation used for process control. These advantages can result in better product uniform~ty and greater overall efficiency when used correctly.

There are, however, certain guidelines regarding lnstallatlon and wiring which must be carefully followed in order to achieve this performance. In addition to the traditional precaution of the separation of signal and power wiring in separate condu~ts, other measures must be taken to minimize the effects of electromagnetic interference (EMI) and rad~o frequency Interference (RFI) on the operation of the equipment. Otherwise, i f high level, short duration, noise spikes are permitted to enter the digital equipment, the noise can be transferred into the system's logic networks and can be misinterpreted as signal data, resulting in erroneous system operation and other unpredictable responses.

Potential Noise Sources Nose can enter electronic equipment via three methods of coupling, namely:

capacitive (or electrostatic) inductive (or magnetic) impedanc~

Capacitive and inductive coupling have the same essential effect -- they couple current or voltage, w~thout any actual connection of the two circuits. lmpedance coupling requlres a connection between the two circuits.

Typical noise-generating sources that could affect electronic equipment through capacitive and inductive coupling include:

Relay coils Solenoids AC power wires -- particularly at or above 100 Vac Current carrying cables Thyristor field exciters Radio frequency transmissions

lmpedance couple noise may enter by way of the lines used to power the digital equipment or by way of Improper grounding. Most power lines, at typical industrial locations, are far from noise-free. The noise on them can be generated in many ways, but are

nearly always associated with switching clrcurts of some nature.

These include:

large relays Contactors motor starters busrness and lndustr~al mach~nes power tools HID (H~gh lntenslty Discharge) llghts Slllcon Controlled Rectlflers (SCRs) that are phase angled flred.

These are three ways to prevent electrical noise frorrr Interfering with the operation of the electron~c dlgltal equipment. One is to suppress the noise at ~ t s source. This IS the most effective but also the most difficult because it is not easy to identify all of the potential nolse sources in a typical industrial ~nstallation. There- fore, "suppression" is usually a last resort for those extreme situations where the other methods are insufficient by themselves.

The second method is to prevent noise from getting on the signal and power lines that are connected to the equipment. This is achieved by proper separation and shieldlng of those lines. In some cases separate power lines or special power line regulation or filtering may be requ~red for satisfactory electronic digital equipment operation. It is the responsibility of the installer to follow good wiring practices.

The third method is to design the digltal equipment with a high degree of noise rejection built-in. Thls Includes rlousing the equipment in a case that will provlde shieldlng, liberal use of noise reject~on filters and opto-isolators, and the use of noise suppressors on potential noise sources within the equipment itself. This, of course, is the responsibility of the manufacturer who usually performs extensive laboratory and field testing of newly designed digital equipment to insure the adequacy of its immunity to noise. As a minimum requirement, the equipment should be able to pass the tests outlined in the IEEE Standard 472- 1974 (Surge Withstand Capacity Tests).

Recommended Wiring Practices All wiring must conform to local codes and practices.

Wires carrying similar types of signals (Table 9-1) may be bundled together, but bundles with differenl types of signals must be kept separated to prevent inductive or capacitive coupling.

For distances over five (5) feet, and when shielding is recommended, use a separate metal tray or conduit for each bundle. Where condults or trays are not practical, use twisted wires with a metal

51-52-19-19, Page 9-1

LIMIT CONTROLLER APPENDIX B

overbraid and provide physical separation of at least one foot.


When unlike signal levels must cross, either in trays or conduits, they should cross at a 90-degree angle and at a maximum spacing. Where it is not possible to provide spacing, a grounded steel barrier or grid should be placed between the unlike levels at the crossover points.

Trays containing low level wiring should have solid bottoms and sides. Tray covers must be used for complete shielding. Tray cover contact with side rails must be positive and continuous to avoid high reluctance air gaps, which impair shielding. Trays for low level cables should be metal and solidly grounded.

Wires containing low level signals should not be routed near any of the following:

- contactors - motors - generators - radio transmitters - wlres carrying high current that is being switched

on and off


All shields should be grounded at one end only -- preferably the instrument end.

Power Source

The AC power for the dig~tal electronic equipment rrrust be withtn the voltage and frequency l ~m~ ts specifled for that equipment. Attempts to operate outslde the specified limlts will result in no performance For those ~nstallat~ons where the supply voltage w~ll not stay wrth~n the specifled limits; a ferro-resonant transformer, tor voltage resolution, should be used

For protection against noise, the AC source for the d~gital electronic equipment should be indeperldent ot all other loads espec~ally when switching loads are involved. For example, tt should not provide power tor air-condit~oning, convenience outlets, Iight~ng, nrotors, or similar noise generat~ng devrces To obtain electrical isolation (Figure 9-1) a separate transtorrr~er IS required to supply power to the digital equlprrieilt For additional noise and translent rejection, shielded prrmary and secondary wrndrr~gs may be requ~red Ar)tl 11 necessary, power line filters rrray be added to attenuate noise srgnals that have a trlgtwr t r t ~ c l ~ r t ~ r l ~ , than the power line trequer~cy

TABLE 9-1 -- External Wiring

5 1-52- 19- 19, Page 9-2

Wire Function Bundle

No.

1

2

3

N 0. I

1 2 3

4

5

6 7

Are Shielded Twisted Wires Recommended?

I

NO

YES

YES

Type

HIGH VOLTAGE Line Power Earth Ground Line Voltage Digital I!O

ANALOG I10 Process Variable

RTD Thermocouple dc Millivolts

Low Level ( < 100V) 4-20 mA dc 1-5 Vdc

DIGITAL 110 Low Voltage (c 1OOV) Computer Interface

r - - - - - - - - - -1 I I

Power source To d~g~tal 120i240 Vac '7 i electron~c s~ngle phase equ~pment

I I I I I G L ---------- 1

- -

Figure 9 -1 Trar~sfornler for d~yltal equtprnent


Generally speaking, when good wiring practices are used with well designed drg~tal electronic equipment, no further noise protection is necessary. However, in some severe electrical envrronments, the magnitude of the electrical noise is so great that it must be suppressed at the source. In most control cabinets, the main sources of noise are motor starters, contactors, relays, and switch gear. For thls reason, many manufacturers of these devices supply "surge suppressors" which mount directly on the noise source, for example, on the coil of a control relay or motor starter.

For those devices that do not have accessory "surge suppressors," resistance-capacitance (RC) circuits and1or voltage limiters such as metal varistors may be added when and where needed. This can be broken down into two categories, namely inductive loads(e.g., a relay sw~tch in series w~th a relay coil) and contacts.

Inductive Coils: Metal Ox~de Varistors (MOVs) are recommended for transrent suppression in inductive coils. An MOV is connected in parallel with the coil and is as close as physically possible to the coil (Figure 9-2). MOV devices (Table 9-2) are recommended for general purpose applications.


TABLE 9-2 - MOV Devices

0

- 0.5 mtd Metal rn

I l0OV oxide var~stor --

A.C. supply

F~gure 9-2 Translent suppressloll In i~iductlve colls

Honeywell Part Number I

Maximum AC

Energy Pulse Rating

Supplier (General Electric)

51-52-19-19, Page 9 - 3

30732481-001

130V

10 Joules

V130LA1OA

30732481-002

275V

15 Joules - V275LA15A


Noise Suppression at the Source (continued) Additional protection may be provided by adding an RC circuit in parallel with the MOV. This consists of a 220 ohm resistor in series with a 0.5 microfarad, lOOOV capacitor. The power rating of the resistor will depend on the voltage rating of the coil (Table 9-3).

TABLE 9-3 -- Coil Voltage vs Resistor Voltage Rating

I Coil Voltage I Resistor Voltage Rating I I 115V I 1 14 Watt I 11

5 Watt

Contacts: When a contact interrupts an inductive load, a certain amount of energy is stored in the load. A MOV or RC circuit in parallel with the load provides a place where this energy may be dissipated. However, i f there is no MOV or RC circuit, the energy may create a visible electrical arc across the open contacts. And this, in turn, results in electrical noise as well as damage to the contacts.

One way to eliminate this arc is to connect a resistor and capacitor across the contacts (Figure 9-3). A combination of 47 ohms and 0.022 microfarads (1000 Vdc) is recommended for circuits up to 3 amps and 300 Vac. (NOTE 1) And for voltage above 2000 Vac, an MOV across the contact may be added for extra protection.

For large load currents, a rule-of-thumb is to size the capacitor so that the number of microfarads equals the number of amperes in the load current, and the resistor is the same value as the load. This objective IS to eliminate the visible arc.

Either discreet resistors and capacitors or packaged RC networks may be used. An RC network (47 ohms and 0.1 microfarad) is available from Honeywell as part number 30371 852-001. Similar RC networks are available from Electrocube Inc. (part number RG1782-3) and from industrial Condensor Corporation.

In DC circuits, the power dissipation under steady- state condition can be eliminated by placing a diode (in series with a resistor) in parallel with the load (Figure 9-4). The value of R should be less than or equal to the DC resistance of the inductive load.

NOTE 1: For very small relay loads, a larger value of C (figure 9-3) may keep the external relay energized.

I I

Inductive

F~gure 9-3 Contact nolsc suppression

I Induc t~vu I load

F~gure 9-4 DC load nolsc suppresslor1 ,

5 1-52- 19- 19, Page 9-4

READER COMMl3NTS Honeywell's IAC Automation College welcomes your comments and suggestions to improve future editions of this and other publications.

You can communicate your thoughts to us either by mail using this form, or a toll-free telephone call.

BY TELEPHONE: In the U.S.A. use our toll-free number 1'800-822-7673 (available in the 48 contiguous states except Arizona; .in Arizona dial 1-602-863-5558).

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Title of Publication: UDMOOO Limit Control Model Product Manual

Publication Number: 51 -52-25-1 5A Issue Date: 1 I93

Writer: Dan O'Connor

COMMENTS:

RECOMMENDATIONS:

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TITLE

COMPANY

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I I I I I I I I I I I I

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Automation College Industrial Automation and Control Honeywell Inc. 2820 West Kelton Lane Phoenix, Arizona 85023

From:

BUSINESS REPLY MAIL FIRST CLASS PERRMT NO. 4332 PHOENIX, ARIZONA


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NECESSARY IF MAILED IN THE USA

Attention: Manager, Quality I - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - FOLD KXD I

Industrial Automation and Control Honeywell Inc.

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- - Helping You Control Your World

INDEX NO. 20

LOW FLOW CUTOFF

Differential Pressure Controls for NEMA 4,4X & Gen. Purpose Service

Working pressure ranges within 30" Hg to 225 PSI0

J400K with indicating option M210

Dimensions

NEMA 4 cast aluminum enclosures with minimum copper content. Many models available from stock H105K: -External dial with gasketed tamper resistant

cover - NEMA 4X -1 5 Amp SPDT switch output -Terminal block wiring 400K -Choice of one, two or three SPDT switch outputs. -Internal reference dial on "H" types -Many models available from stock -Direct replacement for UE 300K series -Indication option M210 available

Specifications Approvals:

105K 400K

Storage Temperature: Amblent Temperature Limits: Shock:

Vibration: Enclosure Classificat~on:

105K 400K

Set Polnt Repeatablllty:

Switch output:

Electrical Ratlng: Enclosure:

400K E!ectrical Connection:

105K 400K

Pressure Connections: lnalcator Optlon M210

UL listed. CSA certified. UL itsted (types 400K & 402K). UL recognized component (types 403K). CSA certified. -65 to + 1 60°E -40 to 16OoF ~ e i polnt repeats after 15 G, 10 millisecond duration. Set potnt repeats after 2.5 G, 5-500 CPS.

NEMA4,4X. NEMA 4, 13 when used with a watertight electrical connection. Nema 4X wrth optron M315 IAvallao!e on J402K onl\li I I '

odei is 455-559-'/2% of adjustable range. Models 147-Sl57B - 1 % ot adlustable ranae. Switches may be wlred "normaliy open" or - "normally closed." (1) SPDT ( I ) , (2) or (3) SPDT outputs. Swltches may be separated up to 100% of range. 15 amp 125/250/480 VAC resistive. Dle cast alumrnum, grey baked enamel hnrsh, gasketed. Olal cover 105K IS steel and tamper resistant

Approx 2 lbs.. 6 oz Approx 3 lbs.

A " diameter knockouts 8' NPTF: Dlfferent~al pressure ~ndlcatron avallable J400K. J402K models 147-S1578 lndlcator accuracy 1.5% mld 50% of range. 3% at ends Wlndow IS plexlglass and gasketed lndlcator may be freld adjusted for approx _c 196 ac curacy at any set polnt wlthln ranQe

-- 2 4 - -CLEAR FOR I/4SCREW

63.5 2 MT'G HOLE

Sw~tch Head All Types

400K

U ~ ~ A O I A E/C 3KNOCKOUTS 1 OPPOSITE SIDE 8 1 CENTERE IN REAR

1s OF ENCL~SURE 30.7

- 4.- Control Head ,-- 0731 All Types

107 SS

1- GREEN* 1 -CLEAR FOR f

GROUND r SCREW 2 SCREW 6s 0s MT'G HOLES

80 95 - - 3 1 - -

18 - I f -

NPT' EIC

Models 147-S157B - DIM A - Modeis 01m. A NPT 1 + ,,, Models 456-559

(m) (mm)

,3 iTm i S1478.51578 9'1.. 239.n '/a 147,157 8'1. I 219.08 % 1 ' '/a' NPT

Models 147-S157B

-DIM A; Ootion M210

- f NPT STlST ONLY

Follow steps 1-4 to specify the 105K or 400K differential pressure switch for your application. 1 Specify Type: -7

H105K - one SPDT output, external dial with '

tamper resistant , cover -=

J400K - one SPDT output. internal adjustment

J402K - two SPDT outputs. internal adjustment

J403K - three SPDT outputs, internal adjustment

H400K - one SPDT output, internal adjustment via reference dial

H402K - two SPDT ~ u t p u t ~ , internal adjustment via reference dial

2 Select standard models in stock

DIFFERENTIAL PRESSURE Model Chart Type HIOSK, H400K, H402K, H403K

for fast delivery. Order by speci- fying type and stock number (e.g. H105K-9942). If your selection is not in stock, go to step 3.

3 For models not ~n stock. specify type and model (eg. J400K model 457)

4 If an opt~on is required, add code numbers from pages 46 and 4 7 to type and model (e.g. J400K model 457*M315)

Buna-N diaphragm, "On ring and 'A" NPTF aluminum pressure connection. Model 455 is Dacron-based silicone.

Modei Chart Types J400K, J402K, J403K

*'Note: Double the deadband for dual and triple switches. tWelded 316 Sta~nless Steel bellows and wetted mater~al available with models 147 and 157. Proof pressures for both models change to 300 PSI. Working" pressure for model S157B is 0 to 180 PSI. To specify 316SS Sensor and % NPTF pressure connection prefix model number switch "S" and suffix model number with "B" (eg. S157B).

1

1

Buna-N diaphragm, "0" ring and 'A" NPTF aluminum pressure connection. Model 455 is Dacron-based silicone

Type with Stock Model Number Adjustable Range Deadband" Proof Working Pressure

J400K J402K J403K - (English) (Metric) Pressure Range 455 1 9953 656 1 9961 457

1 0 to 4 0"WC 0.1 to 0.3 PSI 0.1 to 0.4 PSI

Teflon diaphragm, seal and Y," NPTF aluminum pressure connection.

0 to 20 kPa 0 to 140 kPa 0 to 200 kPa

225 PSI 225 PSI 225 PSI

9925 9947

559 1 9990 1 95983 1

30"Hg Vac to 225 PSI 30"Hg Vac to 225 PSI 30"Hg Vac to 225 PSI

0 to 80"WCD 0 to 20 PSID 0 to 30 PSlD

0 to 100 PSID I 0 to 700 kPa I 0.2 to 1.0 PSI I 225 PSI I 30"Hg Vac to 225 PSI

Brass bellows and %" NPTF pressure connection or optional 316 SS bellows and L" NPTF pressure connection and 300 proof pressure. 1477

157t

Not Available

Not Available

20 to 200 kPa

70 to 700 kPa

3 to 30 PSlD

10 to 100 PSID

30"Hg Vac to 100 PSI

30"Hg Vac to 150 PSI

0.5 to 2.5 PSI

0.5 to 4.0 PSI

180 PSI

180 PSI

INDEX NO. 21

DIFFERENTIAL PRESSURE GAGES

D IFFERENTIAL PRESSURE GAGES

P D I - 0 1 2 - A , P D I - 0 1 3 - A P D I - 0 1 2 - 8 , P D I - 0 1 3 - B

Manual no. 120M75

INSTALLATION, OPERATION and MAINTENANCE INSTRUCTIONS

A sealed magnetically operated reed switch i s available with the Model 120 for use as an electrical alarm or control.

A maximum indicating follower pointer is available with the Model 120.

Available with a stainless steel pressure housing asModeI 120-S or SS, or with an aluminum housing as Model 120-A.

Seals are available in either Buna N. Butyl. Neoprene. Viton or Teflon.

MID-WEST MODEL 120 2%" Dial Differential Pressure Gauge

PISTON TYPE, 5000 PSI SERVICE. S.W.P.

0 - 2 to 0-100 PSID D IAL (0 -15 to 0 -700 PASCALS)

4 Front View The Model 120 Differential Pres- sure Gauge is a rugged 2-1/2" dial

Back View

I instrument used to measure and control the pressure drop across filters, valves and equipment and for flow measurement and control. Differential pressure is measured in a solid high pressure housing as the deflection of a spring by a free floating precision piston. The piston carries a magnet that is magne- t ical ly coupled to a magnet on the gauge pointer outside the pressure housing so that the pointer accurately tracks the position of the piston and indicates differential pressure on a cal ibrated dial scale.

The pressure housings are supplied with a 0.50 inch diameter piston for pressure ranges above0-10 PSID, (0-70 Kilo pascals) and with a 0.70 inch diameter piston for pressure ranges below 0-10 PSlD (0-70 Kilo pascals). The gauges with an 0.70 inch piston are identified as Model 120-AL, 120-SL or 120-SSL.

INSTALLATION

Mid-West Model 120 Differential Pressure Gauges are carefully adjusted, calibrated and scaled according to specifications before shipment and are ready for installation and use on receipt.

The gauge as supplied may be either l ine mounted on the inlet and outlet pressure connections to the gauge or may be flush panel mounted. An accessory to mount the gauge on a 2 inch support pipe for stanchion or wall mounting i s available.

A. Line Mounting

When line mounting the gauge on the inlet (High and outlet (Low) pressure connections, use full size 1/4 inch pipe i f possible. The gauge can be solidly supported with input nipples up to 3 inches long. The nipple- connections should be solidly supported at the piping ends.

INSTALLATION - continued

0. Panel Mounting

The Model 120 gauge i s designed wi th a bui l t- in panel mounting bracket for mounting the gauge on panels-plates or enclosures. The gauge mounts in a clearance hole 3.00 inches diameter, with 4, No. 8 mounting bolts on 3.50 inch bolt circle. To mount the gauge, insert the gauge thru the panel and hold with the 4 mounting screws.

The inlet (high pressure) and outlet ( low pressure) connections to the gauge should be made with relatively flexible tubing connections, rather than with rigid pipe, to reduce the chance of mis-alignment between the panel and the piping system.

C. Piping Connections

A Differential Pressure Gauge senses the direction of the pressure difference, High - Low, plus and minus, it i s essential that the "high" inlet side of the differential pressure gauge be connected to the high pressure side of the system and the "low" outlet side be connected to the low pressure side of the system. If on start-up, the gauge reads zero, it may be that the high and low connections on the gauge are reversed.

(1) Very High Temperature Conditions - When the Model 120 is used in a high temperature system, the connecting tubing to the inlet and outlet of the gauge should be as long as possible to cool the fluid, so that the f luid temperature at the gauge is less than 200.F (90.C). This precaution is to reduce the chance of dis- coloring the dial or warping the dial housing of the gauge due to high temperatures. A length of tubing of 6 feet i s usually adequate for most applications.

ASSEMBLY and CALIBRATION An exploded view of the Model 120 Differential Pressure Gauge, shows the piece parts of the gauge and

the method of assembly. CAUTION: When tightening or loosening the pressure connect ions at the back of the gauge, or the seal nuts at the left and right side of the gauge, hold the bar-stock body of the gauge securely with a 1 inch wrench. Do not wrench the front Dia l Chamber and bezel.

To Disassemble the Pressure housing;

(a) On the standard type, loosen the seal nuts and remove the adjustment screws. See exploded view. (b) On the low pressure 120-1 ) L type, loosen the seal plugs and remove. See exploded view. (c) With a peneil or a wooden dowel, push out the piston assembly and spring. (d l Cleaning. Thoroughly clean the housing, piston and metal parts with detergent solutions or mild

solvent. Do not use strong solvents (acetone, ether, toluene, and such) These may damage the dial and bezel assembly.

(e l Re-Assembly. Inspect a l l parts, use new '0' Ring seals i f available. Coat a l l '0' Ring seals and al l sealing surfaces with silicone grease; also, apply a thin fi lm of silicone grease to the piston and cylinder. Check that the piston assembly is a free sliding f i t to the cylinder. On the low pressure Model 120 -( ) L, if the pointer moves in reverse as the piston is moved, reverse the piston end for end. Re-assemble seal nuts and adjustments as shown in exploded view.

( f ) ~ s n . The adjustment screw on the right side of the gauge is for "zero adjust" and that on the left side is for calibration.

(1) Zero adjust. Turn right hand screw in, until pointer moves off zero stop on dial; tap lightly and back off screw until pointer reads zero. Lock adjustment nut securely; recheck to see i f zero holds.

(2) D ia l Calibration. Check gauge at approximately 30%. 50% and 70% of ful l scale pressure and adjust calibration screw at left end of gauge for proper calibration. Lock adjustment securely.

MAXIMUM INDICATION FOLLOWER POINTER The maximum indication follower pointer that is supplied with the Model 125 is a light weight and bal-

anced 'lazy' pointer on a free pivot that moves with the main indicating pointer and remains at the highest point, that the main pointer travels. The 'maximum' pointer i s reset with a knob on the front of the gauge.

The 'maximum' pointer i s free moving and does not affect the accuracy of the gauge. The 'maximum' pointer i s affected by severe vibration and gauges equipped with 'maximum' pointers should be mounted as solidly as possible and where vibration is not severe. The piece parts and the method of assembly of the maximum pointer i s shown on the exploded view.

DIMENSIONAL D A T A

FOLLOWER POINTER

----------

LOW PRESSURE MODEL 120-1 ) L

REED SWITCH. I or 2 YODEL l l O E Onlr

ASSEMBLY and REPLACEMENT PARTS LIST

4 - - -

-, PISTON (0.501

P A R T NO.

7 64

1117 703 23 7

989 1118

1005

1113 7 63 1119

ITEM

Bezel

Follower Polnter Assy. V; Bezel Gasket. P A R T ITEM

Lens, Glass. NO.

Lens, Acryllc. a 5/16-18 Hex Jam Nut. Brass (2)

Polnter Assy. 5/16-18 Hex Jam Nut, 316 Stainless Steel (2)

Brldge @ 2 - 1 0 "0" Rlng Seal - Speclfy Materlal (2)

Dlal @) 3 -908 "0" R~ng Seal - Spec~fy Materlal (2)

Housing

Fastener Hardware (not i 1 lus.) 4 Bezel Screws 4 Housing Screws 2 Pointer Stops

@ 318 Seal Nut. Brass (2)

566 Seal Nut. 316 Stainless Steel (2)

@ 3-906 "0" Ring Seal - Specify Material (2)

@ 1066 Switch Assembly.

INDEX NO. 22

FLAME PROGRAM CONTROL

BC-A , BC-B

SCANNERS

SC-A, SC-B

DESCRIPTION - The FIREYE FLAME MONITOR is a MICROPROCESSOR On a safety shutdown, the MESSAGE CENTER will advise the

BASED BURNER MANAGEMENT CONTROL with self- operator that the control is in "ALARM" and scroll a message in- diagnostics, non-volatile memory and a vocabulary of twenty dicating the cause. nine different messages which scroll ou t on the built-in Interchangeable flame amplifier and programmer modules allow MESSAGE CENTER to provide the operator status and failure for COMPLETE VERSATILITY in the selection of flame detec- mode information. The syslem is designed to provide the proper tors and display language (English, French, German). BURNER SEQUENCING AND FLAME MONITORING on The FIREYE FLAME MONITOR has REMOTE DISPLAY automatic burners, single or dual fuel fired burners, direct spark CAPABILITY. Ribbon cable connector pins which allow for a or pilot ignited burners and on/off or modulating burners. remote display are standard on the chassis.

Inputs for all burner interlocks are provided: i.e. recycling limit Additional accessories include an EXPANSION MODULE. and operating controls, non-recycling running interlocks, purge The expansion module for the FIREYE FLAME MONITOR air flow switch and firing rate motor end switches. adds the capability of individually displaying any malfunction for

The FLAME MONITOR programs the burner/blower motor, an additional sixteen interlock switches. The module provides ignition transformer, pilot and main valve for proper and safe first-out annunciation of all interlocks. burner operation to meet specifications of approval authorities.

APPLICATION DESIGN FEATURES

For single o r fuel fired burners, pilot ignited or direct ignited * Microprocessor based technology. continuous duty. * Plug-in control unit with "snap-on" protection cover. One basic model meeting various European standards. * "Burnt-in" electronic circuits eliminating aging and Message center (built-in or {remote use) indicating in English, temperahre problems French or German program sequence and reasons of alarm * Epoxy coated circuit board to eliminate moisture and burner shutdown. humiditv Read-out of burner history, number of cycles and hours of * Gold-plated plug-in contact fingers burner operation; a non-volatile memory allows the control to , Accurate timings; watchdog timer to supervise ignition and store this data even when power is off. travel timt: of modulator motor Different detection methodls * Overload dnd short-circuit protection

--infra-red -ultra-violet * Built-in self-diagnostic

-ultra-violet self-check with corresponding large choice of flame scanner constructions

SPECIFICATIONS Operating temperatures limits: Temperature -- Max. Mia. Chassis

EB720 60°C -20°C* EB72 1 60 "C -20°C*

Amplifiers, Programmer 62°C -20°C* All UV scanners 100°C -20°C* All infra-red scanners 52 "C -20°C"

Humidity 85% RH maximum (non-condensing) All components epoxy coating sealed. Supply voltage & electrical ratings Supply Voltage:

El3720 220V (Europe) (min. 187V., max. 242V.) 240V (U.K.) (min. 204V. max. 264V.)

EB721 llOV (min. 94V. max. 121V.) Frequency: 50/60Hz Power consumption:

-Operating : 25 VA -Standby : 13 VA

Typical timings - Timing chart Prepurge time : 30 or 60 s (selectable by switch on programmer module) Pilot ignition time : 5 s Pilot proving time : 10 s Main flame ignition time

*Gas-pilot valve terminal 5 : 2s *Oil-pilot valve terminal 6: 5s

Post-purge : 10s becomes 20 s in case of flame failure or ignition failure

Flame failure response time : maximum 1 s

Maximum simultaneous connected load 2000 VA

* Unit tested down to - 20 "C. Minimum operating characteristics, subject to supply voltage changes.

FLAME-MONITOR ORDERING INFORMATION

E201 consists of: EB721-chassis EC6OO-dust cover ED500-display module Mounting Screw

E200 consists of: EB72O-chassis ECGOO-dust cover ED500-display module Mounting Screw

mgrammer Module TYPE EP11E (Messages In English) TYPE EP113D (Messages In German) TYPE EP113F (Messages In French) Flame Amplifier Module

(See page 5 for details)

i

Wiring Base 60-1386-2 Surface Mounting

Mounting Screw'

4

Mounting Screw* - EP Series Programmer Module

Serial Number Label on bottom

* The mounting screw must be removed to replace the Modules. *

This screw must be used to prevent electrical shock or damage to the control. .

Dust Cover EC600

i

AMPLIFIER MODULES * Type E1R 3 : With infra-red scanners * Type EUV 1 : With ultra-violet scanners * Type EUVS 4: With ultra-violet

self-check scanners

SCANNERS

Infra-red

Ultra-violet Self-check

45UV5-1007 1800 mm 1 " BSP

S p e 48FT2 Model

1003 1007 9003 9007

Ultra-violet

FLAME SCANNERS

Type UV 1 A3 UV 1 A6

u v 2 45UV3/1050

--!

UVlA UV-2

Cable length

2400 mm 1200 mm 2400 mm l200mm

43 SCANNER TYPE 45UV5

Cable length

900 mm 1800 mm

900 2400 mm 45UV3 SCANNER

Version

Straight head Straight ahead

90 " head 90 " head

Mounting

% " % " NPT

% " for % "pipe

ACCESSORIES I SPARE PARTS

Mounting

% " % " % " % "

FOR 48PT2 45UV3,45UVS 48PT2 45UV3 45UV5

48PT2 UVlA UVlA 48PT2/UV1 A 45UV5 48PT2/UV1 A 45UV5

DESCRIPTION Firetron cell UV tube Lens Quartz lens

Union coupling - with glass lens - with quartz glass - with quartz lens Heat insulator Heat insulator Swivel mount Swivel mount

TYPE 4-263- 1 4-3 14 61-436 46-56 46-38

60-801 60-1257 60-1290 35-69 35-127-3 60-302 60-1664-4

OPERATION The FIREYE FLAME MONITOR is designed to provide

proper burner sequencing and flame monitoring on automatic burners. It also provides the operator a status read-out as well as diagnostic information. It has a number of unique messages which are designed to be simple to understand and interpret. These messages are, at option, in English, French or German.

1. Description of Interlocks A. The opening of any interlock in the L,-3 circuit mill stop the burner without causing lock-out or alarm. When the interlocks are closed, the burner start sequence is initiated. These interlocks include the thermostat switch, which is closed when heat is required. B. Non-recycling interlocks: (3-P)

If any interlock switch in this circuit opens, all open fuel valves will be closed immediately and the control will always go in alarm or lock-out. The control must then be manually reset. These interlocks include for instance the air flow switch.

C. High fire or purge interlock: (D-8) This is the firing rate motor linkage position switch or

a differential air pressure switch that proves a maximum purge air flow rate.

D. Low fire start interlock: (M-D) This is the firing rate motor linkage position switch or

a damper position switch, which will prove both the linkage and damper are in their proper positions to begin burner light off.

START-UP PROGRAM

The FIREYE Flame Monitor E2OO with programmer module and flame amplifier module, together with the appropriate flame detector, provides the following burner operation sequence.

1. With vower a~vIied the blower motor is energized through -Low-fire switch (minimum air flow switch) closed. terminal M whin the following conditions are met:

- 6. The spark ignition and the pilot valve are energize. * Recycling limits (demand for heat) are closed.

* The air flow switch is open at start or opens within 30 sec. 7. The ignition transformer is deenergized after 5 seconds

* No lock-out pilot trial for ignition time.

The air flow switch closes. The other non-recycling interlocks (depending on fuel selection) also close (all within 30 sec.).

2. The firing rate motor is driven to the high fire position. 3. The prepurge is initiated when the high fire interlock 8. As soon as flame is detected, the message center will pro-

(purge air flow interlock) is closed within 300 seconds, con- vide a read-out of the signal strength both during pilot pro- firming that the firing rate motor reached its high fire posi- ving time and main burner operation. tion. The supervised prepurge time is 30 or 60 seconds (selection switch on ~ronrammer module to be set before 9. Following a 10 seconds proved pilot stabilization period,

Comment

Minimum required

20 or more Normal

. " start). the main fuel valve (terminal 7) is energized.

4. When the prepurge is completed, the firing rate motor is 10. After the main burner trial for ignition time (2 seconds for gas, driven towards the low-fire position, to be reached within 5 seconds for oil), the pilot valve is deenergized and the firing 300 seconds. rate motor is released to automatic control.

5. The burner is ready for ignition if the following conditions 11. The supervised start-up program has ended and the burner are met: is in operation. -Recycling and non recycling interlocks closed.

SEQUENCE FLOW CHART

NORMAL BURNER SHUTDOWN 1. When the operating control (recycling interlock) opens, the 2. Following a 10 second post-purge the blower motor is

main fuel valve is deenerpized and the firing rate motor is deenergized. driven to the low position.

ALARM - LOCK-OUT CONDITION

The FIREYE Flame Monitor will lock-out under the following conditions:

-At any time * Excessive current load at either terminal X, 5,6 , or 7 * Self-diagnostic o r failure on - chassis - amplifier module - programming module - self-check UV scanner

-During burner off time * False flame signal sensed for more than 30 seconds

-During burner start * Air flow switch nor open within 30 seconds a t start * Air flow switch not closed 30 seconds after start * High fire switch not closed within 300 seconds * False flame sensed for rnore than 1 second

-During prepurge * Opening of non recycling interlocks and/or high-fire

interlock * False flame sensed

-After prepurge * Low fire interlock not closed within 300 seconds after

purge completed * Opening of non recycling interlocks * False flame sensed

-During burner ignition * Opening of non recycling interlocks * Pilot flame not detected after pilot trial for ignition time * Pilot flame failure during pilot proving time * Flame failure during main burner trial for ignition time

-During burner operation * Opening of non recycling interlocks * Flame failure

CIRCUIT DIAGRAM FLAME MONITOR E200

NON-RECYCLING RECYCIJNG IMERLOCKS RUNNING INTERLOCKS

SCANNER TERMINALS

Z O V Europe 240V. In U,K

(50lE'J nz)

ALARM BLOWER MODULATOR IGNITION PILOT VALVE MAIN VALVE TFWNSFO

* For the E201. Power Connections L l / L 2 are for 110V. 50Hz.

MESSAGES There are two types of messages shown on the message center of the display module ED 500.

1. Normal program start-up and stop messages. 2. Alarm - Lock-out messages. Note: A description of messages in French and German can be found in the bulletins E2001F and E2001D respectively.

MESSAGE DESCRIPTION

WAlT SAFETY

\

BURNER HISTORY 474 HOURS 58 CYCLES

/

WAlT SAFETY

Indication of total burner operating time and total number of burner-on cycles. This message is displayed at burner-off time during three minutes, it also reap- pears every time the reset button is pushed during the burner off time.

HIGH PURGE CIRCUIT u PURGE 00 0 C[

LOW FIRE CIRCUIT

IGNITION 0 PILOT 00 0 FLAME 00 0 POST 00 /I

The burner has stopped. It is waiting for a demand for heat to start burner sequence again.

The control is waiting for the safety circuit (3-P) to open before proceeding. Max- imum waiting time is 30 seconds before a lockout will occur.

The waiting time (maximum 30 seconds) for the non-recycling interlocks to close.

The waiting time (maximum 300 seconds) for the high purge interlock (D-8) to close.

Prepurge in progress, counting of seconds, 30 or 60 seconds.

The waiting time (maximum 300 seconds) for the modulator to run to the LOW position, waiting for the low fire circuit (M-D) to close.

Unsupervised pilot trial for ignition time (maximum 5 seconds).

Pilot flame signal during pilot proving time.

Main flame signal during supervised main trial for ignition and during burner operation.

Postpurge time of 10 seconds (20 seconds in case of flame failure or ignition failure).

ADDITIONAL MESSAGES

ALARM MESSAGES These messages scroll on the display as soon as an abnormal situation occurs. After the postpurge time the control will lockout. The

message remains until the control is reset (even after a power failure). A. Alarm messages related to the safety circuit

These messages scroll on the display when an abnormal status of the safety circuit is confirmed. After the post-purge time of 10 seconds, the control trips (lockout).

MESSAGE n A

DESCRIPTION

SAFETY CIRCUIT

IJ - - - -- -

The safety circuit did not close within 30 seconds after start.

SAFETY ClRCUlT CLOSED

SAFETY CIRCUIT

The safety circuit was not in the open position at start.

SAFETY CIRCUIT OPENED * PILOT

<

SAFETY CIRCUIT OPENED * PILOT

The safety circuit opened during purge time.

The safety circuit opened during pilot trial for ignition time (5 seconds).

The safety circuit opened during the pilot proving time (10 seconds after Pilot Ignition).

SAFETY CIRCUIT OPENED MAlN I I The safety circuit opened during main burner trial for ignition or during burner

firinn time. V V

-

B. Alarm messages related to ignition and flame failure These messages scroll on the display as soon as an ignition failure or a flame failure is detected. After the extended post-purge time

of 20 seconds the control trips (lockout).

MESSAGE DESCRIPTION h 1

PILOT IGNITION FAILURE 1 1 Pilot flame not established within the 5 seconds of the pilot trial for ignition time.

PILOT FLAME

MAlN FLAME FAILURE u Pilot flame fails during pilot proving time.

Flame failure during trial for ignition main burner, or during burner operation.

ADDITIONAL MESSAGES C. Alarm messages related to field conditions

These messges scroll on the display when a wrong field condition is detected. After the post-purge of 10 seconds, thecontrol trips (lock-out).

MESSAGE DESCRIPTION

FALSE FLAME u FALSE FLAME *

HIGH PURGE CIRCUIT

LOW FIRE CIRCUIT

False flame or flame signal detected during burner-off cycle.

False flame or flame signal detected during purge time.

High purge circuit not closed within 300 seconds after start of blower.

Low fire circuit not clcised within 300 seconds after end of purge.

D. Alarm messages related to control diagnostics These messages are scrolled on the display when a failure is detected within the burner management control.

MESSAGE DESCRIPTION

OVERLOAD 0 REPLACE CHASSIS s

REPLACE

REPLACE AMPLIFIER

REPLACE SCANNER

SYSTEM ERROR 0

Excessive current load was sensed at either terminal X, 5,6, or 7

Internal failure detected in chassis.

Internal failure detected in programmer module.

Internal failure detected in flame amplifier module.

Internal failure detecred in self-check scanner 45UVS.

Internal failure detected in programmer module. Check for excessive noise on scanner wires or improper grounding.

INSTALLATION INSTRUCTIONS

CONTROL INSTALLATION Control assembly

The control must be assembled before plugging it into the wiring base. When replacing modules, the control must be removed from the wiring base

- Installing Amplifier Module The flame amplifier module is installed in the third set of

guide channels found in the EB 720 FLAME MONITOR chassis. It is marked "AMPLIFIER MODULE".

To remove the cover, place your fingers and palms on each side Do not force the module into position. and pull forward as shown in the diagram. Press down with thumbs while pulling out with your palms and fingers. The cover will snap off and can be snapped back into place easily.

- Installing Programmer Module Fireye FLAME MONITOR Programmer Modules are us-

ed with Fireye Series EB 720 base chassis. They are installed in the chassis by simply insetting the module into the second slot on the control. This slot is marked "Programmer Module" on the side of the chassis.

Programmer Modules are designed to fit only in the proper slot. They cannot be snapped into place if inserted in the wrong location. DO NOT FORCE THEM.

-Installing Display Module The ED 500 Display Module is inserted into che EB 720

Chassis as shown here. The side guides align the connector pins for easy insertion. D o not force the module into position.

INSTALLING THE CONTROL

1. Check the electrical tabs on the bottom of the chassis - if they are bent out of position, reposirion them witn your fingers so that they are in line as shown here.

2. Slide the slots a t the bottom of the assembled control over the tabs on the wiring base. Push the control into position. Insert a screwdriver through the hole in the top of the control and tighten the retainkg screw.

3. EIectric power may now be turned on.

FIELD WIRING The use of 2.5mm2 wires, rated a t 600V is appropriate for all

field wiring. The wiring base is provided with eighteen (18) numbered terminals plus a n earthing screw.

SCANNER INSTALLATION Infra-red scanner installalion

A single scanner is used to detect both pilot and main main and pilot flames. The scanner must have unobstructed flames, the sight pipe on which the scanner mounts must be view of flame being monitored. To avoid nuisance shut- aimed so that the scanner sights a point at the intersection of downs, it is important to avoid sighting hot refractory.

112"-IR SCANNER #60-302 HEAT INSULATOR 1/2 -IR SCANNER

MOUNTING WlTH HEAT INSULATING NIPPLE

SWIVEL MOUNT AIR ENTRY (PURGE AN0 COOLlNGl

STANDARD MOUNTING WlTH PURGING/COOLING AIR

ALTERNATE STANDARD MOUNTING NOT ADJUSTABLE1

AIR ENTRY (PURGE AND COOLlNGl

MOUNTING FOR EXCESSIVE FURNACE

OR WINDBOX PRESSURE WITH

PURGING COOLING AIR

The figure above shows installation instructions for the TYPICAL UV SCANNER INSTALLATIONS 48PT2 scanner in various circumstances, taking into account the maximum scanner temperature rating of 52 "C. -Standard mounting -Mounting with cooling and/or purging air -Mounting with heat insulating nipple -Mounting in case of excessive furnace or windbox

pressure Note: % "nipples and % "TEE pieces are not available

from ECA; these are to be purchased locally. Ultra-violet scanner installation -Locate the scanner as close as possible to the flame. -Thescanner must not sight the spark directly or any part

of.the burner that can reflect the spark back to the scanner.

-The maximum UV signal from a flame is found in the first one-third of the visible flame taken from the point where the flame begins. The scanner sight pipe should be aimed at this area.

-On installations having negative pressure combustion chambers, a small hole ( X " or drilled in the sight pipe will assist in keeping the pipe clean and free from smoke. Two scanners may be installed on one burner if it is necessary to view two areas to obtain reliable detection of the flame. They should be wired in parallel.

UV SCANNER TYPE 45UV3

The figures on page 14 shows different mounting instructions, taking into account the maximum scanner temperature of 100°C

-Standard mounting -High temperature mounting -High pressure/temperature mounting Note: 1 "TEE pieces are not available from ECA; they are

to be purchased locally.

MOUNTING UVlAlUVlB SCANNERS r

STANOARD MOUNTING MOUNTING WlTH HEAT INSULATING NIPPLE

112" SIGHT PIPE

TEE-PIECE

STANDARO MOUNTING WlTH PURGlNGlCOOLlNG AIR

TEE PIECE

MOUNTING FOR EXCESSIVE FURNACE OR WINOSOX PRESSURE WlTH

MOUNTING 45UV5 SCANNER

SCANNER WIRING Like other FIREYE controls, the FIREYE FLAME

MONITOR is protected against short-circuited scanner input terminals. Following recommendations apply for scanner-control wiring:

Keep scanner wiring as short as possible Use wires rated for scanner voltage and its ambient conditions (temperature, humidity, oil resistant, flame retardant, etc). Do not run scanner wires in the same conduit as other electrical wires. Avoid wire loops and false groundings. Do not ground any scanner wire.

Infra-red scanner wiring Infra-red scanner type 48PT2 is provided with a flexible conduit. The two wires are to be connected to a coaxial cable via a junction box. Maximum cable length between scanner and control is 30 meters.

Ultra-violet scanner wiring -Self-cheek scanner 45UV5 The self-check scanner has four wires 1800mm long

SELECTION OF APPROPRIATE FLAME DETECTOR - Name Detector Selection Guide

02 firing x x I x

1 Continuous firinn I x 1 x 1 I

Gas firing

Strong refractory

-- -

Intermittent firing I x I x I X

TYPE 48PT2 MODEL 1007

Infra-red detectors can be used with almost any single burner application although some difficulty may be encountered with small gas pilots which have a limited infra-red output. The infra- red radiation passes readily through normal combustion products and dirty surfaces which makes them very reliable in a single burner application.

x

Application of Ultra-Violet Detectors

TYPE U V I A

x

x

Two black wires, providing power to shutter drive circuit, to be connected to terminals L1 and N Two red wires for flame signal, to be connected to terminals S1 and S2.

Scanner voltage: Term. S 1 -S2 600 VAC Term. Ll-N: Line Voltage

Voltage above ground: Term. S1-S2 wires: 300 VAC

For extended wiring use standard four conductor cable rated for 600V to be connected via junction to scanner wires Maximum cable length 50 meters (150 feet).

x x

-Other UV scanners These scanners (UVIA3, UVIA6, UV2.4SUV3) are provid-

ed with two wires. Use standard two conductor cable, rated for 600V, to obtained extended wiring via a junction box. Maximum cable length 50 meters (150 feet).

TYPE 48Pf 2 MODEL 9007

When a single scanner is to be used for detecting both pilot and main flame, the field of view of the scanner must be aimed at the intersection of the pilot and the main flame. This is to insure that a satisfactory signal from the scanner indicates that there is a flame at a point which will be sure to ignite the main flame.

Most flames produce sufficient UV for an ultra-violet detec- suited to all gas burners or combination gas-oil burners. tor. Even those flames completely invisible to the eye are easily The area to scan with an ultra-violet detector is within the seen with a UV detector. Since the combustion products of all first length of the flame since this is the major source of flames are opaque in the UV region, this detector is also suited uv and also since the products of the flame are to multiple burner installations. The ultraviolet detector is ideally opaque in the ultra-vioiet region.

PROPER FLAME SIGHTING FORUVSCANNER

The field of view should be area A. Do not try to scan area X at the outer fringes of the flame. The field of view should include the intersection of the pilot and the main flame so that a signal from the scanner will insure that the pilot is in the proper position to ignite the main flame.

Since the radiated energy from an electric spark ignitor is very rich in the UV region, the field of view should be aimed so that it does not see an electric spark ignitor nor any reflector that is close to the spark.

MAINTENANCE Type Infra-Red and Ultra-Violet Scanners

The viewing area of the scanner must be kept clean. Even a small amount of contamination will reduce the flame signal reaching the detector by a measurable amount. Wipe the view-

ing area routinely using a soft cloth dampened with concen- trated detergent. Flame Signal Strength

Routine observation of the flame signal strength on the display will forewarn of any deterioration in the capability of the flame detector or its application. Contacts

There are no accessible contacts in the Fireye Flame Monitor controls. Where contacts are used, their design assures long trouble-free life, when the load circuits are maintained within the published load ratings. Humidity

In areas of high humidity, the control chassis should be removed and placed in a dry atmosphere when the system is expected to be out of service for an extended period.

WARRANTIES, EXCLUSIVE REMEDIES, AND LIMITATION OF DAMAGES

ECA guarantees for one year from date of shipment, to replace or at its option, to repair any product or part hereof (except lamps, electronic tubes and photocells) which is found defective in material or workmanship or which otherwise fails to conform to the description of the product on the face of the sales order.

The foregoing is in lieu of all other warranties and ECA makes no warranty of merchantability or any other warranty, express or implied.

Except as specifically stated, remedies with respect to any product or part manufactured or sold by ECA shall be limited ex- ciusively to the right to replace or repair, F.O.B. Point of Ship- ment as above provided. In no event shall ECA be liable for consequential or special damages of any nature which may arise in connection with such product or part.

COMPONENT DIMENSIONS

MOUNTING HOLES

CONTROL WITH COVER AND WlRl

FLEXIeLE CONOUll LENGTH WP€ UV-%A-3 9001 WUE LENGTH 9801

TYPE UV-IA-(118001WlRE LENGTH 1880'

WlRE LENGTH t 8 8 O

STANDARD MODELS O i l 1 W MOOELS

HEAT INSULATING NIPPLE - 8 0 -

1/4-20

WlRE LENGTH. 1800 mm

CABLE LENGTH

BSP . S M-

INDEX NO. 23

P I L O T I G N I T I O N TRANS.

I T - A , IT-B

Rei: Bulletin 4015, Supplement 4015-1

North American ' 7

Pilot Igni t ion Transformers and Cable

Mfg. Co.

For UL listing, minimum secondary voltage for pilot ignition transformers is 6000 volts. All units listed below meet this requirement. 6000 volt transformers are adequate for North American ignition systems using 10mm automotive type spark plugs in a pilot tip or burner. Larger center electrode igniters generally require 10 000 volt transformers, such as the 4065-6N1-10A.

ELECTRIC PILOT ACCESSORIES SUPPLEMENT 4015-2

All 6000 volt transformers listed below have a junction compartment for the primary splice and a recessed high voltage terminal to minimize the hazard of accidental shocks. The 4065-6N1-10A (10 000 volt1 transformer has a screw-type high voltage terminal.

Cleveland. OH 44105 U S A 1-86 \ J

Transformer cases must be grounded to burner bodies through a metallic connection. Temperature of the transformer mounting surface should not exceed 140 F (60 C).

Dimensions in inches

% Conduit K.O.

6 Slots ,- ' I , long r 5/ra wide

% Conduit K.O. (both sidesl

m High Voltage

Terminal

t-~ 6 3/. ----------t/ I I

% Conduit K.O. (both sidesl 4065-6N 1 -6A

High Voltage Terminal

% Conduit K.O.

'/,.long x 'It6 wide

IGNITION CABLE 4085-5 4085-10 4085-15 4085-20

40855-A 4085-10-A 4085-15-A 408520-A Designation 4085-5-W 408510-W 4085-15-W 4085-20-W

"L" Dimension 5' 10' 15' 20'

Transformer PRIMARY I - Designation , volts hertz VA

Maximum ambient temperature: 220 F Maximum ambient temoerature for UL listino: 200 F

No. of Secondary Weight, Use Ignition

volts mA I Terminals Ib Cable

-

DIMENSIONS SHOWN ARE SUBJECT TO CHANGE. PLEASE OBTAIN CERTIFIED PRINTS FROM NORTH AMERICAN MFG. CO. IF SPACE LIMITATIONS OR OTHER CONSIDERATIONS MAKE EXACT DIMENSIONIS) CRITICAL.

Spark Plug Boot

4065-6N1-6A / 120 60 180 / 6 000 20 1 1 10 4085 4066-6N1-6A , 240 60 180 / 6 000 20 1 10 4085

INDEX NO. 24

DIGITAL DISPLAY HEATER STACK TEMPERATURE

DIGITAL DISPLAY FOR HEATER INLET TEMPERATURE

Honeywell

UDC2000 Mini-Pro Universal Digital Controller

Product Manual





UDC 2000 is a trademark of Honeywell Inc.




ii UDC2000 Product Manual 1 /93

About This Publication

How this manual is This Product Manual is divided into 10 sections numbered 1 through 10. organized These sections contain all the information you need to configure, operate,

monitor, and troubleshoot your controller. To find information quickly, use the comprensive Table of Contents in the front of the manual.

The device described herein has been manufactured and tested for correct operation and is warranted as follows:

The UDC2000 Universal Digital Controller carries a two year warnnty. This warranty includes immediate technical assistance via a toll free telephone number and complete replacement of the controller or parts, if necessary.


1-800-423-9883 An engineer will discuss your problem with you. Please have your complete model number, serial number, and Software version available. The model and serial numbers can be found on the chassis nameplate. The software version can be viewed under Setup Group "Status." If it is determined that a hardware problem exists, a replacement conaoller or part will be shipped with instructions for returning the defective unit.

Do not renun your controller until the replacement has been received.

1 I93 UDC2000 Product Manual iii

UDC 2000 FOREWORD How This Manual Is Organized

The UDC 2000 Mini-Pro Universal Digital Controller Product Manual consists of 10 sections numbered 1 thro~gh 10 titled as shown below and appearing on each page.

Page numbers include a section number prefix so you can readily access the described information.

51-52-99-03, Page 1

300000000000 SECTION 1 - OVERVIEW L

- INSTALLATION 0 0 0 0 0 0 0 0 0 0 0 SECTION 2 1 -

- CONFIGURATION 3 0 0 0 0 0 0 0 0 0 SECTION 3 1

000000000 SECTION4 - - OPERATION

30000000 SECTIONS - - CALIBRATION

3OOO00O SECTION6 m - SERVICE

- PARTS LIST 30OOOO SECTION7 m -

L

APPENDIX A - - 3 0 0 0 0 SECTION 8

APPENDIX B 0 0 0 0 SECTION 9 - I

L

Eliminating electrical noise

Tuning the controller manually

Defining the confrguratron prompts

Ordering replacement parts

Troubleshooting I Servrce

Calibrating the Mini-Pro

Operating tips and procedures

Configuring the Mini-Pro

Installing the Mini-Pro Describing the Mini-Pro

APPENDIX C i

0 0 0 SECTION 10

UDC 2000 TABLE OF CONTENTS

CONTENTS CONTENTS PAGE

CALIBRATION (Continued) Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Thermocouple Inputs . . . . . . . . . . . . . . . 5-4 RTD, Millivolt. Volts. Milhammperes, or

Radiamatic . . . . . . . . . . . . . . . . . . . 5-4 Input 1 Calibration Procedure . . . . . . . . . . . 5-5 Input 2 Calibration Procedure . . . . . . . . . . . 5-6

Output Calibration . . . . . . . . . . . . . . . . . . . . . . 5-7 Current Proportronal Output . . . . . . . . . . . . . 5-7

Introduction . . . . . . . . . . . . . . . . . . . . . . 5-7 Preliminary Procedures . . . . . . . . . . . . . 5-7 Equipment Needed . . . . . . . . ' . . . . . . . . . 5-7 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Calibration Procedure . . . . . . . . . . . . . . . 5-8

Auxiliary (PV) Output . . . . . . . . . . . . . . . . . . 5-9 Introduction . . . . . . . . . . . . . . . . . . . . . . . 5-9 Prelim~nary Procedures . . . . . . . . . . . . . 5-9 Equipment Needed . . . . . . . . . . . . . .-: . 5-9 Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Calibratiorl Procedure . . . . . . . . . . . . . . . 5-1 0

3 Position Step Control. Motor Travel Tlme . . 5-1 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5-1 1 Set Up . . . . . . . . . . . . . . . . . . . . . . . 5-1 t Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1 1

TROUBLESHOOTINGISERVICE (5 1-52- 13-12) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1

Installation Related Problems . . . . . . . . . . 6-1 Application Related Problems . . . . . . . . . . 6- 1 Hardware and Software Related Problems 6-1

Ma~ntenance . . . . . . . . . . . . . . . . . . . . . . . 6- 1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1

ControlleiFailurelndicat~ons . . . . . . . . . . . . . 6-1 Error Messages . . . . . . . . . . . . . . . . . . . . 6- I Other Failure Symptoms . . . . . . . 6-1 Check Installation . . . . . . . . . . . . . . . 6- 1

Customer Support . . . . . . . . . . . 6- r Phone Number . . . . . . . . . . . . . . 6- 1

Error Messages . . . . . . . . . . . . . . . . . . . . . 6-2 Backgrotlnd Tests Error Prompts . . . . . 6-2 Status Test Error P~ornpts . . . . . . . 6-4 Controller Failure Symptoms Chart . . . . 6-5

Coritroller Failure Symptoms Tro~~bleshooting Procedures . . . . 6-6

Power Failure . . . . . . . . . . . . . . . . . 6-6 Current Proportional Output Falure . . . . 6-6 Single or Dual Relay Output Farlure . . 6-7 Alarm Relay Output Fa~lure . . . . . . . . . . 6-7

PARTS LIST (5 I -5 1 - 14-or) Exploded View of the Mini-Pro . . . . . . . . 7- 1 Parts Llst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Parts Kits not Shown . . . . . . . . . . . . . . . . . . 7-2

APPENDIX A - DEFINITIONS ( 5 r -52- 19-12) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 Parameter Groups and Prompts . . . . . . . . . . . 8-1

Tuning . . . . . . . . . . . . . . . . . . . . . . . 8-2 Proportional Band Gain Rate Time Reset Rate or Integral Tlme Manual Reset Ga1n2, PB2. Rate Time2 Reset Rate2, or Integral

T1me2 Cycle Time (Heat) Cycle Time (Cool) Lockout AT Key RH Key

Algorithm . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Control Algorrthms (OnlOff, PID-A, PD + MR, 3 Positlon Step) lnpul 2 Output Algorithms (Relay. Current, Relay Duplex)

APPENDIX A - DEFINITIONS (Cont~r~ued) SP RamplSP Program . . . . . . . . . . . . . . . . . 8-4

Sp Ramp Ramp Time Final SP SP Program

Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Autotune Enable Output Step Size Autotune Error

Input 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Decimal Point Location Temperature Units lnput 1 Actuation Type lnput 1 High Range Value lnput 1 Low Range Value Bias on lnput 1 Filter for lnput 1 Burnout Protectron Emissivlty Frequency Default Display

Input 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 lnput 2 High Range Value lnput 2 Low Range Value Filter for lnput 2

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Set Point Source Ratlo Bias Set Point Hioh Limit Set Point LO; Limit Power up Control Output Direction High Output Limit Low Output Limit Deadband Hysteresis-Output Relay Fadsafe Output Value Proportional Band Unlts Reset Units

Optlons . . . . . . . . . . . . . . . . . . . . . . . . 8- 10 Auxil~ary Output Selection Contact Input(Remote Switcl~ing)

Alarms . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 1 Alarm Set Point Value Alarm Set Point Type Alarm Set Point State

Calibrat~on . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 12 Status Test Data . . . . . . . . . . . . . . . . . . . . . 8-1 2

APPENDIX 6 - MANUAL TUNING (51-52-19.13) Introduction . . . . . . . . . . . . . . . . . . . . . . . 9-1 Controller Tuning Procedures . . . . . . . . . . . 9-1

Time or Current Proportional Control . . . . . 9-1 Duplex Time Proportional Control . . . . . . . 9-2

APPENDIX C (5 i -52-19- 14) "How to Apply Dlgltal Instrumentalrorr III Severc! tluctrra: .r Norse Environments"

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 10- I Potential Norse Sources . . . . . . . . . . . . . . . . . . 10- 1

. . . . . . . . . Recommended Wir~ng Practices 10- 1 Power Source . . . . . . . . . . . . . . . . . . . . . . 10-2

. . . . . . . . . . Noise Suppression at the Source 10-3

51-52-25-14, Paae 2

OVERVIEW SECTION 1

The UDC 2000 Mini-Pro Universal D~gital Controller is a low cost member of Honeywell's family of LeaderLine products. It monitors and controls temperatures and other var~ables In applications such as environmental chambers, plastic processing machines, furnaces and ovens, and packaging mach~nery . The Mini-Pro can be used to control variables such as temperature, pressure, flow, level, and rotation.

The Mini-Pro has a dedicated configuration display which provides plain English prompts prov~ding unmatched operating simplic~ty. Programmed sequences of displays assure quick and accurate entry of all configurable parameters. Simple keystrokes let you change the operating parameters to meet your process control needs.

Easy to Configure -- A bright dedicated confrgurat~on display provides straightforward Engllsh prompts that allow easy set-up with minimum time and effort.

Univer~al Inputs -- Accepts 10 thermocouple types, RTD's, Radiamatic, MA, MV or Voltage inputs through s~mple configurat~on.

Thermocouple Failsafe -- Configurable upscale or downscale burnout and failsafe output level.

High Noise Immunity -- The Mini-Pro is designed to prov~de reliable performance in industrial environments that often affect highly noise-sensit~ve digrtal equipment.

Dual Setpoints -- Simple pushbutton selection allows quick switchover from primary to alternate set polnt with minrmal operator confus~on.

Decimal Point Location -- Configurable for none. one, or two places.

Diagnosticlfailsafe Outputs -- Continuous d~agnostic routines detect failure modes, trigger a failsafe output value and identify the failure to min~mize troubleshooting time.

Highly Secure -- Non-volatile memory assures data ~ntegrity during loss of power. Keyboard security inhibits accidental or unauthorized changes to the process.

Default Display Configuration -- can be configured to ind~cate Process Variable (PV) or Set Polnt (SP) belng displayed Instead of blank display dur~ng normal operation.

Optional Features Remote Set Point -- 4 to 20 mA or 1 to 5 Volt lnput available for remote set point signal.

PV Output -- This Process Variable output can be scaled from 0 to 5 Volt or 1 to 5 Volt tor 0 to 100°O tor any range desired.

Contact Input -- Allows remote swrrch seleclion of: Local set point from Remote set point. Local set point 2 from Local set point 1 or Disable Keyboard

Alarm Selection -- None, one, or two relays lo activate external equipment when preset high low set points are reached. There IS an indicator tor each alarm on the operator rnterface. For Duplex operation. orrly one alarm is available. Fixed Alarm Hysteresrs ot 0 5'- of (PV) lnput Span.

Solid State External Control Relay Output - - Opt~onal output rated at 1 Amp at 120 240V or 10 Amps at 120i240V. Minrmum load 0.1 Amp.

Autotune -- When enabled. this feature will automatically calculate and enter into memory the optlmum tunlng parameters required tor your process. A 'Short Tune" feature lets you obtain approximate tunlng constants.

Set Point RamplProgram - - Erlables you to ruri d single set polnt ramp or program and store 6 ramp arid 6 soak segments for set point programming. Run or Hold of program is keyboard or remote swrtch selectable.

Output Algorithms The Mini-Pro is available with Ihe outpul algor~ttims listed below.

Time Proportional -- provides On-Oft or Til~le Proportional (relay) output.

Current Proportional -- supplies proportional current output tor final control elements that require a 4-20 mA signal.

Time Proportional Duplex (Heat/Cool) -- The tlme proportional duplex output provides independent PID tunlng constants and two time proportional outputs: one for heat zone above the 5O0/0 output, and one for cool zone below 50'0 output.

Thls duplex output algor~thm can also provide 01)-orl duplex control.

Control Algorithms -- The controller can be configured for: On/Off, PID-A, PD + MR, or Three Position Step Control algorithm.

UDC 2000 OVERVIEW

MODEL NUMBER INTERPRETATION

MODEL SELECTION DCPOOX - X - X X X - X X X X X X - 0 AVAILABILITY 1 Key Number Controller Output 1 Current 4 - 20 mA DCZOOC .C

Relay, eleclromechan~cal - 5 amp DCZOOE 4 Relay, soltd slate AC - 1 amp (~nlernal) DCZOOA ).

Open collector output - 20 mA DCZOOT &

Limit Control Output High Llmit (TIC and RTD ~npuls only)' DC200H J Low Lmt (TIC and RTD ~nputs only) ' DC20OL J

Digital lnd~cator D~g~tal Indicator Only DC2001 4

Table 1 Additional Relays None 0 2nd Alarm lor Duplex Oulpul or 3 posltloo Step plus one Alar111 Relay 1

Two Alarm Relays 2

Table 2 External Interface None 0 - - o o o o o

Aux~liarv Out~ul or D~a~tal Inpill 2 - - . O O O - Opt~onal Input None - 0- . . o e .

4-20 mA or 1-5V - 1 - • • •

Software Opt~ons None - - 0 o o o o o

AU~OIUII~ - - A o o o

Set Polnl Programm~r~g and A~1toIi1110 - - B o o o

Table 3 Power Configuration 120Vac (50/60 Hz) 1 - - - - - o o o o o

24OVac (50/60 Hz) 2 - - - - - o o o o o

Approval Body Approval Body Pend~na - o - - - - o o o o o

Solid State Relay Kits Externally Mounted None - . o - - - o o o o o

10 Amp . - I - - - 2 Amp - - 2 - - .

Customer 1.0. Tag None - - - o . - o o o o o Taq (1 line-30 Characters Max Inc. blanks) - - - T - - o o o o o

Custom Configuration Contact Factory -.-- 0 0 o o o o o

I No Selection

I +Available with lempfiralure ranges 011ly

UDC 2000 OVERVIEW

CONDENSED SPECIFICATIONS ----. [operating Conditions

I Ambient Temperature

Reference Rated Operatrve Lim~ts Trans~ortat1on Condrtrons Conditions and Storage

22 23°C 15 to 55°C 0 to 55°C -40 to 66 " C 72 t 5 " F 58 to 131 OF 32 to 131 "F -40 to 151°F

, V~bration

I Frequency (Hz) 0 0 to 70 0 to 200 0 to 200 I Accelerat~on (g) 0 0 1 0.5 0.5 I

7 Mechan~cal Shock Accelerat~on (g) 0 1 5 20 Durat~on (ms) 0 30 30 30

Voltage (Vac) 120 2 1 102 to 132 102 to 132 -- 240 22 204 to 264 204 to 264 --

' Frequency (Hz) 50 20.2 49 to 51 48 to 52 -- 60 20.2 59 to 61 58 to 62 --

51-52-02-03, Paae 1-4

Accuracy

2 0.50% of span typical ( 2 1 dlglt for display)

Tuning Parametrers

Gain or PB 0.1 to 1000 Rate 0.08 to 10.00

mlnutes Reset 0.02 to 50.00

minutes per repeat or repeats per minute

Power Requirements

120:240 Volts, 50 or 60 Hz

L

Field Selectable Input Actuations

PV Input

Thermocouples B E E(Low ) J J(Low) K K(Low) NNM (NINIMoI~) R S T T (LOW) W5W26 NIC (N~cros~l Ntsll)

RTD 100 Ohm Pt 100 Ohm Pt (Low)

Radiamatic (RH)

Linear M~ll~amps M~ll~volts

volts

Range . F C

150 to 3300 66 to 1815 -100 to 1832 -73 to 1000 -100 to 1100 -73 to 593

0 to 1600 -18 to 871 0 to 900 -1 8 to 482 0 to 2400 -18 to 1316

-20 to 1000 -29 to 538 32 to 2500 0 to 1371

0 to3100 -18 to 1704 0 to 3100 -18 10 1704

-300 to 700 -184 to 371 -80 10 500 -63 to 260

0 10 4200 - 18 to 2316 0 to 2372 -17.8 to 1300

-300 to 900 -1 84 to 482 0 to 300 -18 to 149

1400 to 3400 760 to 1871

4 to 20 0 to 10 0 to 100 0 to 1 0 to 5 0 to 10 1 to 5

INSTALLATION SECTION 2

Inspect for Shipping Damage and Check for Accessories If the Minr-Pro has not been removed from its shipprng carton, rnspect the carton for damage, and remove the Mini-Pro. Inspect the Mini-Pro tor any obv~ous shrpplng damage and report any damage due to transit to the carrier. Check that a bag containrng mounting hardware is Included In the carton with the controller. -

Model Number identification Make sure the model number shown on the nameplate on the outsrde of the case agrees with what you have ordered. The model number interpretation is on page 1-3.

Preliminary Checks Betore you rnstall the controller, make the preliminary checks listed below and in the next column. The procedure IS shown on page 2-4.

OPERATING VOLTAGE SELECTION The Operating Voltage Jumper position has been set at the factory (120Vac or 240Vac) depending on what you have specified in your model selection, so there should be no need to change it. If you want to change the voltage selection you will have to position the J1 connector on the I!O printed wrring board to the voltage required. See Figure 2-2 tor jumper placement. CAUTION: Operating a 120 Volt controller at 240 Volts will damage the unit.

CHECK THE INPUT TYPE SELECTION You must check an internal DIP switch to make sure the sw~tches are set for the correct input type. The switches are located at position SW1 on the 110 printed wrrlng board. Set the switches for the Input des~red. See F~gure 2-2 tor sw~tch settings.

CHECK OPTIONAL INPUT 2 (RSP) SELECTION The controller has been shipped with Optional Input 2 configured for a 1-5 Vdc input signal. If you want to change to a 4 to 20mA input signal, position the jumper at J8 on the Transformer- Option prtnted wiring board for 4 to 20 mAdc as the Remote Set Pornt Signal. See Flgure 2-2 tor jumper placement.

Preliminary Checks (Continued)

CHECK CONTROL RELAY #1 ACnON Elect romechan~cal Relay Outpu t Internal Sol id State Relay Outpu t Open Collector Output Externally Mounted Solld State Relay

The jumper at W5 or W6 or1 the I 0 prri?tetl wittrig board is set tar (NO) Norrrlally Open at the factory If you want to change to (NC) Normally Closeti contacts on CONTROL RELAY #1 see f~yure 2 2 for location of W5 W6 Iilrnper and set accorcl~ngly For Duplex Relay Output 3 Posrt~on Step opcxatiorl the jumper J4 on the Transformer Optioi? boarti IS

set for N.O. normally ope11 If you want tu cha~l()c: to N.C. normally closed corltacts on the cor~lrol relay, see Table 2-1 for contact rntornral~or, anil Figure 2-2 for jumper place~rient.

See Control Relay Cautlo~~ Note? - - Payt: 2 3

CHECK ALARM RELAY ACTION The controller has been shipped w~tt l ALARM relays conf~gured for (NC)norrnally closed contacts. If you want to change to (NO) Norrr~ally Ope11 contacts on the relays, posrtio~~ the lurnpers at J1 and J5 on the Transformer Option Prrntcd w~rrng board tor (NO) Normally Open J5 is the ALARM RELAY # 1 corltact selector. J4 is the contact selector for the second Cor~trul Relay tor Duplex Output or 3 Posrtlon Step Cor~ircrl and an ALARM RELAY #2 for all others. See Table 2-2 for alarm co~~tact ~ntorrnatro~~ allti F~gure 2-2 for jumper place~r~ent.

See Alarm Relay Cautior~ Note - - Page 2-3

CHECK OPTIONAL PV OUTPUT (AUX OUT) OR CONTACT INPUT (DIG IN) SELECTION

The controller has beer) has beer] st~rppeti w r l l ~ 1 1 1 ~ :

External lntertace selectiort conlryured lor PV OUTPUT (AUX OUT). If you want lo change the selectiurl to CONTACT INPUT (DIG IN), position t l ~ e lurnper at J6 on tile Transformer 'Opt~on prlrlted wlriilg board lu selec:\ DIG IN (Contact Input) . See Figure 2-2 tor jumper olacernent.

UDC 2000 INSTALLATION

Table 2-1 Control Relay Contact Information Chart

NOTE: Control relays operate tn the standard control mode. i.e. Energized when output state is on.

Table 2-2 Alarm Relay Contact lnforrnation Chart

#I OR #2 OUTPUT

INDICATOR STATUS

I

Off

Of f On

Off On

UNIT POWER

r

Off

On

NOTE: Alarm relays are designed to operate in a failsafe mode. i.e. De-energized during alarm state. This results in alarm actuation when power is OFF o r when init ially applied, unt i l the uni t completes self diagnostics. If power is lost t o the unit, the alarms wi l l function.

CONTROL RELAY

JUMPER

N.O.

N.C.

N.O.

N.C.

5 1-52-09-07, Page 2-2

CONTROL RELAY

CONTACT

Open

Closed

Open Closed

Closed Open

L

Off

On

ALARM RELAY

JUMPER

N.O.

N.C.

N.O.

N.C.

VARIABLE NOT IN ALARM

.

RELAY CONTACT

Open

Closed

Closed

Open

VARIABLE IN ALARM STATE

INDICATORS

Off

Off

Open

Closed

Open

Closed

INDICATORS

I

Off

On


ALARM AND CONTROL RELAY CAUTlON NOTE

The alarm and control relay output suppression (snubber) circuitry can be extremely critical when controlling processes and maintaining plant safety. The UDC 2000 Universal Digital Controller is shipped with a board-mounted R-C suppression circuit. Its purpose is to protect the relay contacts from arong due to high energy spikes. These spikes could occur when drtving highly inductive loads and fast cycle-time processes: However, in certain AC powered, external solid state relays with very high input impedance, an undesirable leakage current can flow in the R-C suppression circuit and cause a voltage across the external load. This prevents deactivation of your external device (such as a Solid State relay) even though our display and internal relay are functioning correctly.

The f~x , as shown in the figure below, is to open the correct R-C circo~t by cutting one of the capacitor leads. This is acceptable because ~f the above problem occurred, the suppression circuit was not needed. Opening the circuit eliminates any leakage current flow and allows the external relay to function normally.

1

1. Remove the chassis from the case and pull the boards out of the chassis. 2. Open the desired circuit by cutting the capacitor lead (shown in the figure below). 3. Return the boards to the chassis and return it to the case.

r - - - TransformerlOption Printed Wirrng Board _ - - , - - - - , I I I I I I I I I I

' I10 Printed Wiring Board @ ! C - , - - - - - - - -

- o0oL

j UDC2OOO . ----------- .

Flyurc 2-1 RC Circ1111 Capactlws


PROCEDURES Before you install the controller, remove the chassis and make any preliminary checks necessary. If necessary, pull the transtormer~option board and the 1'0 Board out to make the adjustment to the power select~on jumper. The figure below shows all the checks listed on page 2-1.

5 1-52-09-07, Page 2-4

:

Alarm Relay #2 or Control Relay #2 ....... Alarm Relay # I

DIG IN (Contact Input)

-- AUX OUT (PV Output)

Input 2 Selection

110 Printed Wiring Board

J1 L 1 2 0 v --I

-. . DIP Switches for I : a a E E ; . - . ,

Control Relay # 1 Input Type Electromechan~cal Relay Output

For Range Type Switch and Position

1 2 3 4 5

TIC

L~near ( m ~ ) , Radiamalic ON OFF i OFF OFF OFF

4 to 20 mA OFF ON OFF OFF ON

5 , 10 vok OFF OFF i OFF OFF ON

RTD ON OFF (OFF ON OFF r-----------------------L----------,

I I Switch 3 Is For TIC BURNOUT I

I

1 OFF for Upscale ON fordownscale EITHER for Failsafe I F~ytrrc 2-2 Prclin~l~rary Ctlccks

* Internal Solid State Relay Output Open Collector Output External Solid State Relay Output

W6 0 NC w5 n Time Proportional

Simplex or ONIOFF Control


Mounting

Physical Considerations The Mini-Pro controller can be mounted on either a vertical or tilted panel using the mounting kit supplied with the controller. Adequate access space must be available at the back of the panel tor installation and servicing acrlvrties. The overall dimensions and panel cutout requirements tor mounting the controller are shown on the dimension data drawing in Figure 2-3. The enclosure into which the Mini-Pro is mounted must be grounded according to CSA standard C22.2 No. 0.4 or Factory Mutual Class No. 3820 paragraph

6.1.5.

The tront panel is moisture rated NEMA3/1P65(1EC) when properly installed wrth panel gasket.

Mounting Before mounting the controller. refer to the narr~upla~i! on the outs~de of the case and make a ~ l o l c 01 1l)u model number. It will help later when seleilrrl~] 1l1e proper wiring diagram. 1. Mark and cut out the controller rriountirlg tiule iil 1t1e

panel according to the dimensions spec~tled on 1 t 1 i b

dimension drawing below. 2. Pull the chassis trom the case. 3. Ortent the case properly and slrde rt ttirotigfl 111e

panel hole from the front. 4. Remove the mounting kit fro~ri t l ~ e stlipprllg

container and rnstall the kit as follows: a. Install the screws Into t t ~c threaded holes ol 1111:

clips. b. Insert the prongs of t t~e c:lips lrlto t t~e two I ~ o l t ! ~

In the top and bottont 01 the case. c. Tighten both screws to secure the c;isi: agarlisl

the panel. d. Caretully slide the chassis assernbly irito 111~:

case, press lo close .

96 Dimensions: 1- - 3.78 -1

v - - 24 -

,945 394 M~AIIIIIIIII

Pal rcl Tt~~chricss

Q0.j'

3.57

---L. 105.4 -

,826 4 .19

_I-- Fig~~rc 2.3 Drtrrer~sro~~s

. ti Ub - 9 2 ; 3.62 * W :

r

rnill~meters inches

Pdir(:l (;IIIOI~I

-- I I) L' -

3 6 2

n - lxzZl t 96 - 3 78


Mounting (continued) Mounting Accessories In addit~on to the panel cutout described previously. other aids for mounting the UDC 2000 controller include the following supplemental accessories and k1ts:

A rear terminal cover kit, part no. 30756091-001 An adapter kit for DIN 43700 Panel Cutout(5.43 in. X 5.43 rn.) to fit DialaTrol, Barber-Coleman 560, and Leeds and Northrup E Max V cutout, part no. 30755223-001 An adaptor plate with hardware to cover UDC 300 or UDC 4000 Cutout (3.62 in. X 5.43 in.), part no.

- 30755223-002

WIRING Identify your Model Number To determine the appropr~ate d~agrams for wlrlng your controller:

Refer to the model nurnber interpretation shown on page 1-3. The model number of the controller contains selection codes that identify the Output type, additional relays, number of Alarms, and optional selections. The model number of your controller can be found on the outside of the case.

Wiring the Controller Using the information contained in the model number, select the appropriate wiring diagrams from the connection diagrams in Figures 2-4 through 2-8 and wire the controller accordingly.

TIME PROPORTIONAL OUTPUT FIGURE 2-4 5 Amp Electromechan~cal Relay

r 1 Amp Solid State relay Open Collecror Output

EXTERNAL SOLID STATE RELAY OUTPUT FIGURE 2-5

10 Amp Solid State relay 1 Amp Solid State relay

CURRENT OUTPUT FIGURE 2-6

EXTERNAL INTERFACE OPTIONS FIGURE 2-7 P V Output (Aux. Out.) Contact Input (Dig. In.)

Taking Electrical Noise Precautions Electrical noise is unabated eleclrlcal signals wliicll produce undesirable effects in measurement aiid control circuits. Digital equipment is especially sensitive to the effects of electrical noise. Your Mini-Pro controller has built-in circu~ts to reduce the effects of electrical noise from various sources. To further reduce these effects:

Separate External Wiring - separate connecting wires into bundles (see table 2-3), and route the individual bundles through separate conduits or metal trays;

8 Use Suppression Devices - for addiliorlal noise protection, you may want to add suppresston devlces at the external source. Appropr~att! suppression devices are cornmerc~ally available

Table 2-3 PERMISSIBLE WIRE BUNDLING Bundle No. Wire Functions

1 a. Line power wirlng b. Earth ground wiring ,

c. Control relay output wlring d. Line voltaae alarm wirlna

2 Analog srgnal wire, such as a. lnput signal wire(T;C, 4-20mA.etc) b. 4-20mA output signal wiring c. Di~i ta l input sianals

3 a. Low voltage alarm relay output wiring

b. Low voltage wiring to solid state type control circuits

3 POSlTlON STEP CONTROL FIGURE 2-8

5 1.52-09-07, Page 2-6


TIME PROPORTIONAL OUTPUT WIRING * 5 Amp Electromechanical Relay 1 Amp Solid State Relay Open Collector Output

'For 3 Posrtion Step Control, See F ~ g u r e 2-8

----- ------

NOTE 2. Control relays 1 and 2 are shipped having N.O. contacts conftgured. Alarrrl relays 1 arid 2 arc. shipped with N.C. contacts configured. N.O. or N.C. contacts are selectable by means ol a

i jumper on the 110 and Transformer/Option prlnted wtring boards. See "Prelinitnary Checks" 11,

I this sectlon of the product manual for details. Each alarm is a SPST relay, raled at 5 arit[)s a1 I 120V. and 2.5 amps at 240 Vac. For External solid state relay outputs, see F~gure 2-5. I

Input 1

I I . Table 2-5 Input 1 Connections

NOTE 3. WARNING - Open Collector Outputs are internally powered. Corlnectlrly ar, external supply will damage the controller.

; Alarm Relay #2 I (SEE NOTE 2) 1 Control L ,- - - - - - - - - - - - -

1 i

i

1

i , I

!

I

I

Connections .............................. , , Relay 2 i See table 2-5 r of Controller i ' 1 Load '

I I ................................ I I 5 A m p

I A L M 2 ' 9 @--I+ relay

CTL 2 I

Alarm Relay #1 I Collector

ALM 1 (SEE NOTE 2 )

i

/ NOTE 1. External fuses or circuit breakers must be rated at 1'2 Amp, 250Vac. I Before powering the unit, see "Preliminary Checks" In this section ol the product rnarlual Sc!l 0 l k J

I switches for input type. Set jumpers for relay contacts and optional selectrons.

RTD mV, Volts, Milliamperes, Thermocouple or Radiamatic

Power CURR CTL 1 + 13

AUX OUT I - NEUTRAL 1 AC Line DIG IN -14

1 Voltage 1 (Note 1) -0- HOT +15 . I IN 2

A C Line Voltage must match I . -16 instrument nameplate and [ -

Usi: TJrt?rrr~~~c;t~u(~lt? ~ X ~ C I I S I I ~ I I wlre llllly 7- 7-

Plarlr~uni RTD 6R

J

I internal power selection, - . 4 to 20 mA - JIJIII~ 11.) 01 I ~"II:,

j 120V or 240V 4-20111A CIII O ~ ~ I O I I lii,,i~\f 1 Ground separately and directly ' Used for Time Proportional Duplex i toearth Alarm 2 not available when used ; Ground U S I I I ~ 12 gauge stranded wlre

0-- External Interface Opt~ons - PV OUTPUT (Aux Out) or CONTACT INPUT (Dig In)

SEE FIGURE 2-7

@--'

0-- lnput 2 Connections

1 to 5 Vol ts or 4 to 20 mA only 1 to 5 volts - J~II I I~IL I ~ ~ I I I ~

I -!)v UII <)IIIIOII t NJ.II, I


EXTERNAL SOLID STATE RELAY OUTPUT WIRING

10 AMP SOLID STATE RELAY ASSEMBLY

REAR OF CONTROLLER

I I

SOLID STATE

RELAY ASSEMBLY

j 1 AMP SOLID STATE RELAY ASSEMBL Y i

REAR OF CONTROLLER I 1 I

/ Ftpllrc 2.5 Ei ter~d Sdtd Slalo Relay O ~ ~ ~ I J I Wlnrq

------ LOAD i

5 1 - 52-09-07, Page 2-8


CURRENT OUTPUT WIRING

Rear of Controller

I

Connecttons See table 2-5

, 120V or 240V Ground separately and directly to earth G~ound using 12 gauye stranded wire

Table 2-5 Input 1 Connec t ions mV, Volts, Milliamperes.

Thermocouple RTD or Radiamatic

7- Plallnun~ RTD

NOTE 1. External fuses or circuit breakers must be rated at lt'2 Amp, 250Vac. Before powering the unit, see 'Preliminary Checks" In thrs sectton of the product nlanuai Sel DIP sw~tches for input type. Set jumpers for relay contacts and optional select~ons.

NOTE 2. Relay 2 is shipped as an alarm relay. It and alarm relay 1 are shipped wrtt~ N.C. cotltacls configured. N.0 or N.C. contact is selectable by means of a jumper on the Ttar~sforrr~er opttor) prtnted wrrtng board. See 'Preliminary Checks" In thts sectron of the product riiarlual lor delalls I Each alarm IS a SPST relay, rated at 5 amps at 120V, and 2.5 amps at 240 Vac.

F~yure 2-6 Current Oulp~r! Ws~ng


EXTERNAL INTERFACE OPTION WIRING

5 1.52-09-07, Page 2- 10

' P V output IS factory calrbrated a t 2500 ohm load Accuracy can be malntarned at other loads by performrng a freldcalrbrarto~~

CONTACT INPUT (Dig In)

/ \ / \ 1 *

I I I I I I

Contact lnput I I

I I I I \ 1

F = Connect Shield to

Ground at one end only

@ @ @ @

O u @

PV OUTPUT (Aux Out)

/ \ / \ I L

+ I I I I

I I Auxiliary Load

1 1 1 1 I 1 5 2500 onms - or Greater

or 1- vO1ts re u ~ r e s field

- Connect Shield to - Ground at one end only

NOTE: The PV output will not be Isolated

ALM2 0

from other Inputs and outputs.

i I I I I I

i

I

I I ,

I I

I

I i

i I

NOTE: Contact lnput and PV Output are mutually exclus~ve. Selection 1s determined by jumper J6 on the Optlon Prlnted W~rrng Board. (See Flgure 2-2.)

F~yure 2-7 External Interface W~ring

@

ALM2

7- IN 1 CTL2

6R l1 ALM 1

5 + CURR

l2

4 - CTL l +13 AUX OUT

DIG IN -14

L1 IN

-16 @A -

7- IN 1 CTL2 10

0 @ @ @ 0 @ @

ALM 1

CURR +13

AUX OUT DIG IN -14

@ 0

I N 2 -16 @ - \ u


3 POSITION STEP CONTROL WIRING

5 1-52-09-07, Page ?. 1 1

9

Rear of Controller Open(CW)

-

1

ALM2 0 [-I .. .

ALM 1 Alarm Relay #l

Motor Power supply

--0 @+4

O u @

Control Relay # 4 \eik

-- N E r n A L AC Line

'

Voltage (Note 1) HOT

1 - AC Line Voltage must match- instrument nameplate and internal power selection , 120V or 240V Ground separately and directly to earth. ' Used for 3 Position Step Control

Ground ustng 12 gauge stranded wire Alarm 2 not available when used

Table 2-5 lnput 1 Connections

4 to 20 mA - Jumper on plns 4 - 20mA on opt1011 board

l2 0--- (SEE NOTE 2)

5 + CURR - mi + 0--' External Interface Options

AUX OUT PV OUTPUT (Aux Out) or

DIG IN -14 CONTACT INPUT (Dig In)

SEE FIGURE 2-7

i

L1 + I 5 IN 2

@ A - -16

NOTE 1. External fuses or circuit breakers must be rated at 1:2 Amp, 250Vac. Before powering the unit, see 'Preliminary Checks" in this section of the product manual. Set DIP switches for input type. Set jumpers for relay contacts and optional select~ons.

NOTE 2. Control relays 1 and 2 are shipped having N.O. contacts configured. Alarm relay 1 1s sh~pped w~th N.C. contacts configured. N.O. or N.C. contacts are selectable by means of a jumper on the 1.0 and TransformerIOption printed wiring boards. See 'Preliminary Checks" In thls section of the product manual for detaiis. Each alarm is a SPST relay, rated at 5 amps at 120V. and 2.5 amps at

I 240 Vac. For External solid state relay outputs, see Figure 2-5.

!

F~yure 2-8 Three Posl~on Step Control Wwng

RTD mV, Volts, Milliamperes, Thermocouple or Radiamatic

. 0-- 0--

Use Thcin~oc:ouplc cg 1::: enlt!rlslorl wire orlly

@ GI

Input 2 Connections 7 to 5 Volts or 4 to 20 mA only 1 to 1 5 - Volts 5 V 011 - opt1011 Jumper boatd on plns

7- Plac~num RTD

6R

ma+ 7- M~llmrnpere

@) GI

CONFIGURATION SECTION 3

SOFTWARE CONFIGURATION

Introduction Software configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent controller data best suited for your specific application.

Prompts To assist you in this process, there are prompts which appear in the upper and lower displays (see Figure 3-1). These prompts let you know what group of configuration data you are working with and also, the specific parameters associated with each group. Figure 3-2 gives you an overview of these prompts. As you can see, the configuration data is divided into 9 main Set-Up groups plus Calibration and Read.

TUNING ALGORITHM

SP RAMPIPROGRAM AUTOTUNE

INPUT 1 INPUT 2

CONTROL OPTIONS ALARMS

Within each of these groups are function prompts of associated parameters. NOTE: This manual explains all the prompts that can appear in the Mini-Pro controller. Some of the prompts won't apply to your specific controller and therefore will not appear.

Key Error When a key is pressed and the prompt "KEY ERROR" appears in the lower display, it will be for either of the following reasons:

Parameter not available Not in Set-Up mode, press [SET UP] first.

How to Get Started Read the procedure (page 3-3) for accessing the groups and the function parameters within each group to become familiar with the key sequences. Read the "Configuration Tips" on page 3-3, then start to configure the controller for your application. The groups and parameters are ail listed on page 3-4, along with the selections and range of setting available for each. If you need a detailed explanation of any Set-Up or Function prompt listed in this section, go to Section 8 - Appendix A. Record your selections on the configuration record sheet (page 3-16) so you'll have a record of how you've configured the controller.

Figure 3-1 is a view of the operator Interface with which you'll be working.

SET UP

F~gure 3-1 Operator Interface

51-52-10-12, Page 3-1

r

Honeywell

1

r <

ALM

OUT

PV

1

UDC 2000 CONFIGURATION

PROMPT HIERARCHY

SETUP Key lets you move from one Set-Up group to another

Refer to operation section for prompts.

A T U N E a

C O N T R L

USED FOR FIELD CALIBRATION

-,,-., .... ""'. P

F A C T S T j:

/ Figure 3-2 Prompt Hierarchy

51-52-10-12, Page 3-2

UDC 2000 CONFlGURATlON

'SOFTWARE CONFIGURATION (continued) How to Call Up and Change a Configuration Parameter

A list of how the controller was configured at the factory "Factory Settingswappears on page 3-16. If you want to change any of these selections or values, follow the procedure listed below. This procedure tells you what keys to press so you can effectively use the prompts to start configuring your controller.

How to Select a Set-Up Group Press the [SET UP] key. You will see SET in the upper display to let you know you are in the Set-Up mode and a SET-UP group title is being displayed in the lower display. TUNING is first. Successive presses of the [SET-UP] key will sequentially display the other Set-Up groups as shown in the prompt hierarchy (page 3-2). Note I : Stop at the group you want to configure then go to 'How to Select a Function" for the parameters within that group.

How to Select a Function As shown in the prompt hierarchy, each of the groups listed contain specific prompts which deal with functions that are pertinent to that particular group. Press the [FUNCTION] key, you will see the individual function prompts for each group and the current value or selection. Successive presses of the [FUNCTION] key will sequencially display all the functions and their values or selections for that group. NOTE 2: Stop at the function you want to configure, then go to 'How to change a value or selection".

Wow to Change Value or Selection Press the IRAISEILOWER] key to change the value or selection in the upper display. If the display blinks, you are trying to select an unacceptable entry or the LOCKOUT is preventing changes.

How to Restore the Original Value or Selection When you change the value or selection of a parameter while in SET UP mode and decide not to enter it, press the [RESET] key once. The original value or selection will be recalled.

How to Enter a Value or Selection Press the [FUNCTION], [SET UP], or [DISPLAY] key. The value or selection will be entered into memory.

Configuration Tips

Listed below are a few procedures that will help you to easily and quickly accomplish the tasks at which you'll be working when you configure the controller.

Scrolling To get to a SET-UP group or FUNCTION parameter quickly, hold (SET UPJ or [FUNCTIONJ key in. The display will scroll through the parameters.

Changing Values Quickly When you press the (RAISULOWER] keys to change a number, the least significant dlg~t increments and decrements. However, i f you momentarily press the opposite key while hold~ng one of these two keys, the next significant d~git begins to increment and decrement and each additional tap of the 'opposite Key" will move the scrolling digit one more step to the left. Remember - you must hold in one key while the other is pressed.

How to Restore the Original Value or Selection When you change the value or selection of a parameter while in SET UP mode and decide not to enter it, press the {RESET] key once. The origlnal value or selection will be recalled.

Timing Out from SE7-UP If you are in SET-UP mode and don't press any keys for one minute, the controller will time out and revert to the mode and display that was being used prior to entry into SET-UP mode.

Refer to Appendix A for additional data about any prompt you're not sure how to configure.

How to Exit Configuration Press the (DISPLAY1 key to exit from configuration and return to norma) operation.

.UDC ,2000 CONFIGURATION

TUNING PARAMETERS GROUP (For definitions, see page 8-2)

PRESS DlSPLA YS AV SETTING REMARKS

SET UP 0 In configuratiorr mode. "Tuning" group displayed.

Select PB or GAIN at "CONTRL" FUNCTION El group prompt "PB or GN"

Also defined as "HEAT" PB or GAIN on Duplex models for HeatlCool applications.

RATE -Also defined as "HEAT" Rate FUNCTION u on duplex models for HeatiCool

applications.

INTEGRAL TIME or RESET RATE - FUNCTION u Used with control algorithm PID-A

Select MIN or RPM at "Contrl" prompt 'MINorRPM" "HEAT" Rate on duplex models to/

HeallCool applications.

MANUAL RESET - Used with control , FUNCTION n algorithm PO + MR..

Select-PB2 or GAIN2 at "Control" FUNCTlON El group prompt "PB or GN"

Also defined as "COOL" PB or GAIN on Duplex models for HeatlCool applications.

RATE2T - Also defined as "COOL" FUNCTION I Rate on duplex models for Heat:Cool

applications.

INTEGRAL TIME2 or RESET RATE2 - FUNCTION n Used with control algorithm PID-A

Select MIN or RPM at "CONTRL" prompt 'MINRPM" 'COOL" Reset Time on duplex

models for HeatlCool applicat~ons.

FUNCTION I CYCLE TlME -Also defined as "HEAT" Cycle Time on duplex models for HeatlCool applications.

Continued Next Page

5 1-52- 10- 12, Page 3-4

UDC 2000.CONFIGURATlON

TUNING PARAMETERS GROUP (Continued)

PRESS DlSPLAYS A V S E m l N G REMARKS

CYCLE TIME -Also defined as FUNCTION El "COOL" Cycle Time on duplex modt~lr;

..for HeatlCool applications.

NO lockout FUNCTION El CAhbratron laded out

CONFuration parameters ale READ only

FUNCTION El AUTOTUNE KEY LOCKOUT -Enables or disables Autotune key lockout

FUNCTION n RUNIHOUI KEY LOCKOUT -Enables or disables Setpoint RamplProgram RunlHold key lockout

SET UP puts you in next set-up group FUNCTION selects the first parameter ,

in the next group DISPLAY exits set-up mode

ALGORITHM PARAMETERS GROUP (For definitions, see page 8-3)


SET UP In configuratior~ mode, "ALGORITHM " group displayed.

ON-OFF control (Relay Output only) FUNCTION PID-A used for three mode control

PO 4 MR PO with Manual Reset Three Position Step Control (Note 7)

ENAble Input 2 FUNCTION

Disable Input 2

RLY Relay Simplex {one relay) FUNCTION CUR Current Simplex

RLYD Relay Duplex (Two relaysl

,-------------------------- ; SEl UP puts you in next set-up group I Note 1: Set Motor Travel Time FUNCTION selects the first parameter at Set Up Prompt "CAL", "TPSC" I in the next group

L - -- - - - - --- - - -- - - - - - - - - - - - - J DISPLAY exits s e f - ~ p mode

51-52-10-1 2, Page 3-5


SET POINT RAMP/PROGRAM GROUP (For definitions, see page 4-6 thru 4-14)

1

PRESS DlS P LA YS Ir,V SETTING REMARKS

In Set Up mode. 'SP RAMPIPROGRAM" group displayed.

SINGLE SET POINT RAMP Enable--SP Ramp Disabl--Must select DISABL to use SP Program

SINGLE SET POINT RAMP TIME The trme if tdkes to go from start to final set point on Single SP Ramp. Entering 0 will imply an immediate change m sef point to the final set point.

SINGLE SET POINT RAMP FINAL SET POINT The controller will operate at the set point set here iit the end of the Single Set Point Ramp.

SET POlNT RAMPISOAK PROGRAM Only available when SP RAMP is disabled. See OPERATION section for prompts. RUN key initiates the program.

SET UP puts you in next set-up group FUNCTION selecfs the first parameter in the next group DISPLAY exits set-up mode

51 -52-10-1 2 , Page 3-6

UDC.2000 CONFIGURATION

AUTOTUNE PARAMETERS GROUP (For definitions, see page 4-15 thru 4-20)

I

PRESS DISPLAYS SETTlNG REMARKS

SET UP El In Set Up mode, 'AUTOTUNE" group displayed.

AUTOTUNE FUNCTION FUNCTION El Dlsable

A Step--Auto Step Change M Step--Manual Step Change Select output step size below.

OUTPUT STEP SIZE FUNCTION CJ Appears if MS TP fs chose/) above.

of output in 1 O h Must be large enough to result r t l a PV change of at least 2.5% of spdt~.

FUNCTION u AUTOTUNE STATUS ERROR MESSAGES See the OPERATION sectiot).

SET UP puts you in r~ext set-lip groiijl FUNCTION selects the first parametet in the next group DlSPLAY exits set-up mode


INPUT 1 PARAMETERS GROUP (For. definitions, see page 8-6)


In configuratio~~ mode, "INPUT 1" group displayed.

No Decimal plijce One Decimal place Two Decimal places ' ' can be used only with Llnear Il~puts

Degrees FAHRENHEIT Degreecs CELSIUS NO Selection

Select which ACTUATION TYPE you are going to use for lnput one. See 'Installation' to set DIP switches for lnput type.

INPUT 1 HIGH RANGE VALUE

Can be changed for Linear Inputs only

INPUT 1 LOW RANGE VALUE

Can be changed for Llnear Ir~puts o111y

INPUT 1 BIAS Vali~e Range: -999 to 9999 A numerical value that can oftset I/),:

process variable PV = lnput 1 + Bias

INPUT 1 FILTER - A Digrtal software Range: 0 to 120 Seconds filter to smooth the Input signal.

0 = No Filter

SENSOR BREAK PROTECTION Selecti0ns:UP (BURNOUT). (TIC onyj

Upscale DOWNscale NO burnout-Failsafe output applied for failed input (TIC only)

Input 1 parameters group continued Next Page

5 1-52- 10- 12, Page 3-8


INPUT 1 PARAMETERS (Continued)

PRESS DISPLAYS IrV SETTING REMARKS

FUNCTION 0 FUNCTION n

EMlSSlVllY FUNCTION n Range: 0.01 to 1.0 will appear only if "RADI" (Radiamatic)

is selected as litput 1 Type. See Page 8-6 tor definltlon

- -- - --- - -. - .

POWER FREQUENCY Selections:60 60 Hertz

50 Hertz See "Installation" to select jumper position for Operating Voltage.

DEFAULT DISPLAY SELECTION SP SP Shows in lower display

SP Valcie in upper display PR-N Lower display blallk

uppet drsplay shows PV PR-Y PV sht~ws in lower d~splay

Process Variable value In upper display

then FUNCTION 0 DISPLAY El SET UP puts you in next set-up I group FUNCTION selects the first parameter in the next group DISPLAY exits set-up mode

INPUT 2 PARAMETERS GROUP (For definitions, see page 8-7)

PRESS DISPLAYS SETTING REMARKS

SET UP n In configuration mode, "INPUT 2 " group displayed. lnput 2 must be ENABLED at "Algorithm" group prompt "lnput 2"

INPUT 2 HIGH RANGE VALUE FUNCTION n This is what 20 mA or 5 Volts is to

represent

INPUT 2 LOW RANGE VALUE FUNCTION El This is what 4 mA or 1 Volt is to

represent

INPUT 2 FILTER - A Digital software FUNCTION n filter to smooth the lnput srgrtdl.

0 = No Filter

SET UP puts you in next set-up group FUNCTION selects the first parameter in the next group DISPLAY exits set-up mode

51-52-10-12, Page 3.9


CONTROL PARAMETERS GROUP (For.definitions,-see page 8-8, 8-9)

I PRESS DISPLAYS SETTING REMARKS I In configuratrott mode, "CONTRL"

SET UP group displayed.

.......

I

FUNCTION E l FUNCTION El FUNCTION n FUNCTION n FUNCTION n FUNCTION n FUNCTION n FUNCTION n

I REM

Range: -20.00 to 20.00

Range: -999 to 9999 Engr.

SET POINT SOURCE 1 LOCal Set Poillt 1 only 2 LOCal set points - Set Pornt 7 !Set Point 2 toggled via [FUNC] key REMote Set Polnt

RATIO - used when lnput 2 is used as a Remote Sat Po~nt.

BIAS - used when lnput 2 is used as a Remote Set Point.

HlGH SET POINT LIMIT The local set pornt will automatically adjust itself to t)e within this liniit The hrghest value to which yoit wan1 an operator to set the control value

LOW SET POINT LIMIT - The local set point will automatr~ally adjust ftself to be wrfh~n thrs Irm~f The lowest value to whrch you want nr~ operator to set the control value

S R POINT AT POWER UP ALSP - Local set pornt ARSP - Remote set point

CONTROL OUTPUT DIRECTION DlRect actron - the controller's output increases as the PV increases. REVerse actron - the controller's output decreases as the PV increases

HlGH OUTPUT LIMIT Use 0 to 700% for Relay output

Use -5 to 70590 for Current oirtput

Continued Next Page

51-52-10-12, Page 3-10


CONTROL PARAMETERS GROUP(Continued) .(For definitions, see page 8-8, 8-9)

PRESS DISPLAYS AT SETTING REMARKS

LOW OUTPUT LIMIT Use 0 to 100°b for Relay outpirt

Use -5 to 1059" for Current oi~lptrt

DEADBAND - an adiustable gap between the operating ranges of control relay o11e and control relay two. Duplex or 3 Povt~on Step c~~n t ro l only

Model DC2004

HYSTERESIS (Output Relay Only) - an adjustahlc! yap of the ON OFF states of each ~elay.

OnlOfY control only

FAILSAFE OUTPUT VALUE - controller will go to the value set here on controller failure.

PROPORTIONAL BAND UNITS - Pb - units of percent proportional band for the P term of the PID algorithm. GN-unitless term of Gain for the P term of the PI0 algorithm

RESET UNITS Selections:MIN MIN - Minutes per Repeat. The time

betwen each repeat of the proportional action by reset RPM - Repeats per Minute. The number of times per minute that the proportional actron is repeated hy reset.

SET UP puts you m next set-up group FUNTION selects the first pararneter 111 the next group DISPLAY exits set-up mode


OPTION PARAMETERS GROUP (For. definitions, see page 8-1 0)


In configuration mode. "OPTIONS" group displayed.

AUXILIARY OUTPUT OPTION NO selection

PROCess Variable

LOW SCALING FACTOR use a value in engineerrng irn~ts

LIMITS OF INPUT 1

HIGH SCALING FACTOR use a value in engineering tmits

REMOTE SWITCHING Contact closirre selects configtrred item. Openrny contact causes return to prewous stste. NONE - No selection LSP - puts cor~troller in local set point if in remote SP2 - selects set point 2 if in set point 7 HOLD -- Holds Set Point Ramp! Program

I DIS KB -- Disables Keyboard

F b h e n i] or ~1 SET UP puts you in next set-up groirp FUNCTION selects the first parameter in the next group DISPLAY exits set-up mode

51-52-10-12, Page 3-12


ALARM PARAMETERS GROUP (For definitions, see page 8-1 1)

51-52-10-12, Page 3 13

I


In configuration mode, "ALARMS" SET UP El group displayed.

ALARM 1 SET POINT 1 VALUE FUNCTION n Will not appear unless selection PROC

or DE is made at "A 1S1TY" Enter value in engineering unrls When EVON or EVOF is selected at "A1SITYU, select alarm segment here

ALARM f SET POINT 2 VALUE FUNCTION El Will not appear unless selec:t/on PROC

or DEis made at "AISPTY" Enter value in engineering unrts When EVON or EVOF is selectell dl "AISSTY". select alarm segment here

ALARM 2 SET POlNT 1 VALUE FUNCTION n Will not appear unless selectior, PROC

or DE is made at "APSITY" Enter value 11) engineering units When EVON or EVOF is selected at "A2SITY", select alarm segment here

FUNCTION n ALARM 2 SET POlNT 2 VALUE Will not appeal unless selectron PROC or DE is made at "A2S2TY" Enter value m engineering units When EVON or EVOF is selected at "A2S2TY ", selc!cf alum segmerlt here

ALARM 1 SET POlNT 1 TYPE FUNCTION n NO selection

PROCess. variable DEviation EVent - ON (SP Prograrnm~l~g) EVent - OFF (SP Programmtng)

ALARM 1 SET POlNT 2 TYPE FUNCTION El NO selection

PROCess varrable DEvia tion EVent - ON (SP Programm~rtg) EVent - OFF (SP Programmtng)

ALARM 2 SET POINT 1 TYPE FUNCTION n NO selection

PROCess variable DEviation Went - ON (SP Programmir~g) EVent - OFF (SP Programm~ng)

ALARM 2 SET POlNT 2 TYPE NO selection PROCess vandble DEviation Went - ON (Sf' Programmirrg) EVent - OFF (SP Programmrng)

r'--"-'-"'------------------------------------------------------ 1 : Note: When Alarm type is reconfigured. the vabe of the current Alarm set pointdoes not automatically I change to be consistent with the range of the new alarmtype untilit is viewed on the display. I L-,----,-,-------,------------------------------------------------J

Continued Next Page


ALARM PARAMETERS GROUP (Continued)

PRESS DISPLAYS AV SETTING REMARKS ALARM 1 SET POINT 7 STATE

FUNCTION I LOW Alarm Hlgh Alarm

ALARM 7 SET POlNT 7 STATE FUNCTION El for set point programming

BEGN - Alarm on beginnrng segmel)l END - Alarm 01, ending segment

ALARM 1 SET POINT 2 STATE FUNCTION I LOW Alarm

Hlgh Alarm

ALARM 1 SET POlNT 2 STATE FUNCTION n for set point programming

BEGN - Alarm on beginning segment END - Alarm on ending segment

ALARM 2 SET POlNT 1 STATE FUNCTION n LOW Alarm

Hlgh Alarm

ALARM 2 SET POlNT 1 STATE FUNCTION El for set point programming

BEGN - Alarn? on begrnnlng segmer~t END - Alarm on ending segment

ALARM 2 SET POINT 2 STATE FUNCTION I LOW Alarm

High Alarm

ALARM 2 SET POlNT 2 STATE FUNCTION 1 for set point programming

BEGN - Alarm on beginning segmelll END - Alarm on ending segment

( I t h TO EXIT SET UP MODE

51-52-10-12, Page 3-14


CALIBRATION PARAMETERS GROUP

STATUS GROUP

USED FOR FIELD TROUBLESHOOTING SEE THE TROUBLESHOOTING SECTION

51-52-10-12, Page 3 -15

UDC 2000 CONFlGURATlON

UDC 2000 CONFIGURATION RECORD SHEET

GROUP FUNCTION DESCRIPTION DESCRIPTION

VALUE OR SELECTION

FACTORY SETTING

TUNING GAIN PB RATE T I MIN l RPM MANRST GAIN 2 PB 2 RATE2T 12 MIN 12 RPM CYC TI CYC2TI LOCK AT KEY RH KEY

ALGORITHM CTRALG INPUT 2 OUTALG

SP RAMP SPRAMP TI MIN FINLSP SP PROG

A TUNE AT ENB OUTSTP AT ERR

INPUT 1 DECMAL UNITS IN1 N P IN1 HI IN1 LO BlAS 1 FILTR1 EMlSS BRNOUT FREQ DISPLY

INPUT 2 IN2 HI IN2 LO FILTR2

0.0 0.2

20 20 CAL ENAB ENAB

PlDA ENAB* dl

DlSABL 0 0 DISABL

DISABL 10 NONE

8888 NONE K H 2400 0 0 0 1.0 UP 60 PR N

1000 0 0

GROUP FUNCTION VALUE OR FACTORY I DESCRIPTION DESCRIPTION SELECTION S m l N G

1 CONTROL SP SRC 1 LOC RATIO 1 0 , BIAS 0.0 SP HI 2400 SP LO 0

1 PWR UP ALSP ACTION REV OUT HI 100

I OUT LO 0 DBAND 2.0 HYST 0.5 FAILSF 0 PB or GN GAIN MIN RPM MIN

OPTIONS AUXOUT NONE' 0 PCT 0 100 PCT 1000 REM SW NONE'

ALARMS A1S1VA A1 S2VA A2S1 VA A2S2VA A1 S l TY A1 S2TY A2S1 TY A2S2N A1 S1 HL A1 S1 EV A1 S2HL A1 S2EV A2S1 HL A2S1 EV A2S2HL A2S2EV Note:

5 PROC PROC PROC PROC U I , ,.

BEGN LO END Hi BEGN LO END

Fixed Alarm Hysteresis of 0.5% of (PV) Input Span

*Appears only if model number allows

-elected according to model number

51-52-10-12, Page 3-16

OPERATION SECTION-4

OPERATOR INTERFACE OVERVIEW

F = "Fahrenheit C = 'Celsius

R = Remote set point active (flashes when contact input is active)

L = Local set point active

.

R \

Honeywell

LOWER DISPLAY UPPER DISPLAY A dedicated 6 digit, 14 A 4 diglt. 9 segment uppel segment lower display display is dedicated to the provides guidance, through process variable or set potnt prompts. for the operator during normal operatton, durrng conf~guration. with alternate informat~on Durlng normal operation, displayed during the lower d~splay is blank unless configured for Set Point. Deviation. PV, default prompt of PV or and Output values may be

shown on demand. [DISPLAY] Key selects parameter prompts such as Set Point 1 , Set Point 2. PV. Deviation and Output on demand.

Key Functions Eight keys enable complete configuration and operation.

Selects functions within each Scrolls through the configuration group. Also configuration groups. alternately selects local or remote set point or between local set points.

Allows viewing of the local Used to restore original set point, remote set point, value or selection when output, or deviation. Returns in SET UP mode. the controller to normal operation from SET UP mode.

Starts the Initiates Run or Hold of Autotune procedure. set point ramp or set

point program.

Decreases the set point Increases the set point or configuration values.

or configuration

Figure 4 - 1 Operator lnlerface L

r STATUS INDICATORS They provide the status of the alarm and control relays. There is also indication to show the temperature units and whether Remote set point or Local set point is active.

A

UDC 2000 OPERATION

POWERING THE CONTROLLER Apply Power The Mini-Pro runs four on-going background tests to determine the status of the controller:

RAM TEST - checks internal memory CONFIGURATION TEST - checks the controller's software configuration for inconsistencies CALIBRATION - check calibration of the controller's configured analog inputs (Input 1 /Input 2) and outputs (Control Current/ PV

Output Voltage) FACTORY CALIBRATION CHECKSUM - check factory set input constants

If all these Background tests pass, the controller will function in a normal manner without any diagnostic message. However, if one or more of these tests fail, the controller will go to FAILSAFE ('FAILSF" blinking in the lower display). Refer to the 'Troubleshooting" section in this manual to identify and correct the problem.

MONITORING THE CONTROLLER The Displays and Indicators The displays and indicators on the operator interface as shown in figure 4-1 let you see what is happening to your process and how the controller is responding.

Displays The Mini-Pro is a single display device except when in the SET-UP mode or [DISPLAY] key is pressed.

The UPPER display area has 4 digits dedicated to the value of the process var~able or set point during normal operation with alternate information displayed on demand during configuration. Set Point, Output, PV, and Deviation values can also be shown on demand using [DISPLAY] key.

The LOWER display area has 6 digits which are normally blank unless configured to show SP or PV. It indicates Set Point, Output, and Deviation prompts upon request. It also provides alphanumeric prompts during configuration as well as diagnostic and error messages when appropriate.

lndicators The annunciator displays, as shown in figure 4-1, give the following indications:

ALM 1 2 = Alarm Relay ONIOFF status OUT 1 2 = Output (Control) Relay status F or C = Temperature Units (OF or OC) R or L = ~ c t i v e Set Point (LSPI vs L S P ~ or

RSP)

MONITORING THE CONTROLLER (cont.) The [DISPLAY] key Press the [DISPLAY] to scroll through the following operating parameters in the lower display: NOTE - The display will show only those that apply to your specific model and the way it was configured.

Local Set Point 1

Remote Set Point (when available)

Local Set Point 2 (when remote set point does not apply)

PV Deviation from Set Point

Output (For 3 Position Step Control, see Note 1.)

Process Variable

Press the [RAISULOWER] keys to change the valtle of set point 1 or set point 2 shown In the lower display. You cannot change Remote Set Point, Dev~atron or output.

Timing out from Lower Display The normal Process Variable display will automatically return in the upper display if the [DISPLAY] key is not pressed for 60 seconds.

The [DISPLAY] key is also used to return to normal control from SET-UP mode.

r----'-"--'-'-----"'-----------------------, f Note 1: When using 3 Position Step Control I

I I t algorithm, the OUT display will indicate an I I I estimated motor position of from 0 to 100%. f I I t The 'Motor Time", the time it takes the I I I motor to travel from 0 to loo%, is set under f I I I Set Up Prompt 'CAL", 'TPSC". I L------,-,-----,--------------------------J

UDC 2000 OPERATION

MONITORING THE CONTROLLER (cont.) The [RAISEILOW ER] key When you press the (RAISULOWERJ keys to change a number, the least significant digit increments ar decrements. However, i f you momentarily press the opposite key while holding one of these two keys, the next significant digit begins to increment or decrement and each additional tap of the "opposite Key" will move the scrolling digit one more step to the lett. Remember - you must hold in one key while the other is pressed.

Key Error When a key is pressed and the prompt 'KEY ERR" appears in the lower display. it will be for one of the following reasons:

Parameter not available Not in SET-UP mode. Press [SET UP] key first.

Diagnostic Error Messages The Mini-Pro performs additional background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed. In the case of more than one, the one with the highest priority wi)) appear on the lower display.

LOWER DISPLAY CONDITION PROMPT

E FAIL Unable to write to non-volatile memory

FAILSF Failsafe

IN1 FL Two consecutive failures of Input 1 integration

IN2FL Two consecutive failures of Input 2 integration

IN1 RNG input 1 out-of-range

IN2 RNG Input 2 out-of -range

RV LIM Remote variable out-of-range NOTE: RV = (input 2 X ratio) + Bias

IF ANY OF THESE ERROR MESSAGES OCCUR, REFER TO THE TROUBLESHOOTING SECTION IN THIS MANUAL.

START UP

Tune the Controller Make sure the controller has been configured properly and all the values and selections have been recorded on the Configuration Record Sheet. Refer to the "TUNINGn set-up group to ensure desired selections for 'PB" or 'GAINn. 'RATE T", and "I MIN" or "I RPM" have been entered. Tune your controller using Autotune or the procedure found in Appendix B - Manual Tuning.

Enter a Local Set Point if SP is not normaliy displayed, press the fDISPLAY] key until you see

Press the IRAISULOWER] keys to adjust the Local Set Point ta the value at which you want the process variable maintained.

Return to PV Display If normal display is PV, press the [RESET] key after changing the set point. You will see

The controller will automatically adjust the output to maintain the process variable at the set po~nt, 11 the controller is properly configured and tuned.

UDC-2000 OPERATION

OPERATING THE CONTROLLER

Selecting the Set Point Source You can select what you want your set point(s) to be:

A Single Local Set Point A Local Set Point and Remote Set Point Two Local Set Points

Press [SET UP] key until you see

Press the [FUNC] key until you see

- - -

Se1ections:l LOC 7 G c a l Set Point Only REM Remote Set Point 2LOC 2 Local Set Pojnis - Set

Pornt llSet Point 2 kev I toggled via [FUNC] key 1

- -

Press the [RAISULOWER] keys to change selection.


Changing the Set Point(s)

Press the [DISPLAY] key until you see

Local Set Point 1

Local Set Point 2 (when configured)

Press the [RAISULOWER] keys to change the Local Set Point value in the upper display. The display "blinks" if you attempt to enter Set point values beyond the high and low set point limits.

Press the [RESET] to return to PV display. YOU CANNOT CHANGE THE REMOTE SET POINT VALUE

OPERATING THE CONTROLLER (CONT.) Switching Between Local and Remote Set Points or Between 2 Local Set Points (when configured) The current Set Point IS indicated in the lower dlsplay (right side)

R = Remote Set Point (if configured) or Local Set Point 2 shown

press the [DISPLAY] key to show set point in the lower display. Press the [FUNCTION] key to alternately select LOCAL or REMOTE set point or switch between 2 LOCAL set points (when configured). NOTE: 'KEY ERR" will appear in the lower display 11 the remote or 2nd local set point is not configured as a set point source.

REFER TO THE CONFIGURATION SECTION OF THIS MANUAL TO DISPLAY OR CHANGE THESE ASSOCIATED PARAMETERS

SET UP GROUP PROMPT

CONTRL

FUNCTION PROMPT

SP HI or SP LO

BIAS

PWR UP

PARAMETER

Set Point h~gh and low limits

Used when rernote set point selected

Used when remote set point selected

Set Point at Power up - Local or Remote

UDC 2000 OPERATION

OPERATING THE CONTROLLER (CONT.) Changing the Alarm Set Points The Alarm Set Point Values can be changed for each of the four alarm set points.



Within lnput 1 span for DEV type

This is the Alarm 1 Set Point 1 Value. Press the [RAISVLOWER) keys to change the value in the upper display.

Press the [FUNCTION] key 3 more times and repeat the procedure after each press to set the other three alarm set point values.

A 1 S 2 V A A 2 S 1 V A A 2 S 2 V A

REFER TO THE CONFIGURATION SECTION OF THIS MANUAL TO DISPLAY OR CHANGE THESE ASSOCIATED ALARM PARAMETERS

A jumper selection configures the relay contacts for Normally Open (open with power off) or Normally Closed. Refer to the Installation Section under 'Preliminary Checks" for Alarm relay contact information chart and jumper placement.

SET UP GROUP PROMPT

ALARMS

OPERATING THE CONTROLLER (CONT.) Using Contact lnput Option (Remote Switching) The Contact lnput Option detects the state of external contacts. On contact closure, the controller will respond according to how the controller is configured for Contact Input. Make the Contact CIosure Selection as follows:



FUNCTION

AlSlTY A1 S2TY A2SlTY A2S2TY

A1 Sf HL A1 S2HL A2S1 HL A2S2HL

Press the [RAISEILOWER] keys to make your selection in the upper display. See below.

PARAMETER

Alarm Set Point type

Alarm High or Low event

ACTION ON DISPLAY

I NONE I NONE I NONE I LSP If you are currently

using the remote SP, it switches out of Remote SP and seiects the local set point.

Flash~ng R

Indicator

If you are currently using Local SP, it switches out of first local set point and selects the 2nd local set point

Flashing R

Indicator



UDC 2000 OPERATION

OPERATING A SINGLE SET POINT RAMP.

Configuring a Single Set Point Ramp You can configure a single set point ramp to occur between the current local set point and a final local set point over a time interval of from 1 to 255 minutes. You can RUN or HOLD the ramp at any time after starting the RampISoak via the front panel.

Procedure Select SP RAMP Group Press the [SET UP] key until you see

-

Enable SP RAMP Function Press the [FUNCTION] key, you will see

Press the [RAISE] key to enable the set point ramp function. You will see

Procedure (continued) Press the [RAISELOWER] keys to change the upper display value to the desired final set point for the ramp. Setting Range = within the set point limits.

Running a Single Set Point Ramp Procedure Press [DISPLAY] key to exit Configuration (SET- UP) mode. You will see, a

HOLD and the PV value

Note: Press [DISPLAY] key and ver~fy starting Set Point. Press the [RAISULOWER] keys to adjust the upper display value to the desired final set point tor the ramp.

Start Ramp Press the [RUNtHOLD] key, you will see

I

RUN and the PV value ,

T and output value, or I DE and deviation value I

The value in the lower display will be increasing or decreasing as the controller moves toward the final

Set Ramp Time set point value. Press the [FUNCTION] key, you will see NOTE: You cannot change the current local set

point if the set point ramp is running, you can change it in "HOLD". Press the [RUNIHOLD] key to hold the ramp at the current set point value. Press again to continue run. A "KEY ERR" prompt will appear if [RUNIHOLD] key is pressed while "SPRAMP" is disabled.

Press the [RAISULOWER] keys to change the upper View the Remaining Time for the Ramp or Soak display value to the number of minutes in which you Press the [DISPLAY] key until you see want the final set point to be reached. Setting Range = 0 to 255 minutes NOTE: Entering 0 will imply an immediate step change in set point to the final set point.

Set FINAL SP Value Press the [FUNCTION], you will see

End Ramp When the final set point value is reached, the "RUN" changes to "HOLD" in the upper display and the controller operates at the new final set point.

51-52-1 1-12, Page 4-6

UDC 2000 OPERATION

Running a Single Set Point Ramp (continued)

Procedure (continued) Disable SP RAMP Function Press the [SET UP] key until you see

Press the [FUNCTION] key, you will see

Press the [RAISE] key to disable the set point ramp function. You will see

Press the [DISPLAY] to return to normal display.

NOTE: Set Point RAMP can be disabled while in RUN or HOLD.

51-52-1 1-12, Page 4 7

UDC 2000 OPERATION

SET POINT RAMP / SOAK PROGRAMMING

Introduction The term "Programming" is being used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required Set Point vs Time profile (also called a program). A segment is a ramp or soak function which together make up a set point program. Set Point Ramp 1 Soak Programming lets you configure 6 ramp and 6 soak segments to be stored for use as one program or several small programs. You designate the beginning and end segments to determine where the program is to start and stop. Each ramp segment can be configured to be run in hours and minutes or degrees per minute. 0 implies an immediate step change in set point to the next soak. All soak segments can have a guaranteed soak deviation which guarantees the value for each soak. This means that the timer will not start until the process variable (PV) is within the deviation limit ( 2 ) and then if the PV subsequently exceeds the deviation range, the timer holds until the PV enters the range. All segments, Ramps or Soaks, have a minimum setting of one minute. Configuration What you will configure Basically, you will configure all the data that is relevant to each ramp and soak segment for a given set point versus time profile. The controller will prompt you through the sequence of segments and associated functions. These will include:

RAMP TlME or RATE A ramp segment is the time it will take to change the set polnt to the next set point value in the program. RAMPS are odd number segments. Segment #I will be the initial ramp time. Ramp time is determined in either TIME* (Hours:Minutes)

Range 1-99 hrs : 59 min. Enter value XX.W where XX = hours (0-99) W = minutes (1 -59)

or RATE' (Degrees per Minute)

Range 1 to 999 Enter value XXX where XXX = degrees/minute

Configuration (continued) SOAK SET POINT RANGE VALUES AND DURATION TlME A soak segment is a combination of soak set point (value) and a soak duration (time). Soaks are even number segments. Segment 2 will be the initial soak value and soak time. The soak SET POlNT VALUE must be within the set point high and low range limits in engineering units.

SOAK TlME is the duratlon of the soak and is determined in TlME (Hours:Minutes)

Range 0-99 hrs : 59 min. Enter value XX.W where XX = hours (0-99) W = minutes (1-59) Minimum setting = 1 minute

START SEGMENT NUMBER This designates the number of the first segment.

The selection is 1 to 11 END SEGMENT NUMBER This designates the number of the last segment. It must be a soak segment (even number).

The selection is 2 to 12 (evet~ only) RECYCLE NUMBER This number allows the program to recycle a specific number of times from beginning to end.

The range is 0 to 99 GUARANTEED SOAK DEVIATION IN ENGINEERING UNITS Guaranteed soaks can be enabled or disabled via the configuration prompts. When enabled, all soak segments will have a positive or negative dev~ation value of 0 to 99 which guarantees the value for each segment.

Guaranteed soak segment values guarantee that the segments process variable is w~thln the dev~at~on for the configured soak time. There are no guaranteed soaks whenever the deviation value is configured to 0, i.e., soak segments start timing soak duration as soon as the soak set point is first reached, regardless of where the process variable remains relative to the soak segment. The value is the number in engineering units, above or below the set point, outside of which the timer halts. The decimal location corresponds to input 1 decimal selection.

This selection of time or rate is made at prompt "RP UNIT", the last prompt in the group.

5 1-52- 1 1 - 12, Page 4-8

UDC ZOO0 OPERATION

SET POINT RAMP I SOAK ,PROGRAMMING (continued) Configuration (continued) PROGRAM TERMINATION STATE RAMP UNIT This function determines the status of the controller This determines the engineering units for the ramp upon completion of the program. segments.

LAST = controls to last set point. TIME = Hours : Minutes LSP2 = Control using Local Set Point 2 RATE = Degrees 1 Minute

Will only appear if "2 Local Set Pointsn is selected under "Control" group.

PROGRAM STATE This selection determines the program state after completion of the program

DIS = Program is disabled HOLD = Program on Hold

DRAWING A RAMP / SOAK PROFILE Before you do the actual configuration, we recommend that you draw a RampISoak profile in the space provided on the program record sheet (page 4-1 1) and fill in the associated information.

AN EXAMPLE OF A RAMP I SOAK PROFILE IS SHOWN ON THE NEXT PAGE

51-52-1 1-12, Page 4 9

UDC 2000 OPERATION

UDC ZOO0 OPERATION

- - - - - - - -

RAMPI SOAK PROFILE WORKSHEET

VALUE SEGMENT

7

8

8

9

10

10

11

12

12

PROMPT

STRSEG

RECYCL

SOKDEV

SGl RP

SG2 SP

SG2 TI

s t 3 ~p

SG4 SP

SG4 TI

SGS ~p

SG6 SP

SG6 TI

FUNCTION

Ramp Time

Soak Set Point

Soak Time

Ramp Time

Soak Set Point

Soak Time

Ramp Time

Soak Set Point

Soak Time

Controller Status

Program State

Engf unit for Ramp

FUNCTION

Start Seqment

End Seqment

Number of recycles

Guaranteed Soak

Deviation

Ramp Time

Soak Set Po~nt

Soak Time

Ramp Time

Soak Set Point

Soak Time

Ramp Time

Soak Set Point

Soak Time

VALUE SEGMENT

1

2

2

3

4

4

5

6

6

PROMPT

SG7 RP

SG8 SP

SGB TI

SG9 RP

SG 1 OSP

56 1 0 ~ 1

SG 1 1 RP

SG 12SP

SG 1 2 ~ 1

p~ END

STATE

RPUNIT

UDC 2000 OPERATION

SET POINT RAMP / SOAK PROGRAMMING (continued) Entering the Set Point Program Data This procedure tells you what keys to press and what prompts you will see when entering the Set Point Program data. Press [SET UP] key until you see

'Set SP RAMP to disable first

Press the [FUNCTION] key, until you see

Press the [RAISE] key to ENABLE the Set Point Program function. You will see

Successive presses of the [FUNCTION] key will sequentially display all the functions and their value and selections as shown below.

Entering the Set -Point Program Data (continued)

Changing Values or Selections Press [RAISULOWER] keys to change the value or selection in the upper display. It the display blinks, you are trying to make an unacceptable selection. Entering a Value or Selection Press the [FUNCTION] or [SET UP] key or any other key. The value or selection will be entered into memory. Time Out will also enter value or selection into memory. Exiting SET-UP mode Press the [DISPLAY] key. This returns the display to the same state it was in immediately preceding entry into the SET-UP mode and stores any change you made. Alarming on the Set Point Program You can configure an event to go ON or OFF at the beginning or end of any segment. Refer to the Configuration Section under "ALARMS" for details.

NOTES: All parameters can be changed while the program is disabled or in Hold mode. Any changes occurring to the present segment are ignored.

Set Point Programming cannot be enabled while an Auto Tune process is in operation.

SINGLE SET POINT RAMP Dis - Disabled Enab- Must select ENABLED to use Sef Point Program Set Point RAMP must be disabled

START SEGMENT NUMBER This designates the number of the beginning segment

END SEGMENT NUMBER ..The program always ends in a Soak

XX = 2 to 12 Segmenf (2,4.6 ....... 12)

UDC 2000 OPERATION

- - - - .. . . . . PRESS DISPLAYS AT SETTING REMARKS

FUNCTION NUMBER OF PROGRAM RECYCLES This function allows the prograni to recycle from beginning to end a specified number of times

GUARANTEED SOAK DEVIATION FUNCTION

This. applies to soak segments

The value 0 = No Soak Devration

SEGMENT # I RAMP TlME FUNCTION ange: 0-99 Hrs : 1-59 Min Select TIME or RATE at Prornpt "RP

UNIT". All ramps will use the same selection

SEGMENT #2 SOAK SET POINT FUNCTION ange: Within the Set Point

SEGMENT #2 SOAK DURATION

I I w m - m - B m r PROGRAM THE RAMPS. SOAKSETPOINTS. AND SOAK 7 DURATIONS FOR SEGMENTS 3 THROUGH 12 IN TURN IN THE I

SAME MANNER - - - - m m - - - - - m - - - - m - m m 1

FUNCTION SEGMENT 4'1 1 RAMP TIME Select TlME or RATE at Prompt "RP UNIT". All ramps wrll use the sarlre selection

FUNCTION SEGMENT 4'12 SOAK SET POINT

SEGMENT #12 SOAK DURATION FUNCTION

UDC 2000 OPERATION

I

PRESS DISPLAYS AT SETTING REMARKS

FUNCTION CONTROLLER STATUS AT PROGRAM END LAST = Control at last set point in program LSP2 = Control using Local Set Point 2 Will only appear if "2 local set points" is selected under "control" group

PROGRAM CONTROLLER STATE AT FUNCTION END OF PROGRAM

Dis = terminates sp program Hold = RUN key restarts set pornt program

ENGlNEERlNG UNITS FOR RAMP SEGMENTS

RATE Time = Hours : Minutes Rate = Degrees I Minute

Running the Set Point Ramp / Soak Program Make sure all the SET POINT PROGRAM function prompts have been configured with the required data. Make sure the RUN/HOLD key is not locked out. See Set UP group "TUNINGe in the Configuration section for details. An 'HOLDn will appear in the upper display indicating the program is in HOLD state. Press [LOWER DISPLAY] until SP appears. Adjust the setpoint to the desired starting value. RUN STATE Press [RUNIHOLD] key to initiate the Set Point Program. An 'RUNn will appear in the upper display indicating the.program is running. HOLD STATE Press [RUNIHOLD] key to hold the Set Point Program. An "HOLD" will appear in the upper display indicating the program is in the hold state. The set point holds at the current set point.

EXTERNAL HOLD If Remote Switching Option is present on your controller, contact closure places the controller in the HOLD state if the Set Point Program is running. "HOLD" will appear in the upper display indicating that the program has been placed in the HOLD state by the remote contact closure.

NOTE: The keyboard takes priority over the external switch for the RUNIHOLD function

VIEWING PRESENT SEGMENT NUMBER AND TIME Press [DISPLAY] key until you see

r------------------------- 7

I Time remaining in the I 1

I SEGMENT in hours and minutes ; I I 1

VIEWING NUMBER OF CYCLES LEFT IN PROGRAM

Press [DISPLAY] key until you see r - - - - - - - - - - - - - - - - - - - - - - - - - ,

RECYCLES REMAINING I I

; Number of cycles remaining in I : the set point program I I

; x = 1 to 99 I I

I You cannot change th~s r\umber ! i Will not appear if 0 is I

I selected I I I

.-----------------_-------A

END PROGRAM When the final segment is completed, the "RUN" the upper display either changes to "HOLD" if configured for HOLD state, or disappears il configured for disable of Set Point Programming. The controller operates at the last set point in the program or will control using Local Set Point 2.

-

AUTOTUNE

UDC ,2000 OPERATION

Configuring for Autotune

Introduction Autotune automatically calculates Gain (PROP BD), Rate (Derivative), and Reset (Integral) Time tuning constants on demand. These tuning constants are calculated at the end of the Autotune procedure based on the output step introduced onto the process. An output step causing an approximately 4.0% change in PV will be automatically generated when autotune is performed using the Auto step approach. If you select the manual step approach, you must select a specific output step size in O/O that will be large enough to result in at least a 2.5% PV change. These constants, once calculated, are automatically entered into the controller memory in their normal locations. Autotune provides the theoretical PID constants which results in little or no overshoot. This usually provides a conservative Gain value which results in a slower response to insure no overshoot. If faster response is desired and some overshoot can be tolerated, the calculated Gain value can be increased by a factor of 2 or perhaps more or PB decreased by 2. Of course, the process loop must be checked for stability. Alarm 1 is available to protect the process during Autotune. If alarm set point is exceeded during the sampling period Autotune will abort. This eliminates the need to continually monitor the Autotune sequence. There is a SHORT TUNE feature that lets you obtain approximate tuning constants by prematurely implementing the Autotune calculation before the PV has fully lined out during the Autotune process. Autotune is most effective when implemented in the region of PV where you plan to operate. Don't Autotune at 900" F if you plan to operate at 1300°F. The process dynamics may be different at different energy levels. Always try to start Autotune 2.5% below your operating set point. In summary, Autotune and Short Tune can be used as a flexible tool to quickly identify Gain. Rate, and Reset time constants. Further tuning can then be done using these values as a starting point. IMPORTANT: Autotune will function only when the controller is in a closed loop system. Attempts to Autotune open loop will result in "ABORT" error message. NOTE: Set Point Ramp and Set Point

Programming cannot be enabled while Autotune is in operation.

Before starting Autotune, you must enable the Autotune feature, make sure Autotune key is not locked out. select whether you want the controller to generate an output step automatically (ASTP) or whether you want to enter an output step slze manually (MSTP). set alarm 1 Set Point 1 to proper type and value to protect process if desired -- otherw~se set to NONE to avoid accidental abort. Select the set point you want to line out at after Autotune.

Procedure Enter Configuration Mode Press [SET UP1 kev until vou see

Enable Autotune and Select Output Step Type Press lFUNCTlON1 kev. vou will see

Press [RAISE/LOWER] keys to select "ASTP" OR 'MSTPn in upper display. Press again to select step type-

manually enter a step size value under prompt "OUT STP")

Select Output Step She for MSTP Press the [FUNCTION] key (only i f selection MSTF is made) and you will see

the value of the controller

Press [RAISE/LOWER] keys to choose an outpul step in percent that will be appl~ed to the output ot the controller when Autotune is initiated. This step must be large enough to result in a PV change of at least 2.5% of span. Use as large a step as possible. Range of Setting = -1 00 to + 100"/0 of output. NOTE: The process can be tuned using either an upscale or downscale step change.

UDC 2000 OPERATION

Configuring for Autotune (continued)

Procedure (continued)

Exit Configuration Mode Start Autotune Press [DISPLAY] key once to exit configuration Press the [AUTOTUNE] key. The Autotune mode and you will see algorithm automatically introduces the output step

change (manual or automatic) to the process. "TUNE" appears in the upper clisplay to indicate that Autotune is in progress. You will see

variable

Starting Autotune

ASTP (Automatic Step Change) The algorithm samples the step response of the

staft Autotune using Auto let process until that response has lined out. The line the controller PV line out (PV = SP) and press [AUTOTUNE] key. (See "Start Autotune") The out time depends on the process reaction time.

Autotune will abort if no line-out has occurred after controller automatically calculates an output step which is intended to provide a PV transient of 4%. 6.07 hours of sampling.

In "Auto Step" if the resultant PV step is less than MSTP (Manual Step Change) 2.5% the Autotune will abort. In order to start Autotune in manual step approach, Viewing the Remaining Samples

make sure you have an Output step You can view the remaining number of samples left in that will result in a PV change of at least 2.5% . the most recently initiated time window. (See next (see "OUTSTP" on previous page) Page.) let the controller PV line out (PV = SP) and press Press the [DISPLAY] key until you see [AUTOTUNE] key. (See "Start Autotune") This will cause the controller to go into a quasi- manual mode and generate the step change in output as selected at prompt "OUTSTP".

SAM and the number of samples counting down in the current time window

j NOTE: The output value upon which the output step is based is not the instantaneous I I displayed output value, but an internal averaged value of the output. I 1 I

UDC 2000 OPERATION

STEP RESPONSE SAMPLING Introduction When Autotune is initiated, the controller output is step changed. The algorithm samples the step response of the process until the response has lined out (PV stabilized). The line-out time depends on the process reaction time.

Time Window A time window is the time it takes for the algor~thm to sample the step response of the process for line- out. The first time window takes 256 PV samples at a rate of one every 1!3 second. The lower display counts down from 256 until it reaches 0 (total time elapsed = 85-1!3 seconds) at which time the algorithm checks for line-out. If line-out has not occurred, another time window takes 128 samples at a rate of one every 2'3 second. The lower display

TABLE 4-1 - Time Windows

counts down from 128 until it reaches 0 (total time elapsed ,for two windows = 170-2:3 seconds) and again checks for line-out. If there is no line-out, a third window of 128 samples, at 1-113 seconds each, is initiated. As long as there is no line-out, this time windowing will continue 6 more times, each time sampling at a lower rate. See Table 4-1 to determine what time window the controller IS

displaying. By determining how long one sample takes (column C in table), you can find out what time window the controller is displaying (column A) and how long the time window will last (column D). For Example: If one sample takes 42-2.'3 seconds then the Autotune algorithm is in the #8 time window and will take 91 minutes to complete. At the end of window #8 the total time elapsed for all windows is 3.03 hours. If line-out has not occurred after the 9th window (6.07 hours) the Autotune will abort.

I Window Sampling I Time for I Total Time Number I Samples' I Time This Window Window I

I 2 I 128 I 213 sec 85-113 sec 170-213 sec I 1

I I

I 3 I 128 1-11'3 sec 1 170-20 sec 341-1!3 sec 1 I I I

1 4 I 128 2-213 sec ( 341 -213 sec 1 1-1 14 mln I

256

I I I I

I 5 1 128 1 5-113 sec 1 11-114min I 22.7 min I

1/3 sec

I 8 1 128 1 42-2/3 see 1 91.0 rnin ( 3.03 hrs (

85-1/3 sec

6

7

I 9 1 128 1 85-1 0 sec I 3.03 hrs I 6.07 hrs I 'The lower display indicates the number of samples remaining in the present window number.

128

128

10-113 see

21-1/3 sec

22.7 min

45.5 min

45.5 min

91.0 min

UDC 2000 OPERATION

"SHORT TUNE" FEATURE Introduction This feature lets you obtain approximate tuning constants by prematurely implementing the Autotune calculation before the PV has fully lined-out during the Autotune process. This typically results in a different Gain value; however, Rate and Reset time will be relatively close to the optimum calculated value. You can then increase gain by a factor of 2 to 4 until an acceptable stable closed loop response is achieved. -- all in a short time -- without prior process knowledge or trial and error guesswork.

Implementing Short Tune

After implementing the Autotune process, press [AUTOTUNE] key while the controller is sampling the process response. "tunE" in the upper display will change to 'tunE acknowledging the short tune procedure. At the end of the time wlndow (when lower display SAM = 0). the Autotune algorithm will calculate constants based on the PV response up to that time if the PV has changed by at least 2.5% of span.

TABLE 4-2 -- Error Codes

AUTOTUNE ERROR CODES When an error is detected in the Autotune process, the message "ABORT" will appear in the lower display. Access function prompt "ATERR" to determine what is causing the error. Refer to Table 4-2 for the definrt~on of the error code and what action to take to correct it.

Access "AT ERR" To examine the autotune error code, press the [SET UP] key until you see


Error Code I WPWr Display) I Definition Action to Take

--

OTLM

DPLM

OUTPUT GREATER THAN HIGH OUTPUT LIMIT OR LESS THAN LOW OUTPUT LIMIT

OUTPUT GREATER OR LESS THAN THE HEATICOOL LIMITS The step entered cool zone when tuning heat or the step entered heat zone when tuning cool.

.check the output llrnrts under "CONTRL" function prompts "OUTHI" and "OUTLO." See Configurat~on Sect~ori. If you are using a manual step change, reconfigure "OUTSTP" prompt under ATUNE group. Restart Autotune procedure.

Reconfigure the step size to fall only within heat or cool zone. Autotune function prompt "OUTSTP." Restart Autotune procedure.

ALM 1

LOWP

- - - -

ALARM 1 LIMIT EXCEEDED Alarm 1 error code wtll show if you have conf~gured alarm 1 to activate at a value of a parameter and it is exceeded.

- - --

Check alarm type and limit under "ALARM" funct~on prompts "A1 S1 VA" and "A1SlTY." Reconfigure smaller step slze. Restart Autotune procedure.

I I I I - TABLE CONTINUED ON NEXT PAGE

-

PV CHANGE NOT GREATER THAN 2.5% The algorithm has sampled the process step response for a per~od of tlme (6.07 hours max) and the PV has llned out with less than a 2.5% chanqe.

-- --- -

Reconfigure to MSTP and use a larger Step size "ATUNE" funct~on prompt "OUTSTP."

Autotune procedure.

UDC 2000 OPERATION

TABLE 4-2 - Error Codes (continued)

ABORTING AUTOTUNE To abort Autotune and return to the last previous operation (SP or output level), press [RESET] key to abort the Autotune process. Autotune will abort automatically if alarm 1 set point is exceeded or if the Autotune procedure requires more than 9 windows.

Error Code (Upper Display)

IDFL

ILIM

PLlM

AbRT

lNPl

RAMP

RMSW

COMPLETING AUTOTUNE When Autotune is complete,

The calculated tuning parameters are stored in their proper memory location in the controller. The controller will control at the local set point using the newly calculated tuning constants.

Definition

PROCESS IDENTIFICATION FAILURE Autotune has aborted due to either excessive noise or a step response interruption, or because the process cannot be tuned.

RESET LIMITS EXCEEDED The reset value has exceeded high or low limits. The unit control at high or low limits Low = 0.02 minutes High = 50.00 minutes

GAIN LIMITS EXCEEDED The Gain value has exceeded high or low limits. The unit control at high or low limits. Low = 0.1 High = 999.9

MANUAL ABORT Autotune has been manually aborted.

INPUT ERROR Any input is outside of its 0 to 100% range, or any input failed.

AUTOTUNE ILLEGAL DURING RAMP OR SET POINT PROGRAM

AUTOTUNE IS ABORTED WHEN EXTERNAL SWITCH IS DETECTED

Action to Take

1

Excessive noise - reconfigure larger step size

"AUTOTUNE" function prompt "OUT STP."

Step response interruption - make sure interruption is not repeated. - restart Autotune procedure. Untunable process -- contact local application engineer.

Increase or decrease PB or Gain to br~ng reset within the defined limits. Check the final ~0fltrol ekment for proper application. Untunable process -- contact local application engineer.

Increase or decrease Reset to bring Gain or PB to within def~ned limits. Check the final control element tor PrOpt'r application. Untunable process -- contact local application engineer.

Autotune will abort i f the [RESET] key is pressed during Autotune.

Make sure the range and actuat~on are configured properly. Check the input source(s).

Wait until Ramp is complete and restart Autotune.

Restart Autotune -- Do not interrupt with digital input (Remote Switching) contact closure.

UDC 2000 OPERATION

RESTARTING AFTER A POWER LOSS If the power to the controller fails and power is reapplied, the controller goes through the power-up tests then goes to a user configured FAILSAFE OUTPUT VALUE.

Set The Failsafe Output Value Press the[SET UP] key until you see


-5 to 105 for Current

Press the [RAISWLOWER] keys to select a Failsafe Output Value.

Press the [DISPLAY] key to return to normal control. At Power up, the Output will be at the value set here.

51-52-1 1-1 2, Page 4-20

CALIBRATION SECTION 5 This section basically has two parts, lnput Calibration and Output Calibration Each part has the following sub-headings:

Introduction - when calibration is required. Preliminary Procedures - disconnecting the field

wiring, setting internal DIP switches, etc. Equipment Needed - what you need to do the

calibration. Set Up - how to set-up the controller for the

calibration procedure, i.e. terminal connections, etc. Calibration Procedures - how to do the

calibration.

Also, included in this section is a procedure for setting Motor Travel Time when you are using 3 Position Step Control.

INPUT CALIBRATION - describes the field calibration procedures for lnput 1 and lnput 2.

lnput 1 - can be calibrated for a variety of thermocouples, RTDs, Radiamatic AH, mA, mV, and Volt ranges. You select which type of input you will be calibrating by SETTING A DIP SWITCH inside the chassis on the I10 Printed Wiring board, then connect a calibrating device as described in SET UP and following the PROCEDURE for lnput 1.

lnput 2 - can be calibrated for two ranges: 1 to 5 Volts or 4 to 20 mA, by connecting a calibrating device as described in SET UP and following the PROCEDURE for lnput 2.

OUTPUT CALIBRATION - describes the field calibration procedures for Current Proportional Output and PV (Auxiliary) Output.

Current Proportional Output - can be calibrated for a range of 4 to 20 milliamperes by connecting a calibrating device as described in SET UP and following the PROCEDURE.

INPUT CALIBRATION

lntroduction This part describes the field calibration procedures for input 1 and input 2. However, this procedure should only be implemented if the factory calibration of the desired input range is not within specifications. Note that every Mini-Pro controller contains all input ranges fully factory calibrated and ready for configurat~on to the range by the user. It should not be necessary to recalibrate the controller.

Note also, that the field calibration will be lost if a change in input type configuration is implemented at a later time. The input will revert to whatever is stored in memory.

Minimum and Maximum Range Values Calibrate the Mini-Pro controller to the minimum (090) and maximum (1 0O0/0) range values for your part~cular sensor. If you have a two input controller, calibrate each input separately.

Select the voltage or resistance equivalent for 0% and 100% range values from Table 5-1 on page 5-2. Use these values when calibrating the inputs.

P V (Auxiliary) Output - can be calibrated for a range of 0 to 5 Volts or 1 to 5 Volts by connecting a calibrating device as described in SET UP and following the PROCEDURE.

51-52-13-1 1, Page 5- 1

UDC 2000 CALIBRATION

TABLE 5-1 - Voltage and Resistance Equivalents for 0% and 100% Range Values

PV Input Range Range Value

Sensor Type OF "C 0 Oh 100% I I

B TIC 150 to 3300 166 to 1815 10.009 mV 13.763 mV

I E TIC ' 1-100 to 1832

E (low) TIC

J (TIC)

J (low) TIC

I K (low) TIC 1 -20 to 1000

1 NNM NiNiMoly TIC 132 to 2500

I S TIC ( 0 to 3100

I T TIC

-

1 NIC N~crosil Nisi1 TIC 10 to 2372 I - 1 7 . 8 T Z 0 - 12.461 mV 1 4 7 5 0 2 m v

RTD IEC alpha = 0.00385

100 ohms -300 to 900 -1 84 to 482 25.1 8 ohms

0 to 300 -18 to 149 93.03 ohms

274.96 ohms

156.90 ohms

Radiamatic RH 1 1400 to 3400 1 760 to 1871 10.99 mV

Linear Milliamps 4 to 20 mA 4 mA 20 mA

Millivolts 0 to 10 mV 0 mV 10 mV

0 to 100 mV 0 mV 100 mV

Volts 0 to 1 Volt ov 1 v

0 to 5 Volts ov 5v

0 to 10 Volts ov 1 OV

I I I I 1 to 5 Volts 1 v

I 5v

51-52-13-11, Page 5-2



Preliminary Procedures

Disconnect Field Wiring Depending on which input (#1 or #2) you are going to calibrate, tag and disconnect any field wiring connected to the input terminals on the rear of the controller. (See Figure 5-1 .)

Set the DIP Switches for lnput 1 Before you calibrate lnput 1, you must check an internal DIP switch to make sure the switches are set for the correct lnput type;

Thermocouples, Mill~volts ,

Radiamatic, RTD,

Milliamp, or Voltage

Procedure 1. Loosen the screw on the front

of the controller and pull the chassis out of the case.

2. The switches are located at position SW1 on the 110 Printed Wiring Board. (See Figure 5-2.)

3. Set the switches for the range type desired according to the table in Figure 5-2.

REAR OF CONTROLLER

7

14 ~ - , I INPUT 2 : 1 TERMINALS :

Figure 5-1 lnput Connections

51-52-13-1 1, Page 5 3

110 Printed Wiring Board

n u n . t, 00 . . I to LCBEI

SWl Off

1 2 3 4 5

-

I

'----------------A

Figure 5-2 DIP Switch Positions

r-------------..--.,

For Range Type Switch and Position

1 2 3 4 5

TIC ON OFF - X--I OFF OFF

Linear ( m ~ ) , Radiamatic ON OFF OFF: OFF OFF

4 to 20 mA OFF ON OFF! OFF ON

e , l o volt OFF OFF OFF: OFF ON

RTD ON OFF OFF: ON OFF

I SW3 IS FOR T: BURNOUT ( I OFF tor Upscale ON for

; ---- - - ----- - ---- -- - - - -- -- - - I ( : EITHER for Failsafe I



Equipment Needed Screwdriver

THERMOCOUPLE INPUTS A calibrating device with 2 0.02% accuracy for use as a signal source. Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input.

If you are using an Ice Bath Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the mV source. Two containers of crushed ice.

RTD (RESISTANCE THERMOMETER DEVICE)

A Decade Box, with f 0.02% accuracy, capable of providing stepped resolution of .O1 ohm. Three insulated copper leads of equal length for connecting the Decade Box to the controller.

MILLIVOLTS, VOLTS, MILLIAMPERES, or RADIAMATIC

A calibrating device with ?: 0.02O/0 accuracy for use as a signal source. Two insulated copper leads for connecting the calibrator to the controller.

Set-Up (SEE FIGURE 5-3) THERMOCOUPLE INPUTS (Ice Bath)

Connect the copper leads to the calibrator. Connect a length of thermocouple wire to the end of each copper wire and insert each junction point into an ice bath. Connect the thermocouple extension wire to the terminals for input 1.

THERMOCOUPLE INPUTS (TIC Source) Connect the thermocouple extension wire to the terminals for input 1.

RTD, MILLIVOLT, VOLTS, MILLIAMPERES, or RADIAMATIC

Connect the copper leads from the calibrator to the input 1 terminals as shown in Figure 5-3. Place current source at zero before switching on. Do not switch current sources onloff while connected to the UDC 2000 input.

NOTE- For Radiamatic Inputs only set Emissivity value to 1.0 See Set Up Prompt *INPUT 1"

Function Prompt "EMISS".

REAR OF CONTROLLER

1 lo 5 Volls or

4 to 20 mA

C - - - - - - - - - - -

f INPUT 1 0 8 + ;TERMINALS 0 7 - L------u - - 0 6 R

0 0 0 0

1 5 + mA t INPUT 2 1 6 - 0

i TERMINALS i L----------d

THERMOCOUPLES USING AN ICE BATH

TIC EXTENSION

COPPER WIRE

I r r

+ - mV

SOURCE BATHS

THERMOCOUPLES WITHOUT AN E E BATH

RESISTANCE THERMOMETER DEVICE (RTD)

COPPER

DECADE RESISTANCE

MILUVOLT, VOLT, MILLIAMPERES, or RADIAMATIC

0 0

T I 7

+ - L- 8 * mV,

COPPER 7 -

VOLT, mA 0 6 R

SOURCE -

- -

1

Figure 5-3 Calibration Equipment Connect~ons



INPUT 1 CALIBRATION PROCEDURE Apply power and let the controller warm up for 15 minutes before you calibrate.

NOTE: Set "LOCK" in tuning section to 'NONE."

CAUTION: For Linear inputs, avoid step changes in inputs. Vary smoothly from initial value to the final 100% value.

Please read "SET UP" on previous page before beginning the procedure.

See Table 5-1 on page 5-2 for Voltage vs Resistance equivalent.'

PROCEDURE PRESS DISPLAYS ACTION

Enter Calibration ,,, ,, 0 Go to next key press. Mode

Go to next key press to enable INPUT 1 FUNCTION 0 calibration.

r-"--"'---'--'---'---------------

Note: After complebon of the calrbrabon I I

1 sequence, the controller automatrcally reverts to I : disable. I L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J

El This begins the callbration procedure, Go to next step.

Calibrate 0% FUNCTION u Adjust your calibrating device to an output signal equal to the 0% range value for your particular input sensor. (table 5-1 ) Wait 30 seconds, then go to next step.

Calibrate 100°/~ 0 Adjust your calibrating device to an oul put signal equal to (he 100% range valul-. for your particular input sensor. Wait 30 seconds, then go to next step it the input is configured for thermocouple; otherwise, go to "Exit Calibration Mode".

Check the FUNCTION n The value in the upper display is in tenths

Cold Junction of a degree. It is the current reading of Temperature the temperature as measured at the

thermocouple terminals and recognized by the controller. You can change this value, if it is in error, using Av keys.


51-52-13-1 1, Page 5-5



INPUT 2 CALIBRATION PROCEDURE (Ranges 4 to 20 mA or 1 to 5 Volts only) Apply power and let the controller warm up for 15 minutes before you calibrate.

NOTE: Set *LOCKv in tuning group to 'NONE."

CAUTION: For these inputs, avoid step changes in inputs. Vary smoothly from initial value to the final 100% value.

Please read 'SET UP" before beginning the procedure.

NOTE: For Current (4-20mA) input, install jumper on pins 4 .- 20mA of J8 on the Transformerloption board. For Voltage (1 -5Vdc) input, install jumper on pins 1 - 5V of J8 on the Transformer1 option board.

- -. . - . - - -- - - - - -- - - - - - . - - - . . - PROCEDURE PRESS DISPLAYS ACTION

Go to next key press.

Go to next key press to enable INPUT 2 calibration.

re-"'------'--------------------

I Note: After completion of me calibrat~on I I 1 sequence, the controller automatrcally reverts lo I

I disable. I L- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -J

This begins the calibration procedure, Go to next step.

Calibrate 0% Adjust your calibrating device to an output signal equal to the 0% range value for your particular input (table 5-1). Wait 30 seconds, then go to next step.

Adjust your calibrat~ng device to an output signal equal to the 100% range value for your particular input .

Wait 30 seconds, then go to next step .


5 1-52- 13- 1 1, Page 5-6


OUTPUT CALIBRATION

CURRENT PROPORTiONAL OUTPUT

Introduction Calibrate the controller so that the output provides the proper amount of current over the desired range. The controller can provide an output current range of 2 to 21 milliamperes and can be calibrated at 4 mA for 0% of output and 20 mA for 100'?/0 of output or any other values between 2 and 21 mA.

Preliminary Procedures Tag and disconnect the field wiring at the rear of the controller from terminals 4 and 5 (See Figure 5-4)

Equipment needed A standard shop type milliammeter with whatever accuracy is required, capable of measuring 0 to 20 milliamps.

Set-Up a Connect a milliammeter across

termrnals 4 and 5 (see Figure 5-4). Apply the power and allow the controller to warm up for 15 minutes before you calibrate. Set "LOCK" in tuning group to "NONE."


MILLIAMMETER

*+ ?-

1

REAR OF CONTROLLER

7

0 0

- () 5+ I 4 - .

OUTPUT TERMINALS L------

Flgure 5-4 Callbrat~on Equ~pment Connections



CURRENT PROPORTIONAL OUTPUT CALIBRATION PROCEDURE

PROCEDURE PRESS DlSPLAYS ACTlON

Enter Calibration Go to next step. Mode

Calibrate 0% Go to next step. F UNCrlON

the desired 0% output is read on the milliammeter. Use table 1 to find the correct value.

until

This stores the minimum value and gives you the display shown. Go to the next .

key press. -

the desired 100% (span) output is read on the milliammeter. Use table 1 to find the correct value.

This stores the spar1 value and exits the calibration mode.

DISPLAY

TABLE 1

Reading 4-20 mA Direct 4-20 mA Reverse

0% 4 mA 20 mA 100% 20 mA 4 mA

51-52-13-11, Page 5-8


OUTPUT CALIBRATION (CONTINUED)

AUXILIARY OUTPUT CALIBRATiON

Introduction Calibrate the controller so that the output provides the proper amount of voltage over the desired range. The controller can provide a Voltage output range of trom 0 to 5 Volts and can be calibrated at 0 Volt for 0% of output and 5 Volts for 100% of output or any other values between 0 and 5 Volts.

Preliminary Procedures Tag and disconnect the field wiring at the rear of the controller from terminals 13 and 14 (See Figure 5-5)

Equipment needed A calibrating device with whatever accuracy is necessary, capable of measuring 0 to 5 Volts.

Set-Up Connect a calibrating device across terminals 13 and 14 (see Figure 5-5). Apply the power and allow the controller to warm up for 15 minutes before you calibrate. Set "LOCK" in tuning group to "NONE."


CALIBRATING DEVICE

r-----l

a+ VOLTMETER

REAR OF CONTROLLER

r-----l I I

I I AUXILIARY f OUTPUT TERMINALS

Figure 5-5 Calibration Equipment Connections



AUXILIARY OUTPUT CALIBRATION PROCEDURE


Enter Calibration ,,, ,, El Go to next step. Mode

Calibrate 0% FUNCTION u Go to next step.

the desired 0% output is read on the voltmeter.

un ti1

Calibrate 100°/~ ,,,,,,, n This stores the minimum value and gives you the display shown. Go to the next key press.

the desired 100°/~ (span) output is read on the voltmeter.

until

This stores the spar) value and exlts the calibration mode.


THREE POSITION STEP CONTROL ALGORITHM, MOTOR TRAVEL TIME SETTING Introduction Three Position Step Control lets you control a valve or other actuator with an eletric motor driven by the output relays. These relays actuate two sets of coils, one to move clockwise and the other counter-clockwise without a feedback slidewire linked to the motor shaft. There is internal feedback of the state of the relays. A TPSC controller provides an estimated pos~tion of the motor since the motor is not using any feedback from a slidewire. The *OUTn display will indicate this estimated motor position. The only calibration required is setting the Motor Travel Time (The time it takes for the motor to travel from 0% to 100%).

Set Up Set 'LOCK" in tuning group to 'NONE"

Procedure - - - - - --


Enter Calibration Go to next step. Mode

Select Motor The value in the upper display represents Time Prompt the time it takes the motor to travel from

0 to 100%.

Change the the desired Motor Travel Time is reached. See the Motor Specifications or measure the time from 0 -to 10O0/o

Range of setting = 15 to 240 seconds until

51-52-13-1 1, Page 5-1 1

TROUBLESHOOTINGISERVICE SECTION 6

INTRODUCTION CONTROLLER FAILURE INDICATIONS Instrument performance can be adversely affected by installation and application problems as well as hardware problems. We recommend that you investigate the problems in the following order:

lnstallation Related Problems - Read the lnstallation Section in this manual to make sure the Mini-Pro has been properly installed. The lnstallation section provides information on protection against electrical noise, connecting external equipment to the controller, and shielding and routing external wiring. IMPORTANT: System noise induced into the controller will result in diagnostic error messages recurring. If the diagnostic error message can be cleared, it indicates a 'soft" failure and is probably noise related. If system noise is suspected, completely isolate the controller from all field wiring. Use calibration sources to simulate PV and check all controller functions i.e. Gain, Rate Reset, Output, Alarms, etc.

Application Related Problems - Review the application of the controller; then, if necessary, direct your questions to the local sales office.

Hardware and Software Related Problems Use the troubleshooting error message prompts and controller failure symptoms to identify typical failures which may occur in the controller. Follow the troubleshooting procedures to correct them.

MAINTENANCE

Error Messages The Mini-Pro runs background tests during normal operation. If a problem with the Background tests occurs, an error message will be displayed on the operator interface. Table 6-1 shows you the error message, what the failure is, and how to correct the problem.

Other Failure Symptoms Other failure symptoms may occur that deal w~th the Power, Output, or Alarms. Refer to the controller failure symptoms in Table 6-3 to determ~ne what IS wrong and the troubleshooting procedure to use to correct the problem.

Check lnstallation If a set of symptoms still persists, refer to the lnstallation section of this manual and ensure proper installation and proper use of the controller in the system.

CUSTOMER SUPPORT If you cannot solve the problem using the troubleshooting procedures listed in this section, get model and serial number from the chassis label and

Call Customer Support Phone Number 1-800-423-9883

If the Elastomer Bezel!Display lens requires cleaning, use a soft cloth with alchohol or a mild solution of soapy water.

51-52-13-12, Page 6-1

UDC 2000 TROUBLESHOOTlNG/SERVICE

ERROR MESSAGES The Mini-Pro performs on-going background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed (blinking) in the lower display. In the case of more than one simultaneous malfunction, only the one with the highest priority will appear in the lower display.

Table 6-1 below shows these error messages, the reason for the failure, and how to correct the problem.

TABLE 6-1 BACKGROUND TESTS ERROR PROMPTS

Prompt Reason For Failure How to Correct the Problem

E FAIL Unable to write to non-volatile memory. 1. Check the accuracy of the parameter and Anytime you change a parameter and it is not re-enter. accepted, you will see E FAIL.

FAILSF This error message shows whenever the 1. Run through STATUS check to determine controller goes into failsafe mode of the reason for the failure: operation. This will happen if: Press [SET UP] until READ appears in the

RAM Test failed lower display. Configuration Test Failed Press [FUNCTION] to see which tests Calibration Test Failed Pass or Fail. Factory Calibration Checksum Failed RAMTST CFGTST CALTST FACTST

2. Correct according to the recommendations given for a particular failure in Table 6-2.

IN1 FAIL Two consecutive failures of input one 1. Make sure the actuation is configured integration, i.e. cannot make analog to digital correctly. See Configuration Section 3. conversion 2. Make sure the input is correct.

3. Check for gross overranging.

lN2FAlL Two consecutive failures of input two 1. Make sure the actuation is configured integration, i.e. cannot make analog to digital correctly. See Configuration Section 3. conversion 2. Make sure the input is correct.

3. Make sure the position of the jumper at J8 on the option board is correct for the given input 2 signal.

4. Check for gross overranging.

continued next page

5 1-52- 13- 12, Page 6-2

UDC 2000 TROUBLESHOOTINGISERViCE

ERROR MESSAGES (continued).

TABLE 6-1 BACKGROUND TESTS ERROR PROMPTS (continued)

Prompt Reason For Failure How to Correct the Problem

IN1 RNG Input 1 - out of range. The process is 1. Make sure the range and actuation are outside the range limits. configured properly.

2. Check the input source. NOTE: I I the range goes ouls~de the Range Llrn~ls, the 3. Restore the factory calibration: controiler WIII go to the fallsafe output value. a. Disconnect the wiring from and place a

jumper across terminals 7 and 8. The controller should read room temperature if it is configured for a thermocouple input. b. If it does not read room temperature, see Section 3 - Configuration, and change INl lYP prompt in the INPUT 1 group to another type of thermocouple. c. After the change, press [FUNCTION] key, then press the [LOWER DISPLAY] key. The controller should read room temperature. If it does not, the unit has an input failure. d. Repeat step b. This time switch the INlTYP back to the originally selected thermocouple. e. Repeat step c. The controller is restored with factory calibration. f . Remove the jumper and reconnect the thermocouple.

4. Check the lnput type switch placement. Refer to 'Preliminary Checks" In Installation Section 2.

5. Field calibrate - See Calibrat~on section 5.

INZRNG Input 2 - out of range Same as INPUT 1 The remote input is outside the range criteria listed under Input 1 above.

RV LIM The result of the formula shown below is 1. Make sure the input signal is correct. beyond the range of the remote variable. 2. Make sure the Ratio and Bias settings are

RV = (INP2 x RATIO) + BIAS correct. 3. To recheck calibration, use Ratio 1.0 and

Bias 0.0

UDC 2000TROUBLESHOOT1NG/SERVICE

STATUS TESTS When required, the results of these STATUS tests can the ISET 1 key until

be checked to determine the reason the controller has you see gone to failsafe.

:!.;<;.$ik;x*~.;.,<< .,-. <<<+;*<:.:,*.:.>.. :::: Press [FUNCTION] key until gj$$<

you see :>.:, ,,:::::.. .>

~~*F~E:~~~<;.g:::<>;:j:;i;j*,.: .. : :$

TABLE 6-2 STATUS TESTS

Lower Upper Display Definition Display Reason for Failure How to Correct the Problem Prompt Prompt

FAILSF Fallsafe NO No Failure Fault YES Burnout configured for 1. Step through the rest of the STATUS

none and input fails check to identify the particular failure. RAMTST failed Press [FUNCTION] key. CFGTST failed CALTST failed FACTST failed

-

RAMTST RAM Test PASS No Failure FAIL RAM Failure 1. Power cycle to see if the error clears.

CFGTST Configuration PASS No Failure Checksum FAIL Configuration data in the 1. Step through the STATUS tests, the

controller in error. controller will calculate the checksum. 2. Check all the configuration prompts tor

accuracv. See Confiauration Sect~on 3.

CALTST Working PASS No Failure Calibration FAIL Working calibration 1. If the controller has not been field Checksum constants in the controller calibrated, see the configuration sectton

in error. and change the input type to a different type. Enter it, loop through all the STATUS tests then return input type to the original.

2. If the controller has been field calibrated, recalibrate the controller.

FACTST Factory PASS No Failure Calibration FAIL Factory set input I. Cycle through STATUS to clear the Cyclic constants in the controller error. Redundancy are in error. 2. Check the calibration - make sure 0 Check and 100% are the correct values. See

Calibration Section 5. 3. Recalibrate. If step 1 is unsatisfactory,

always do step 3 - See Calibratron Section 5.

5 1-52- 13- 12, Page 6-4

UDC 2000 TROUBLESHOOTINGfSERVICE

CONTROLLER FAILURE SYMPTOMS In addition to the error message prompts there are failure symptoms that can be identified by noting how the controllers displays, indicators, and controller functions are reacting. Compare your symptoms with those shown in Table 6-3 and refer to the troubleshooting procedure indicated to correct the problem.

EQUIPMENT NEEDED TO FOLLOW TROUBLESHOOTING PROCEDURES

DC Milliammeter XX.XX mAdc Calibration Sources - TIC, mV, Volt, etc. Voltmeter

The troubleshooting procedures begin on the next page.

If a set of symptoms or prompts other than the one you started wlth appears wh~le troubleshoot~ng. re- evaluate the symptoms. This may lead to a different troubleshooting procedure. If the symptoms still persist, refer to the lnstallat~on Section in this manual to ensure proper installation and proper use of the controller in your system.

TABLE 6-3 CONTROLLER FAILURE SYMPTOMS

51-52-t3-12, Page 6-5

Upper Display

Blank

OK

OK

Controller Output

None

Controller Output

Disagrees wi th

Displayed Output

External Alarm

Function Does Not Operate Properly

Lower Display

Blank

Displayed Output

Disagrees w i th

Controller Output

OK

Indicators

Off

OK

OK

Probable Cause

Power Failure

Current Proportional

Output Time(Relay) Proportional

Output

Malfunction in Alarm Output

Troubleshooting Procedure

1

2

3

4

UDC 2000 TROUBLESHOOTING/SERVICE

CONTROLLER FAILURE SYMPTOMS TROUBLESHOOTING PROCEDURES

PROCEDURE 1: TROUBLESHOOTING POWER FAILURE

PROCEDURE 2: TROUBLESHOOTING CURRENTPROPORTIONAL OUTPUT

What to Do I

1. Check the AC line Voltage.

2. Make sure the chassis plugs into the rear of the case properly.

3. Check the Voltage selection.

4. Check the system for brown-outs, heavy load switching, etc.; and conformance to installation instructions. .


1. Use a Voltmeter to measure the AC Voltage across terminals L1 and L2 on the rear terminal panel of the controller.

2. Withdraw the chassis from the case and visually inspect the I/O printed wiring board for damage.

3. See i f the J 1 connector on the 110 printed wiring board i s in the proper position for the voltage being used. See "Preliminary Checks" in the lnstallation Section.

4. Refer to the installation Section.

5 1-52- 13- 12, Page 6-6

What to Do

1. Make sure the controller is configured for current output.

2. Check the field wiring.

3. Make sure all the configurable constants, limits and configuration data stored in the controller are correct. Reconfigure if necessary.

4. Check the Output.

5. Recalibrate the Current Proportional output.

How to do it or where to find the Data I

1. Make [SET UP] group "ALGOR" , [FUNC] prompt "OUTALG' = selection "CUR". See the Configuration Section.

2. Load must be less than or equal t o 750 Ohms.

3. See the configuration section in this manual to check constants, limits and configuration data and to reconfigure.

4. Press the [DISP] key until you see OUT in the lower display. Use a DC milliammeter at the rear of the terminals to verify the output. 4 to 20 mA output corresponds to an output of 0 to 100%.

5. See the Calibration Section. &

UDC ZOOOTROUBLESHOOTINGISERVICE

CONTROLLER FAILURE SYMPTOMS TROUBLESHOOTING PROCEDURES(continuec4)

PROCEDURE 3: TROUBLESHOOTING SINGLE RELAY O R DUAL RELAY OUTPUT FAILURE

PROCEDURE 4: TROUBLESHOOTING ALARM RELAY OUTPUT FAILURE

What to Do I

1. Make sure the controller has at least one relay for relay simplex operation or an option board with an additional 2 relays for Duplex operation.

2. Make sure all the configurable constants, limits and configuration data stored in the controller are correct. Reconfigure if necessary..

3. Check that the applicable output relay actuates properly. If it doesn't go to step 5. If it does, go to step 4.

4. Check the Output (control) relay jumper position.

5. Check the field wiring


1. Make [SET UP] group "ALGOR" , [FUNC] prompt "OUTALG" = selection "RLY" or "RLYD". See the Configuration Section.

2. See the configuration section in this manual to check constants, limits and configuration data and to reconfigure.

3. Vary the set point around the PV. Listen for the click of the relay as the Set Point moves in either direction. Observe OUT 1 or 2 light on the operator interface.

4. See the Installation Section for relay jumper placement and relay contact information.

5. See the Installation Section for wiring diagrams.

51-52-13-1 2, Page 6-7

What to Do I

1. Check the alarm configuration data. If it i s correct, check the field wiring. Reconfigure if necessary.

2. Check the alarm relay jumper position.

3. Check that the applicable alarm relay actuates properly depending on what you have set at "ALARMS" group prompt "AxSxTYm. If it does, check the field wiring.


1. See the Configuration Section.

2. See the Installation Section for jumper placement and contact information.

3. If the alarm type is set for PROC (process variable), press [DISPLAY] to display SP. Vary the set point around the alarm set point creating a deviation value and listen for a click from the relay as the PV moves in either direction and note that the proper ALM 1 or 2 is lit. If the alarm i s set for DEV (deviation), raise or lower the set point above or below the PV to get the deviation you have set as the alarm set point.

PARTS LIST SECTION 7

51 -52- 14-07, Page 7- 1

UDC 2000 PARTS LIST

UDC 2000 Mini-Pro Exploded View Parts List

PARTS KITS NOT SHOWN

KEY NO. L

1

2

3

4

5

5 1-52- 14-07, Page 7-2

QUANTITY

1

1

1

1

1 *

PART NUMBER

30757023-501

30757032-501 30757032-503

30755306-501 30756725-501 30756679-501

30754 142-003 '

30756091 -00 1

DESCRIPTION

DisplayIKeyboard Printed Wiring Board

Transformer Printed Wiring Board Transformer/Option Printed Wiring

Board

Electromechanical Relay - 5 Amps Internal Solid State Relay - 1 Amp

Open Collector Printed wiring Jumper

Terminal Strip

Rear Terminal Cover Kit

APPENDIX A

INTRODUCTION This Appendix provides information for all the user configurable parameters listed in the configuration section. If you aren't familiar with these parameters, this appendix gives you a definition of how each parameter setting affects .controller performance. It will also refer you to any other prompts that might be affected by your selection.

PARAMETER GROUPS AND PROMPTS As shown in the Table of Contents, the information is divided into 9 configuration groups which are accessed by pressing the [SET UP] key.

Each of these groups contain prompts, viewed in the lower display, which deal with functions that are pertinent to that particular group. These are accessed by pressing the [FUNCTION] key.

The selections or values are listed in the upper display. Refer to the Configuration section for step by step instructions.

SECTION 8

TABLE OF CONTENTS Group Page Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

SP RampISP Program . . . . . . . . . . . . . . . . . 8-4

Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input 1 8-6

Input 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Control 8-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Options 8-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms 8-10

. . . . . . . . . . . . . . . . . . . . . . . . . Calibration 8-1 1

Status Test Data . . . . . . . . . . . . . . . . . . . . 8-1 2

51-52-19-12, Page 8-1

UDC 2000 APPENDIX A

f

TUNING Tuning consists of establishing the appropriate values for the tuning constants you are uslng so that your controller responds correctly to changes in process variable and 'set point. You can start with pre-determined values but you will have to watch the system to see how to modify them.

PB PROPORTIONAL BAND is the percent of the range of the measured variable for which a proportional controller will produce a 100% change in its output.

GAlN GAlN is the ratio of output change (%) over the measured variable change (%) that caused it.

100% where PB is the proportional G =

PBO/o band (in %)

If the PB is 20%, then the Gain is 5. Likewise, a 3% change in the error signal (SP-PV) will result in a 15% change in the controller's output due to proportional action. If the gain is 2 then the PB is 50%. Defined as "HEAT" Gain on Duplex models for variations of HeatICool applications. The selection of Prop. Band or Gain is made in the control parameter group under Prompt "PBorGN."

RATE T RATE TlME affects the controller's output whenever the deviation is changing; and affects it more when the deviation is changing faster. Defined as "HEAT" Rate on Duplex models for variations of HeatICool applrcations.

RESET RATE or INTEGRAL TlME adjusts the controller's output in accordance with both the size of the deviation (SP-PV) and the time it lasts. The amount of the corrective action depends on the value of Gain. The Reset adjustment is measured as how many times proportional action is repeatedlminute.

Defined as "HEAT" Reset on Duplex models for variations of Heat/Cool applications. The selection of minutes per repeat or repeats per minute is made in the control parameters group under Prompt "MINRPM."

~MIN = I RPM

MANRST MANUAL RESET Only appl~cable if you have control algorithm PD WITH MANUAL RESET. Because a praportional controller will not necessarily line out at set point, there will be a deviation (offset) from set point. This eliminates the offset and lets the PV line out at set point.

GAIN2, PB2, RATEILT, 12MIN, I2RPM PROPORTIONAL BAND 2 or GAlN 2, RATE 2, and RESET RATE 2 or INTEGRAL TlME 2 are the same as previously described except that they refer to the cool zone tuning constants on duplex models.

CYC T I CYCLE TlME (HEAT) determines the length of one time proportional output relay cycle. Defined as "HEAT" cycle time for Heat'Cool applicat~ons.

CYC T2 CYCLE TlME 2 (COOL) is the same as above except it applies to Duplex models as the cycle time in the "COOL" zone of Heat/Cool applications.

LOCKOUT LOCKOUT applies to one of the functional groups: Configuration or Calibration. DO NOT CONFIGURE LOCKOUT UNTIL ALL OTHER CONFIGURATION IS COMPLETE.

NONE No Lockout -- all groups read!write.

CAL Calibration is deleted from the SETUP list.

CONF Tuning is readlwrite. All other groups are read only.

AT KEY ENAB - Enables Autotune key lockout.

DIS - Disables Autotune key lockout.

RH KEY ENAB - Enables Setpoint Ramp~Program RUNIHOLD key lockout. DIS - Disables Setpoint Ramp~Program RUNIHOLD key lockout.

5 1-52- 19- 12, Page 8-2

UDC 2000 APPENDIX A

ALGOR This data deals with various algorithms in the controller: Control algorithm, Enabling the second input, or the Output algorithm.

CTRALG The CONTROL ALGORITHM lets you select the type of control that is best for your process.

ONOF ONIOFF is the simplest control type. The output can be either ON (100%) or OFF (0%). The Process Variable (PV) is compared with the set point (SP) to determine the sign of the error (ERROR = PV-SP). The ONIOFF algorithm operates on the sign of the error signal.

In Direct Acting Control, when the error signal is positive, the output is 100%; and when the error s~gnal is negative the output is OO/O. If the control action is reverse, the opposite is true. An adjustable overlap (Hysteresis Band) is provided between the on and off states.

DUPLEX ON/OFF is an extension of this algorithm when the output is configured for Relay Duplex. It allows the operation of a second ONIOFF output. There is a deadband between the switching points of the relays and a hysteresis band for the on and off states of each relay. Both Deadband and Hysteresis are separately adjustable. With no relay action the controller will read 5O0/0.

PlDA PID A is normally used for three-mode control. This means that the output can be adjusted somewhere between 100% and 0%. It applies all three control actions -- Proportional (P), Integral (I), and Derivative (D) -- to the error signal.

Proportional (Gain) -- regulates the controller's output in proportion to the error signal (the difference between Process Variable and Set Point).

Integral (Reset) -- regulates the controller's output proportional to the size of the error and the time the error has existed (the amount of corrective action depends on the value of proportional Gain).

Derivative (Rate) -- regulates the controller's output in proportion to the rate of change of the error (the amount of corrective action depends on the value of proportional Gain).

PD + MR PD WITH MANUAL RESET is used whenever integral action is not wanted for automatic control. The equation is computed with no integral contribution. The MANUAL RESET, which is operator adjustable, is then added to the present output to form the controller output. If you select PO with Manual Reset you can also configure the following variations

PO (Two Mode) control, P (Single Mode) control.

Set Rate to 0 Other prompts affected: "MANRST"

CTRALG (continued) TPSC

Three Position Step Control is an extension of the On/Off Duplex control. It lets you control a valve or other actuator with an eletric motor driven by the output relays. These relays actuate two sets of coils, one to move clockwise and the other counterclockwise without a feedback slidewire linked to the motor shaft. There is internal feedback of the state of the relays. The effect of the control action is that the On,Off times of the output relay change in proportion to the error signal and the Gain and Reset tlme settings. A TPSC controller provides an estimated posltlon of the motor since the motor is not using any feedback from a slidewire. The Deadband is adjustable rn the same manner as the Duplex Output algorithm.

INPUT 2 algorithm allows you to enable or disable the second input.

€NAB Enable lnput 2

DIS Disable lnput 2

OUTALG The OUTPUT ALGORITHM lets you select the type of output you want.

RLY RELAY SIMPLEX -- Type of output using one SPDT relay. Its normally open (NO) or normally closed (NC) contacts are selected by positioning an internal jumper. (See "Preliminary Checks" in the Installation section.)

Other prompts affected: "OUTHYST"

CUR CURRENT SIMPLEX -- Type ot output using one 4 to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 750 ohms. The signal can be recalibrated for any desired range trom 4 to 20 mA for 0 to 100% output.

RLYD RELAY DUPLEX -- Type of output using two SPDT relays. Its normally open (NO) or normally closed (NC) contacts are selected by positioning an internal jumper for each relay. (See "Preliminary Checks" in the Installation section.)

Other prompts affected: "DEjPDBAND" and "OUT HYST"

51-52-19-12, Page 8-3

UDC 2000 APPENDIX A

SP RAMP / SP PROGRAM This data deals with enabling Single Set Point Ramp function and enabling Set Point Rarnp.;Soak Programrn~ng. You can start and stop the ramp or program using the Run~Hold key.

SP RAMP Make selection to enable or disable the set point ramp function. Make sure you configure a ramp time and a final set point value.

ENAB Allows the single set point ramp prompts to be shown.

DIS Must select disable to use the Set Point RampISoak Programming option.

TI MIN The Single Set Point Ramp Time is the time it takes to go from start to the final set point on a single set point ramp. 0 will imply an immediate change in set point to the final set point.

Enter the number of minutes desired to reach the final set point.

FIN LSP The controller will operate at the set polnt set here at the completion of the single set point ramp. Enter the desired value.

SPPROG

DIS Must select disable to use the SP Ramp option.

ENAB Allows the prompts for Set Point Ramp/Soak Programming.

See the Operation Section for definitions and prompt hierarchy.

5 1-52- 19- 12, Page 8-4

UDC 2000 APPENDIX A

AUTOTUNE Autotune automatically calculates Gain, Rate, and Reset Time (PID) tuning constants for your control loop. When initiated on demand, the Autotune algorithm measures a process step response and automatically generates the PID tuning constants needed for no overshoot on your process.

1

AT ENB

DIS Disables the Autotune function.

ASTP Automatic steps let you perform an Autotune with a step size automatically generated.

MSTP

Manual step lets you choose an output step size in percent, that will be large enough to result in a PV change. The value of the output step size is selected under function prompt 'OUT STP."

OUTSTP Choose an output step size, in percent, that will be applied to the output of the controller when Autotune is initiated. This step must be large enough to result in a process variable (PV) change of at least 2.5% of span. This step can be predetermined by stroking the process in manual mode.

The process can be tuned using either an upscale or downscale step change.

AT ERR See the Operating section for a list of error prompts.

51-52-19- 12, Page 8-5

UDC 2000 APPENDIX A

INPUT1 These are the parameters required for input 1; temperature units, decimal location, actuat~on, high and low range values in engineering units, bias, filter, burnout, emissivity, frequency, and display default.

DECMAL DECIMAL POINT LOCATION -- This selection determines where the decimal point appears in the display.

None One Place Two Places

UNITS TEMPERATURE UNITS -- This selection will affect the indicator. What display of temperature do you want.

F = Degrees Fahrenheit C = Degrees Celsius None = None

INlTYP INPUT 1 ACTUATION TYPE -- This selection determines what actuation you are going to use for input one. b B thermocouple E H E thermocouple high E L E thermocouple low J H J thermocouple high J L J thermocouple low K H K thermocouple high K L K thermocouple low N NiNiMo thermocouple R R thermocouple S S thermocouple T H T thermocouple high T L T thermocouple low W W thermocouple 1 OOH 100 ohm RTD high 100L 100 ohm RTD low 4-20 4 to 20 milliamps 10.M 0 to 10 millivolts 1 OOM 0 to 100 millivolts 0-1 0 to 1 volt 0-5 0 to 5 volts 0-10 0 to 10 volts 1-5 1 to 5 volts NIC Nicrosil Nisil Thermocouple RADl Radiamatic RH

IN1 HI INPUT 1 HIGH RANGE VALUE in engineering units. Scale the #I input signal to the display value you want for 100%. Example:

Actuation (Input) = 4 to 20 mA Process Variable = Flow Range of Flow = 0 to 250 GalIMin High Range display value = 250 Then 20 mA = 250 GalIMin

The control set point will be limited by the range of units selected here.

IN1 LO INPUT 1 LOW RANGE VALUE in engineering unlts. Scale the #I input signal to the display value you want tor 0%. The control set point for Input 1 will be limited by the range of units selected here.

BIAS 1 BIAS ON INPUT 1 -- Select the bias value you want on input one.

FILTR1 FILTER FOR INPUT ONE -- A sottware dig~tal filter is provided for input 1 to smooth the Input signal. You can configure the first order lag time constant from 0 to 120 seconds. If you don't want filtering, enter 0.

BRNOUT BURNOUT PROTECTION (SENSOR BREAK) provides thermocouple types with upscale or downscale protection if the input tails. NONE NO BURNOUT -- Failsafe output applied for tailed input.

UP UPSCALE BURNOUT will make the indicated PV signal increase when a sensor fails, and flash the upper display.

DOWN DOWNSCALE BURNOUT will make the indicated PV signal decrease when a sensor fails, and flash the upper display.

EMlSSlVIN EMlSSlVlTY FOR RADIAMATIC (RH) INPUTS A radiarnatic pyrometer converts radiant energy emitted by a target into electrical energy. Emissivity is a correction factor applied to the radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a pertect radiator. Range: 0.01 to 1.0

FREQ Power Line Frequency - Select whether your controller is operating at 60 Hz or 50 Hz.

60 Hertz 50 Hertz

DISPLY Default Display Configuration - select what the default display will be during normal operation:

PR - N Upper display - PV value Lower display - blank

PR - Y Upper display - PV value Lower display - PV

SP Upper display - Set Point value Lower display - SP

5 1-52- 19- 12, Page 8-6

UDC 2000 APPENDIX A

INPUT2 These are the parameters required for input 2; high and low range values in engineer~ng unlts, f~iter.

IN2 HI INPUT 2 HIGH RANGE VALUE in engineering units, for linear actuations only. Scale the #2 input signal to the display value you want for 100%.

Example: Same as input one.

IN2 LO INPUT 2 LOW RANGE VALUE in engineering units, for linear actuations only. Scale the #2 input signal to the display value you want for 0%.

Example: Same as input one.

FlLTR2 FILTER FOR INPUT TWO -- A software digital filter is provided for input 2 to smooth the input signal. You can configure the first order lag time constant from 0 to 120 seconds. If you don't want filtering, enter 0.

51-52-19-12. Page 8-7

UDC 2000 APPENDIX A

CONTRL

The functions listed in this group deal with how the Mini-Pro will control the process including: Set point source, Ratio, Bias. Set point limits, Output direction and limits, Deadband, Hysteresis and Failsate.

SP SRC SET POINT SOURCE -- This selection determines what your set point source will be; One local, Remote, or Two local-Key toggled.

1 LOC LOCAL SET POlNT -- The set point entered from the keyboard.

REM REMOTE SET POINT -- A signal is brought in through the input 2 terminals and used as the control set point. Ratio and Bias can be applied to the remote set point.

2LOC TWO LOCAL SET POINTS -- This selection lets you switch between two local set points.

RATIO RATIO -- Used when input 2 operates as a remote set point, prompt "RSP." This ratio value can be applied to the remote set point. It establishes the correct relationship between the remote set point and the input 2 signal applied according to the formula below ...

BIAS -- Used when input 2 operates as a remote set point prompt "RSP." Bias, together with ratio, establishes the correct relationship between the remote set point and the input 2 signal applied according to the formula:

(RATIO x INPUT 2) + BIAS = REMOTE SET POINT

SP HI SET POlNT HIGH LIMIT' -- This selection prevents the local and remote set points from going above the value selected here. The setting must be equal or less than the upper range of input 1 and input 2. lnput 2, when configured for remote set point, will be restricted to this upper limit.

SP LO SET POINT LOW LIMIT' -- This selection prevents the local and remote set points from going below the value selected here. The setting must be equal or greater than the lower range of input 1 and input 2. Input 2, when configured for remote set point, will be restricted to this lower limit.

PWR UP SET POINT AT POWER UP -- Thls select~on determines which set point the controller w11l use when the controller restarts after a power loss

ALSP LOCAL SET POINT -- The set point entered from the keyboard

ARSP REMOTE SET POlNT -- A signal brought In through the input 2 terminals and used as the control set point.

ACTION CONTROL OUTPUT DIRECTION -- Which direction do you want the controller output to go when the process var~able increases.

DIR DIRECT ACTING CONTROL -- The controller's output increases as the process vanable Increases.

REV REVERSE ACTING CONTROL -- The controller's output decreases as the process variable Increases.

OUT HI HIGH OUTPUT LIMIT -- This is the highest value of output beyond which you do not want the controller automatic output to exceed. Use 0 to 100% for time proporttonal output type.

OUT LO LOW OUTPUT LIMIT -- This is the lowest value of output below which you do not want the controller automatic output to exceed. Use 0 to 100% tor time proportional output type.

The Local Set Point will automatically adjust itself to be within the set point limit range. For example, i f SP = 1500 and the SP HI LIM is changed to 1200, the new Local Set Point will be 1200.

5 1-52- 19- 12, Page 8-8

UDC 2000 APPENDIX A

CONTRL (continued)

DBAND DEADBAND is an adjustable gap between the operating ranges of output 1 and output 2. It is the difference between the nominal trip points of relay 1 and relay 2.

HYST HYSTERESIS (OUTPUT RELAY ONLY) is an adjustable overlap of the ONIOFF states of each control relay. This is the difference between the value of the process variable at which the control reiay(s) energize and the value at which they de- energize. Only applicable for ON-OFF control.

FAILSF FAILSAFE OUTPUT VALUE -- Select the value you want the output to be when power is returned after a power-down. The value used here will also be the output level when input 1 fails, tor all inputs except TIC. Similarly, the value used here will be the output level when no burnout is configured and input 1 fails for TIC inputs.

PB or GN PROPORTIONAL BAND UNITS -- Select one of the following:

PB PROPORTIONAL BAND selects units of percent proportional band for the P term of the PID algorithm.

GN GAIN selects the unitless term of gain for the P term of the PID algorithm.

MINRPM RESET UNITS -- Selects units of minutes or repeat per minutes for the I term of the PID algorithm. 20 Repeats per Minute = 0.05 Minutes per Repeat.

RPM REPEATS PER MINUTE -- The number of times per minute that the proportional action is repeated by reset.

MIN MINUTES PER REPEAT -- The time between each repeat of the proportional action by reset.

51-52- 19- 12, Page 8-9

UDC 2000 APPENDIX A

OPTONS Contact Input (Remote Mode Switching) and PV (Auxiliary) Output options are mutually exclusive. Configure the contact input to a specific contact closure response, or configure the PV Output to be a specific select~on with desired scaling.

REM SW REMOTE SWITCHING (DIGITAL INPUT) enables remote selection of set point source (SPllSP2).

NONE No remote switching

LSP TO LOCAL SET POINT -- Contact closure puts the controller into local set point if in Remote.

SP2 TO LOCAL SET POINT TWO -- Contact closure selects set point 2 if in Set Point 1.

HOLD HOLD SET POINT FiAMP/PROGRAM -- Contact closure holds set point ramp or program. DIS KB DISABLE KEYBOARD -- Contact closure disables the operator interface keyboard

AUXOUT AUXILIARY OUTPUT SELECTION provides a voltage output representing they process variable. The display for auxiliary output viewing will be in engrneertng units.

Other prompts affected by this selection: "OPCT" and - " I OOPCT. "

NONE No auxiliary output

PROC PROCESS VARIABLE -- Represents the value of the Process Variable.

0 PCT PV (AUXILIARY) OUTPUT LOW SCALING FACTOR -- Use a value in engineering units for Process Variable.

100 PCT PV (AUXILIARY) OUTPUT HIGH SCALING FACTOR -- Use a value in engineering units for Process Variable.

UDC 2000 APPENDIX A

ALARMS An alarm is an indication that an event that you have configured (for example--Process Variable) has exceeded one or more alarm limits. There are two alarms available. Each alarm has two set points. You can configure each of these two set points to alarm on the process variable or deviation. There are two alarm output selections, High and Low. You can configure each set point to alarm either on High or Low. These are called single alarms. You can also configure the two set points to alarm on the same event and to alarm both high and low. There is a Fixed Alarm Hysteresis of 0.5% of (PV) Input Span. You can also configure an alarm to go on or off in a segment of Set Point Programming.

AISIVA ALARM 1 SET POlNT 1 VALUE -- This is the value at which you want the alarm type chosen in Prompt "A1 S1 TY' to actuate. The value depends on what the alarm set point has been configured to represent. Also, segment No# for EVON 1 EVOF.

A1S2VA ALARM 1 SET POlNT 2 VALUE -- This is the value at which you want the alarm type chosen in Prompt "AlS2TY" to actuate. The value depends on what the alarm set point has been configured to represent. Also, segment No# for EVON 1 EVOF.

A2S 1 VA ALARM 2 SET POINT 1 VALUE -- This is the value at which you want the alarm type chosen in Prompt "A2S1TY" to actuate. The value depends on what the alarm set point has been configured to represent. Also, segment No# for EVON 1 EVOF.

A2S2VA ALARM 2 SET POlNT 2 VALUE -- This is the value at which you want the alarm type chosen in Prompt "A2S2TY" to actuate. The value depends on what the alarm set point has been configured to represent. Also, segment No# for EVON 1 EVOF.

AISITY ALARM 1 SET POlNT 1 TYPE -- Select what you want set point 1 of alarm 1 to represent. It can represent the process variable or deviation. NONE No alarm PROC Process Variable DE Deviation EVON Event ON (SP Programming) EVOF Event OFF (SP Programming)

AlS2lY ALARM 1 SET POlNT 2 TYPE -- Select what you want set point 2 of alarm 1 to represent. The selections are the same as A1 S1 TY.

A2S1TY ALARM 2 SET POlNT 1 TYPE -- Select what you want set point 1 of alarm 2 to represent. The selections are the same as A1 S l TY. NOTE: Not applicable with relay duplex output.

A2S2TY ALARM 2 SET POINT 2 TYPE -- Select what you want set point 2 of alarm 2 to represent. The selections are the same as A1S1TY. NOTE: Not applicable with relay duplex output.

A1SIHL ALARM 1 SET POlNT 1 STATE -- Select whether you want the alarm type chosen in Prompt "A1 SlTY" to alarm HlGH or LOW.

If SP Programming is configured do you want alarm on begin or end event.

HI High alarm LO Low alarm BEGN Beginning Event END End Event

A1S2HL ALARM 1 SET POlNT 2 STATE -- Select whether you want the alarm type chosen In Prompt "AlS2N" to alarm HlGH or LOW.

If SP Programming is configured do you want alarm on begin or end event. HI High alarm LO Low alarm BEGN Beginning Event END End Event

A2S1 HL

ALARM 2 SET POlNT 1 STATE -- Select whether you want the alarm type chosen in Prompt "A2SlTY" to alarm HlGH or LOW.

If SP Programming is configured do you want alarm on begin or end event. HI High alarm LO Low alarm BEGN Beginning Event END End Event

A2S2HL

ALARM 2 SET POINT 2 STATE -- Select whether you want the alarm type chosen in Prompt "A2S2TY" to alarm HlGH or LOW.

If SP Programming is configured do you want alarm on begin or end event.

HI High alarm LO Low alarm BEGN Beginning Event END End Event

UDC 2000 APPENDIX A

CAL The prompts used here are for field calibration purposes. Refer to the Calibration section in this manual for complete information.

L

READ The prompts used here are for determining the reason for a controller failure. Refer to the Troubleshooting section in this manual for complete information.

APPENDIX B MANUAL TUNING

When you tune a controller, there are some things to consider:

Process Characteristics -- Gain (PB), Time, Constants, etc. Desired Response -- Minimal overshoot

Basically, controller tuning consists of determining the appropriate values for the Gain (PB), Rate (Derivative), and Reset (Integral) Time tuning parameters (control constants) that will give the control you want. De- pending on the characteristics of the deviation of the process variable from the set point, the tuning parameters interact to alter the controller's output and produce changes in the value of the process variable. Since each parameter responds to a specific characteristic of the deviation, you may not need a combination of all three. It depends on the process characteristics and the desired control response.

You can estimate a starting point and the tuning parameters required to give the desired controller response and with some experience become proficient with this method.

An alternate approach is to rely on a tuning technique. In practice, tuning techniques usually do not give exactly the type of response desired; thus, some final adjustments to the tuning parameters must be made. However, you should at least obtain a reasonable starting point from which the desired response characteristics can be obtained.

The tuning method presented here requires finding the Gain (PB) of a proportional-only controller that will cause the loop to cycle indefinitely with a constant amplitude. This Gain (PB) is called the ultimate (measured) Gain (PB).

Tune out all rate and reset (integral) time action. Introduce an upset into the loop, and adjust the Gain (PB) until the loop cycles continuously. Record the value of Gain or PB and the period of time for one oscillation of the process variable (measured time).

Determine the setting from the table of formulas given in the procedure.

CONTROLLER TUNING PROCEDURES There are two procedures for tuning the controller:

Time or Current Proportional control,

Duplex Time Proportional control,

SECTION 9

The suggested procedures describe how to establish and store values of Gain (PB), Rate, and Reset (integral) time constants for your process. You must know the type of control and algorithm your controller has.

A graphic recorder (such as Honeywell model DPR, DR 4500, or VP131) connected to the process variable will make it easier to determine when the oscillations are constant and the time for one osc~llation. If a recorder is not available, you can use a stop watch to time the oscillation of the process variable displayed on the controller.

TlME OR CURRENT PROPORTIONAL CONTROL Procedure STEP 1 Adjust the output to bring the PV (Process Variable) near the desired value. When obtaining HEAT tuning parameters, the output must remain above 50% (to obtain COOL tuning parameters see the procedure for Duplex Time Proportional Control).

STEP 2 Set Rate Time (RATE T) to 0 nlinutes and set Reset Time (IMIN) to maximum value to minimize Reset action.

If applicable, set CYCLE TlME (CYC TI) to 2 seconds and DEADBAND (DBAND) to 0.5 ~f applicable.

STEP 3 lncrease GAIN (decrease PB) significantly. Try a factor of 10 (PB= 10). STEP 4 Adjust the local set point to equal PV.

STEP 5

lncrease the set point by 5 or 10O/0 and observe the process variable response.

STEP 6 If the PV oscillates, continue to the next step. If it doesn't oscillate, return to the original set point and increase GAIN (decrease PB) again by a factor of 2. and repeat step 5.

STEP 7 Compare the oscillations with Figure 9-1 shown on next page.

M the oscillation matches pattern A, go to STEP 8.

UDC 2000 APPENDIX B

If the oscillation matches pattern 0, increase GAIN The "TUNING" function prompts for HEATICOOL are: (decrease PB) by a factor of 2 and repeat steps 4 to HEAT - COOL 6.

PB or GAlN GAIN2 If the oscillation matches pattern C, decrease GAIN IRATE T (increase PB) by a factor of 0.5 and repeat steps 4 MIN or lRPM

RATE2T

to 6. 12MIN or I2RPM RESET2

CYC TI CYC2 TI The amplitude of the cycle is immaterial, but all of the elements of the loop must be within the operating range (i.e., the valve must not go full open TABLE or full closed).

STEP 8 Record the current value of GAlN (or PB) and measure and record the value of time for one complete oscillation of PV (in minutes).

STEP 9 Select the proper set of formulas from the Table 9-1. Use the values of GAlN (or PB) and time (in minutes) in the formulas to arrive at the controller's tuning parameters settings.

STEP 10 Enter the values of GAlN (or PB), RATE, and RESET in Minutes (or Repeats per minute) into the Mini-Pro and verify that the PV response is adequate. Make additional trimming adjustment if necessary to fine tune the controller per the guide lines shown below:

To Reduce Overshoot

Less Gain (More PB) Perhaps longer Rate Time

To lncrease Overshoot or Increase Speed or Response

More Gain (Less PB), perhaps shorter Rate Time

DUPLEX TIME PROPORTIONAL CONTROL For HEAT/COOL applications, tune the controller with the output above 50% for HEAT and below 50% for COOL.

1

Process

Vanable

51-52-19-13. Page 9-2

P a m B P a m C

lime tor one cycle

1 1 1 1 1 1 1 1 1 1 1 1 1 1

k

PrOpdOnal, (PI only

P w + Reset, (PI) (NO Rate)

Pl'OpOIWWIBI + Reset + Rate (PID)

T ~ m e F~gure 9-1

Units

GAIN and RESET TIME in

Minutes Repeat

GAIN = Measured Ga~n X 0 5

RESET TIME = 50 00 (rnmtrnurn reset)

RATE = 0

GAlN = Measured Gdtn x o 45

RE- TIME (MIR) = Measured T~mc -

1 2

RATE = 0

GAIN = Measured Galn x o 6

RATE = Measured Tlrne -

8

RESEF = Measurd Tlrne

2

% PROPORTIONAL BAND and RESET ACTION in

Repeats Minute

% PB = Measured PB X 2

RESET ACTION = o OL (repealsni~rrult?)

RATE = 0

70 PB = Measured PB x 2 2

RESET ACTION (RIM) = 1 2

Measurud Tlrnc

RATE = O

?. PB = Measured PB x 1 7

RESET ACTION = 2

Muasur~d T I ~

RATE = Measured

8

APPENDIX C SECTION 10

HOW TO APPLY DIGITAL lNSTRUMENTAT/ON IN SEVERE ELECTRICAL NOISE ENVIRONMENTS

Introduction Products which incorporate digital technology provide recognized performance advantages over conventional analog instrumentation used for process control. These advantages can result in better product uniformity and greater overall efficiency when used correctly.

There are, however, certain guidelines regarding installation and wiring which must be carefully followed in order to achieve this performance. In addition to the traditional precaution of the separation of signal and power wiring in separate conduits, other measures must be taken to minimize the effects of electromagnetic interference (EMI) and radio frequency interference (RFI) on the operation of the equipment. Otherwise, if high level, short duration, noise spikes are permitted to enter the digital equipment, the noise can be transferred into the system's logic networks and can be misinterpreted as signal data, resulting in erroneous system operation and other unpredictable responses.

Potential Noise Sources Noise can enter electronic equipment via three methods of coupling, namely:

capacitive (or electrostatic) inductive (or magnetic) impedance

Capacitive and inductive coupling have the same essential effect -- they couple current or voltage, without any actual connection of the two circuits. Impedance coupling requires a connection between the two circuits.

Typical noise-generating sources that could affect electronic equipment through capacitive and inductive coupling include: 8 Relay coils

Solenoids AC power wires -- particularly at or above 100 Vac

8 Current carrying cables Thyristor field exciters Radio frequency transmissions

lmpedance couple noise may enter by way of the lines used to power the digital equipment or by way of improper grounding. Most power lines, at typical industrial locations, are far from noise-free. The noise on them can be generated in many ways, but are

nearly always associated with switching circu~ts of some, nature. These include:

large relays contactors motor starters business and industrial machines power tools HID (High Intensity Discharge) lights Silicon Controlled Rectifiers (SCRs) that are phase angled fired.

These are three ways to prevent electrical noise from interfering with the operation of the electronic digltal equipment. One is to suppress the noise at its source. This is the most effective but also the most difficult because it is not easy to identify all of the potential noise sources in a typical industrial installation. There- fore, "suppression" is usually a last resort for those extreme situations where the other methods are insufficient by themselves. The second method is to prevent noise from getting on the signal and power lines that are connected to the equipment. This is achieved by proper separation and shielding of those lines. In some cases separate power lines or special power line regulation or filtering may be required for satisfactory electronic digital equ~pment operation. It is the responsibility of the installer to follow good wiring practices.

The third method is to design the digital equipment with a high degree of noise rejection built-in. This includes housing the equipment in a case that will provide shielding, liberal use of noise rejection filters and opto-isolators, and the use of noise suppressors on potential noise sources within the equipment itself. This, of course, is the responsibility of the manufacturer who usually performs extensive laboratory and field testing of newly designed digital equipment to insure the adequacy of its immunity to noise. As a minimum requirement, the equipment should be able to pass the tests outlined in the IEEE Standard 472- 1974 (Surge Whstand Capacity Tests).

Recommended Wiring Practices All wiring must conform to local codes and practices.

W~res carrying similar types of signals (Table 10-1 ) may be bundled together, but bundles with different types of signals must be kept separated to prevent inductive or capacitive coupling.

For distances over five (5) feet, and when shielding is recommended, use a separate metal tray or conduit for each bundle. Where conduits or trays are not practical, use twisted wires with a metal

51-52-19-14, Page 10-1

UDC 2000 APPENDIX C

overbraid and provide physical separation of at least one foot.


When unlike signal levels must cross, either in trays or conduits, they should cross at a 90degree angle and at a maximum spacing. Where it is not possible to provide spacing, a grounded steel barrier or grid should be placed between the unlike levels at the crossover points. Trays containing low level wiring should have solid bottoms and sides. Tray covers must be used for complete shielding. Tray cover contact with side rails must be positive and continuous to avoid high reluctance air gaps, which impair shielding. Trays for low level cables should be metal and solidly grounded.

Wires containing low level signals should not be routed near any of the following:

- contactors - motors - generators - radio transmitters - wires carrying high current that is being switched

on and off

Power Source The AC power for the digital electronic equipment must be within the voltage and frequency limits specified for that equipment. Attempts to operate outside the specified limits will result in no performance. For those installations where the supply voltage will not stay within the specified limits; a ferro-resonant transformer, for voltage resolution, should be used.

For protection against noise, the AC source for the digital electronic equipment should be independent of all other loads especially when switching loads are involved. For example, it should not provide power for air-conditioning, convenience outlets, lighting, motors, or similar noise generating devices. To obtain electrical isolation (figure 10-1 ) a separate transformer is required to supply power to the digital equipment. For additional noise and transient reject~on, shielded primary and secondary windings may be required. And if necessary, power line filters may be added to attenuate noise signals that have a higher frequency than the power line frequency.


All shields should be grounded at one end only -- preferably the instrument end.

TABLE 10-1 - External Wiring

5 1-52- 19- 14, Page 10-2

Wire Function Bundle No.

1

2

3

No. 1

1 2 3

4

5

6 7

Are Shielded Twisted Wires Recommended?

I

NO

YES

I

YES

L

Type

HIGH VOLTAGE Line Power Earth Ground bne Voltage Digital I10

ANALOG VO Process Varlable

RTD Thermocouple dc Millivolts

Low Level ( < 1 OOV) 4-20 mA dc 1-5 Vdc

DIGITAL I10 Low Voltage (< 100V) Computer Interface

r----------1 I I

To digital 1201240 Vac electronic single phase equipment

I I I i I G

- -

Figure 10-1 -- Transformer for digs equipment

Noise Suppression at the Source Generally speaking, when good wiring practices are used with well designed digital electronic equipment, no further noise protection is necessary. However, in some severe electrical environments, the magnitude of the electrical noise is so great that it must be suppressed at the source. In most control cabinets. the main sources of noise are motor starters, contactors, relays, and switch gear. For this reason, many manufacturers of these devices supply "surge suppressors" which mount directly on the noise source, for example, on the coil of a control relay or motor starter. For those devices that do not have accessory "surge suppressors," resistance-capacitance (RC) circuits andlor voltage limiters such as metal varistors may be added when and where needed. This can be broken down into two categories, namely inductive loads(e.g., a relay switch in series with a relay coil) and contacts.

Inductive Coils: Metal Oxide Varistors (MOVs) are recommended for transient suppression in inductive coils. An MOV is connected in parallel with the coil and is as close as physically possible to the coil (Figure 10-2). MOV devices (Table 10-2) are recommended for general purpose applications.

UDC 2000 APPENDIX C

TABLE 10.2 - MOV Devices

30732481901

Maximum AC 130V

Energy Pulse Rating 10 Joules

Supplier (General Vl3OLAl OA Electric)

51 -52-19-14, Page 10-3

30732481902

275V

15 Joules

V275LA15A

Ftgure 10-2 -- Translent suppressloci III lnduct~ve colls .

UDC 2000 APPENDIX C

Noise Suppression at the Source (continued) Additional protection may be provided by adding an RC circuit in parallel with the MOV. This consists of a 220 ohm resistor in series with a 0.5 microfarad, lOOOV capacitor. The power rating of the resistor will depend on the voltage rating of the coil (Table 10-3).

TABLE 10.3 - Coil Voltaae vs Resistor Voltaae Rating

I Coil Voltage I Resistor Voltage Rating I I 115V I 114 Watt I I -

-

230V I 1 Watt I

Contacts: When a contact interrupts an inductive load, a certain amount of energy is stored in the load. An MOV or RC circuit in parallel with the load provides a place where this energy may be dissipated. However, if there is no MOV or RC circuit, the energy may create a visible electrical arc across the open contacts. And this, in turn, results in electrical noise as well as damage to the contacts.

460V

550V

One way to eliminate this arc is to connect a resistor and capacitor across the contacts (Figure 10-3). A combination of 47 ohms and 0.1 microfarads (1000 Vdc) is recommended for circuits up to 3 amps and 300 Vac. And for voltage above 2000 Vac, an MOV across the contact may be added for extra protection.

3 Watt

5 Watt

For large load currents, a rule-of-thumb is to size the capacitor so that the number of microfarads equals the number of amperes in the load current, and the resistor is the same value as the load. This objective is to eliminate the visible arc. Either discreet resistors and capacitors or packaged RC networks may be used. An RC network (47 ohms and 0.1 microfarad) is available from Honeywell as part number 30371 852-001. Similar RC networks are available from Electrocube Inc. (part number RG1782-3) and from Industrial Condensor Corporation. In DC circuits, the power dissipation under steady- state condition can be eliminated by placing a diode (in series with a resistor) in parallel with the load (Figure 10-4). The value of R should be less than or equal to the DC resistance of the inductive load.

J

i-" I I I

; lnduct~ve

Figure 10-3 -- Contact rase suppression

.

D.C. - supply

Diode

Figure 104 -- DC load nase suppresson

51-52-19-14, Page 10-4

READER COMMENTS Honeywell's IAC Automation College welcomes your cornmentsand suggestions to improve future editions of this and other publications.

You can communicate your thoughts to us either by mall using this form, or a toll-free telephone call.

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BY M . Use this form; detach, fold, tape closed, and mail to us. We would like to acknowledge your comments; please include your complete name and address.

Title of Publication: UDC#)OO Unhrersal Digital Controller Product Manual

Publication Number: 51 -52-25-1 4A Issue Date: 1/93

Writer Dan O'Connor

RECOMMENDATIONS:

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COMPANY ADDRESS CTTY STATE ZIP


Communications concerning technical publications should be dhcted to:

Automation W e g e Industrial Automation and Control Honeywell Inc. 2820 West Kelton Lane Phoenix, Arizona 85023

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NECESSARY IF MAILED

Attention: Manager, Quality I - - . .---------. . I------.-------------

I

INDEX NO. 25

PRESSURE INDICATOR

PI-017-A, PI-017-B

WRY no. s.o.7urc

3 HOLES x2 (5,s) EQUALLY S P A C E D 01.1 5 3/)3 (137) D I A. B0l.T C 1 RCCE

Job Badger

- - a

$3 F 8 \

CJ

American Hydro therm I n s t a l l a t i o n AM2579

D v dOTE -1 - 4 % - \ 2 7 9 - 5 , - ' ~ ~ , - % ,

-hQ OR l/z U P T LOWER COMN PHEUOL

, R" &. a-? m-

i: :by X2 ti"

I f

2

H

TURRET C A S E WALL MOUNTED DUKAGAUGE.

D \ M E M S \ O M S \M ( ) A R E M\LLIMET€E5.

, THIS PRINT CCRTIFIED CORRECT FOR d GENERAL DIMEI . IS \O~ . IS

CUSIOMERS NAME S E E hlO-T€.-%

A m r r i c n n Hydro therm Corpora tion v

@ i j Z S!-currouni DaE-

OlrWIMo.

2579-26096

OIW NO. INPUITFIlAL VALV8 O INICTRUMINT DIVIBION a=T-0. CONNECTICUT 06487

1HA829 76 CRTIFIED DATE b Jeanne Husted March 3, 1993

J

ASHCROFT@ PRESSURE GAUGE INSTALLATION INSTRUCTIONS

GAUGES ARE INSTRUMENTS. HANDLE THEM CAREFULLY

Pressure Ranges-Select a gauge with a full scale pressure Apply pressure Slowly. Do not open the gauge cock or valve range of approximately twice the normal operating pres- too quickly-this imparts a severe strain on the Bourdon sure. The maximum operating pressure should not exceed tube which may rupture it, or result in shortened life. When approximately 7!i0/i of the full scale range. Failure to selecta the service itself is subject to sudden Pressure applications, gauge range within this criteria may ultimately result in use a needle valve, or the Ashcroft Gauge Saver. fatigue failure of the Bourdon tube component. Avoid over-pressure. See that the apparatus is provided with

a relief valve and that the range of the gauge is higher than

Always use a wrench on the flats of the gauge socket to screw the gauge in place. When a fitting is being screwed to the gauge, hold a wrench on the socket flats instead of twisting against the gauge socket screws which are intended to hold the gauge mechanism in the case.

When gauges are mounted on a wall or panel, make sure they are connected free from piping strains. Also see that the mounting surface is flat, or insert washers under the flange of the gauge case to obtain three-point suspension. Preferably, the last length of piping leading up to the gauge should be flexible tubing. This will insure that the gauge is free from strain. Install gauges where they will be free from the effects of mechanical vibration as this will wear out any gauge quickly. Try to mount the gauge on a wall nearby and connect the gauge to the machine which vibrates badly by means of flexible line assembly.

Protect gauges from frequent pressure pulsations by using throttle screws in the socket of the gauge, needle valves, pulsation dampeners, or pressure snubbers.

When any gauge is used for steam pressures, a siphon filled with water must be installed between thegauge and the line. When the system is subject to occasional vacuum, provide a leg of piping which cannot be emptied by the vacuum effect. A drain cock or plug should be installed at the bottom of this leg to enable occasional cleaning out of the sediment. The head effect of this piping leg should be compensated for by resetting the pointer of the gauge.

The operating conditions to which a gauge will be subjected must be considered. If the gauge will be subjected to severe vibration or pressure pulsations, liquid filling the gauge may be necessary to obtain normal product life. Other than discoloration of the dial and hardening of the gasketing that will occur as ambient temperatures exceed 150" F, metal case Duragauges (that are not liquid filled) can withstand continu- ousambient temperatures as high as 350" F. Phenol and polypropylene case gauges can withstand ambient temperatures up to 250" F. Accuracy will beaffected by approximately 1.5O/0 per 100°F. Gauges with welded joints will withstand 750°F (450°F with silver brazed joints) for short times without rupture, although other parts of the gauge will be destroyed and calibration will be lost. For temperature limits on other gauges see General Service Bulletin GS1, Special Service SG1 and Test Gauge Bulletin TG-1.

the set pressure of the relief valve. Sudden Dressure release has the same detrimental effect and sho"ld be compensated for in the same manner as for pressure applications mentioned above. On hydraulic presses, Catalog Number 1056 or 1009DH Gauges with slotted link should be specified. See Special Service bulletin SG-1.

Replace broken glasses and thus keepdirt out of the working bearings and teeth of the movement mechanism.

Never oil gauge movements or linkages except with high grade instrument oil. Regular oil attracts dirt and becomes gummy, thus causing the gauge to act sluggish and inaccurate.

HEAT AFFECTS GAUGE ACCURACY Approximate error or change in calibration of a Bourdon tube type Pressure Gauge caused by changes in temperature.

Example: Gauge working at 500 p.s.i. pressure and at 280" F. temperature would have a -3% correction and would read 3% or 15 p.s.i. fast.

Form NO. 250-1887-6 Printed in USA.

Phenol Case I \ \

Dial \ isket k r e a d e d .n,

The drawing below shows a typical solid front lower When ordering parts - specify as much of the fol- connection Duragauge with all of the parts designated lowing data as possible: by their standard names. The use of these names will Size (Dial Diameter) - Case Material (Stainless Steel, facilitate the ordering of parts and eliminate any Polypropylene, Aluminum or Pheonol) - Case Type misunderstanding in describing gauge construction. (Open Front or Solid Front) - Ring Design (Slip, Inter-

nal Threaded, External Threaded, Bayonet, Snap or Hinged) - Connection Location (Lower or Back) - Connection Size (l/4" or l12") - Bourdon Tubelsocket

1279 case used to (Material Indicated on Dial) - Dial Range. Specify type

clearly ~ilustrate the number if possible; otherwise, mention whether parts gauge components are for Duragauge, General Service Gauge, Special

Application Gauge, Receiver Gauge or Test Gauge.

~ourdkn ~ube system \ \

Micrometer Window Socket Seal Pointer

R

NOTE: The socket, tube and tip assembly is furnished as one integral unit. The movement issupplied complete.

CALIBRATION PROCEDURE

TYPICAL CONSTRUCTION DETAILS

WITH SLIP RING WITH SNAP RING THREADED RING

GASKET

WINDOW

RlNG

(SOLID FRONT) (OPEN FRONT) (OPEN FRONT)

WITH HINGED RING WITH BAYONET LOCK

BAYONET LOCK RlNG

WINDOW

GASKET

(ST ST. CASEIRING OPEN FRONT)

4 1 r 8 6' GAUGE WlTH THREADED METAL RlNG

GASKET

WlTH BAYONET LOCK RlNG -

(POLYPROPYL

SOLID FRONT)

1. Preliminary Gauge Calibration Setting - (SOLID FRONT GAUGE SHOWN)

I IOOY(IYUI*D -~.,".,. 1 M W Y " I C U O L A S

YQ-YOYI LI(YIII."x.MIYnlm WIQNIY- I YUIII ,U(UOIDII-" *3 'CltOlOLYYO7I.LM

"L"

5 I W . I * L I * . W I I

FF&::?w- - -*e.D*ITI YnlWWTI T*(* I W T I N r n 'Tr 2. Calibration -

a. At zero pressure (or at full vacuum for compound or vacuum gauges), assemble pointer to piniorrshaft in the horizontal position.

b. Apply pressure equal to full rangeand adjust the slide in the segment slot until the pointer has rotated 270 degrees (vertical position).

c. Reduce pressure to zero and reset pointer if necessary to horizontal position. if pointerad- justment was required, repeat step (b) above.

d. Apply pressure equal to mid-scale and drive pointer firmly onto pinion.

e. Recheck calibration at the lower and upper ends of the scale.

3. Linearity Adjustment - Although the procedure outlined above should produce a correctly calibrated gauge, linearity adjustment may be raquired. If Me pointer readscorrectly at the bottom of the scale and low at the top of the scale, rotate the movement to increase the angle between the link and the segment. If the pointer reads high, rotate the movement in the opposite direction.

(SOLID FRONT)

INSTRUMENT DIVISION DRESSER INDUSTRIES INC.

STPATFORD. CONNECTICUT 06497

lDEX NO. 26

THERMOMETER

TI-045-A, TI-045-8

TI-046-A, TI-046-6

INSTRUCTIONS FOR THE INSTALLATION AND USE OF THE ASHCROFT@ "EVERY ANGLE" BI-METAL DIAL THERMOMETER

This thermometer was designed to be positioned to face the direction of easiest reading.

CAUTION

To assure longest life, the "EVERY AN- GLE" joint should be operated only when necessary during installation or removal of the thermometer.

SENSITIVE POSITIONING THE STEM PORTION

FIGURE 1 Before installation, the stem should be set to the desired angle as follows:

FIGURE 1: Loosen the six screws labeled " A and "B" in Figure 1, until the harness revolves freely without twisting the flexible housing.

FIGURE: 2: While holding the case revolve the harness clockwise or counterclockwise as indicated by arrows in Figure 2 to place the harness in a position that will permit flexing the stem in the desired direction with respect to the case. Then lock the two screws labeled "A".

MGURE 3: Flex the stem to the desired angle with respect to the face of the thermometer, as shown in Figure 3, then lock the four screws labeled "B".

FIGURE 2 INSTALLATION

The lower 2" of the stem is the sensitive portion. Be sure this part of the stem is exposed to the temperature to be measured.

Tighten the thermometer to the apparatus or into the thermometer well, using a n open-end wrench applied to the hexagon head of the connection bushing. Turn until reasonably tight, then tighten further (in the same manner as a pipe fitting) until the scale is in the desired position for reading. DO NOT TIGHTEN BY TURNING THE THERMOME- TER CASE OR THE HARNESS. INSTALL THE THERMOMETER SO THAT THE MAXIMUM CASE TEMPERATURE IS KEPT BELOW 200°F.

STEM -\I THEMOMETER WELLS

FIGURE 3 When the thermometer is equipped with a well, the well should first be removed from the ther-

\ mometer and screwed into the apparatus.

Coat the thermometer stem with a heat conducting medium such as a mixture of graphite and glycerine. This improves the speed of response of the thermometer.

If the operating temperature does not exceed 350" F. vaseline or any heavy lubricant may be used as a substitute for the glycerine and graphite mixture.

If the operating temperature exceeds 350 OF. the glycerine and graphite mixture may smoke when first subjected to the high temperature. This is

caused by the glycerine vaporizing, leaving the dry graphite behind and should not be acauseforalarm. The dry graphite will act equally well as a heat conducting medium for temperatures up to 1000" F.

CAUTION: Thermowells should be used on all pressurized applications, to protect the thermometer stem from corrosion or physical damage, and to facilitate removal of the thermometer without disturbing the process.

MAINTENANCE

Aside from occasional testing, little or no mainte- If the thermometer is used for measuring the nance is required. temperature of material that may harden and

build up an insulating layer on the stem, the Be sure that the gasketed glass is On the case thermometer should be removed from the appara- at all times as moisture and dirt inside the case will tus occasionally, and the stem cleaned. observe eventually cause the thermometer to lose its accu- this precaution to insure the sensitivity of the racy. (See caution note below). instrument.

ADJUSTMENT

If it is necessary to make an adjustment to the a coin to turn the slotted hexagon head in the back thermometer proceed as follows: of the case until the pointer indicates the proper On thermometers fitted with an "External Adjust- temperature on the dial. ment" - Use a small wrench. small screwdriver or

CAUTION: Bi-metal Thermometers operating below freezing must have a perfectly tight case to prevent entrance of moisture which eventually will condense and freeze inside the stem. This condition shows up as a failure of the thermometer to read accurately below 32°F. or 0°C. For this reason it is important to avoid damage to the glass front while the stem temperature is at freezing or below.

Thermometers fitted with the non-removable ring are hermetically sealed in a dry atmosphere at the factory and require no further maintenance.

INSTRUMENT DIVISION DRESSER INDUSTRIES INC.

STRATFORD. CONNECTICUT 06497

Form No. 2501068D Printed in U.S.A.

INDEX NO, 27

FLANGED THERMOWELLS

STANDARD FOR U . 2 t ~ ~ t f 6 S

American Hydrotherm Corporat ion

CONNECllCUT 0.0" Ha. 2579-

INDEX NO. 28

SAFETY R E L I E F VALVE

P S V - 1 4 - A , P S V - 1 4 - 8

This is to accredit the nomed company os out)rorized to use the indicated symbol of the American Society of Mechon'rnI Engineers (ASME) for hi xope shown bdow in accordance with the oppfiioble rules of the ASME Boiler and Pressure Vessel Code. The use of the code symbol and the authority gronted by this certificate of authorizotiocr are subject to the provisions of the agreement set forth in the application. Any condruction stamped with this symbd shall have hem built siridly in occordance with the provisions of the ASME Boiler and Presswe Vessel Code.

COMPANY I(UM(LE IHOI#IRIES INC.

dba W L E VALVE O I V I S I W P L M 1 'il so dba L O N E M VAl.VE;OIVISIOH PLANT 1

8222 BLUFFTOM ROAD FORT WAYNE, IWOIAHA 46809

SCOPE

HANUFACTURE OF PRESSURE VESSEL SAFETY VALVES AT THE ABOVE LOCATICM ONLY

AUTHORIZE b OCTOBER 2, 1991

EXPIRES OECEHBER 31. 1994

CERTIFICATE NUMBER 2,367

SYMBOL

CHAIZ?.#.AN GF THE 8011E G AND ?RESSUPE VESSEL C O w M l l rEE

b- e y * DIRECTOR. A W E ACCREDITATION

L-Ser ies Safety Relief Valve

Maintenance Manual

Table of Contents

Page

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . Disc and Base Seat Maintenance

Lapping Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-Ring Seat Option

. . . . . . . . . . . . . . . . . . . . . . . . . . Reconditioning Disc and Base Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Pressure Adjustment & Temperature Correction . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Pressure Correction Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LeakageTesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . Required Ordering Information

L-Series Safety and Relief Valve ~aintenance Manual

General:

The L-Series safety relief valve, formerly known as (and identical to) the LCT safety relief valve, is used in various applications. The valve is National Board capacity certified for ASME Section VIII, Steam, Air, Gas and Liquid service. The Lonergan L-Series valve is offered in a range of sizes from l/2" to 2 inlet and set pressures up to 5000 PSI. Blowdown on the Lonergan L-Series is considered fixed. Refer to the Lonergan catalog or consult the manufacturer's representative for size and pressure limits and ordering information.

L40

Model Identification:

Models covered in this maintenance manual are described on page 2. Refer to the Lonergan catalog or consult the manufacturer's representative for further information.

L14-Series General purpose valve, Male inlet by Fe- male outlet, for ASME Section Vlll Steam, Air, Gas and Liquid. (Formerly LCT- 1 4)

L4O-Series General purpose valve, Female inlet by Female outlet, for ASME Section VIII, Steam, Air, Gas and Liquid. (Formerly LCT-40)

L41-Series General purpose valve, Female inlet by Female outlet, for ASME Section Vlll Steam, Air, Gas and Liquid. (Formerly LCT-40)

NOTE: Lonergan nameplates stamped with JL14, JL40 and JL41 - "J" signifies ASME Section VIII, Liquid service. (Formerly LCT-14L & LCT-40L)

Installation: 1. Always install safety and relief valve in a vertical

position - either directly connected to the equipment or to equal size fittings no longer than the end-to-end dimensions of an American Standard extra heavy TEE.

2. Thoroughly clean the inlet connections to the valve before installation. Remove all foreign matter including rust, grease and tape.

3. When flanged end valves are required, use proper gaskets and flange facings to match those on the valve. Tighten flange bolts evenly to exert uniform pressure. Do not overtighten.

4. Connect discharge piping carefully (as described above) and be certain that the piping is as large as the valve outlet, never smaller.

5. Provide rigid support for the discharge piping, taking special care to see that the valve does not support the weight of the discharge piping.

6. Where long piping is necessary on the discharge end of the valve, increase the size of the piping to minimize back pressure.

Maintenance:

Care must be taken during any phase of maintenance since carelessness can be very destructive and costly. Maintenance of the Lonergan L-Series valve should include, but not be limited to, the following: 1. Pretest - Testing of the valve prior to disassem-

bly to determine opening point, and seat tightness. Pretest results will assist in any maintenance which may be required and servicing schedule.

2. Disassembly - Inspection of parts to determine extent of required repairs.

3. Repairs - Cleaning, reconditioning, replacement, lapping and minor remachining of parts.

4. Assembly - Assembly of the valve and valve components (parts).

5. Valve Testing - Set valve to the nameplate set pressure and check seat tightness.

NOTE: Changing the set pressure to other than nameplate setting may require a spring change. Consult the manufacturer's representative.

Maintenance of the Lonergan L-Series safety and relief valves should be performed by qualified repair personnel at facilities holding National Board Valve Repair Stamps (V.R.).

Disassembly: In order to disassemble the Lonergan L Series safety and relief valve for inspection and maintenance, proceed as follows: 1. Remove the seal wire from the guide pin. Then

remove the guide pin by turning counterclockwise.

2. Removal of the valve cap: Lonergan L Series has three (3) cap options. a. Screwed Cap - Remove seal wire and turn

the cap counter-clockwise and remove. b. Packed Lift Cap - L40 & L41- Remove the

seal wire and retaining ring which holds on the lever. Then unscrew the packing gland housing by turning counter-clockwise. Once the gland housing and shaft are removed, remove the cap by turning it counter~clockwise. L14 - Remove the seal wire and retaining rings on both sides of the lever. Remove the packing gland housing by turning it counterclockwise until the housing and shaft are free of the cap. Remove the cap by turning it counter-clockwise.

c. Plain Lever Cap - Remove the seal wire; remove the yoke pin and yoke. Loosen cap set screws enough to lift cap from the bonnet.

3. Remove the lifting disc nut and locknut. Loosen by holding the lifting disc nut and turning the locknut counter-clockwise. Both nuts should now be free. The lifting disc nut and locknut are only supplied on plain and packed lever cap options.

4. Before removing the compression screw, it is suggested that a measurement be taken from the top of the bonnet to the top of the compression screw. This will enable the compression screws to be replaced in approximately the same position for resetting. Loosen the compression screw locknut and release spring compression by turning the compression screw counter-clockwise.

5. Remove the bonnet by securing the valve base vertically in a vise and turn the bonnet counterclockwise until it is free from the base. Be careful not to damage the bonnet or threads during re-

moval. Lift bonnet off the base slowly without disturbing the stem or spring assembly. Dispose of the gasket. Do not reuse.

6. Lift the stem along with the spring assembly from the valve disc.

7. Remove the disc by lifting it from the valve guide. The 0-Ring disc is disassembled by securing the disc in a soft jaw vise and turning the retaining screw counter-clockwise. Once the retainer screw is removed, lift the retainer plate and O-ring from the disc. (Fig. 1 )

DISC RETAINER SCREW O-RING DISC RETAINER

BASE

-GUIDE

(FIGURE 1)

8. The guide may be removed by turning it counterclockwise and lifting it from the base.

Cleaning: Valve External Parts - May be cleaned using solvents or abrasives. Glass bead and sandblasting are acceptable abrasives. Never use steel shot. Exter- nal parts are as follows:

1. Bonnet 2. Cap 3. Guide Pin

Valve Internal Parts - Should be cleaned using solvents. When abrasives are required, be sure to protect guiding surfaces, seating surfaces, moving parts and threads from contacting abrasives. Internal parts are as follows:

1. Base 2. Compression Screw 3. Disc 4. Guide 5. Spring Steps 6. Spring 7. Stem

Disc and Base Seat Maintenance: Lapping of the disc or base is done either by hand or machine. Hand lapping may be accomplished using

a lap ring or lap plate. When using a lap ring, be sure the lap covers the entire seating surface. Apply a thin even amount of compound to the lap ring and place it onto the disc. Begin lapping in a oscillating motion (back and forth) applying light even pressure, being careful not to rock the piece. Lap part for 1-2 minutes. Remove lap ring and clean both parts thoroughly. Continue lapping sequence until disc seat surface exhibits a gray shadow across the entire surface.

Lapping plates are used in much the same manner as a lap ring except the part is placed on the lapping plate and lapped using a figure 8 motion.

Polishing of the disc and base is accomplished in much the same way with a few exceptions. Use a different lap ring for polishing. This will allow the seat to be polished quicker. Apply a thin even amount of polishing compound to the ring lap; begin polishing the disc using a slow oscillating motion. Continue polishing until the lap ring begins to drag on the seat. Remove and clean both surfaces. Repeat polishing sequence until the seat exhibits a mirror-like finish across the entire seat.

When lapping plates are used for polishing of disc and base, apply a small amount of polish to a clean surface of the plate and rotate the part using an oscillating motion. Method for polishing should be the same as above. (Fig. 2)

LAP RINGS - FIGURE 8 MOTION

LAP PLATE OSCILLATING MOTION

(FIGURE 2)

Lapping Compounds: Lapping compounds may vary from coarse to very fine. Generally a medium compound is used first, then a very fine compound to finish t,he piece. Clean the plate thoroughly after each different compound is used. Coarse compounds are to be used only when removing deep scratches and must always be followed by finer grades. It is advisable to have different compounds. The important considerations for good results are: 1. Cleanliness of lapping plates, parts and

compound. 2. Flat surface for a base.

3. Flat lapping plate. ation of the design geometry. If a part is damaged to 4. Light and correct lapping motion (no rocking of the extent that the surfaces cannot be restored by

~iece). lapping, it is recommended that it be replaced.

5. Change lapping compound frequently.

Recommended Lapping Compounds

Medium - #400 to #a00 Grit Fine - #I000 to #I200 Grit

0-Ring Seat Option: Lapping of the disc is not required because of O-ring seat. NOTE: The O-ring should be replaced if damaged in any

manner. For O-ring replacement, follow instructions in Disassembly, item no. 7. Upon replacement of O-ring, it is necessary that O-ring fits evenly into area provided in disc and that retaining screw is not overtightened.

The base seat of the O-ring valve is different than the standard, in that the seat is flat across the seat width of the entire surface. Minor scratches can be removed by lapping. If the seat damage is too severe for lapping, the base should be replaced. (Refer to Table 1 for dimensions)

Reconditioning Disc and Base:

1. If remachining has to be done in lieu of replacement as recommended, the following should be adhered to: a. Secure the base, or disc, into a four jaw (inde-

pendent) chuck of a engine lathe. Use soft shim material between chuck jaws to prevent damage to guide surface of the disc or wrenching surface of base. Using a dial indicator, align "E" and "D, " of the disc, and "G" and "H" of the base within .001" of each other prior to machining. (Fig. 3)

b. Machine damage portion of seat or disc (as applicable) until damaged area is removed or until minimum dimension "C" is reached.

NOTE: If the base or disc length "C" is less than the minimum dimension shown in Table 1, no further machining is permitted and the disc or base must be replaced.

c. Restore all diameters and angles of machined parts (reference Fig. 3, Table 1).

d. Remove all burrs from machined surfaces. e. Lap base to width (D,) shown on Table 1.

Warning: It is not recommended to remachine the base and disc seating surfaces because this may result in alter-

DRAWING OF DlSC & BASE (REFER TO TABLE 1 FOR DIMENSIONS)

DISC \ \ /

BASE

(FIGURE 3)

ELONERGAN

*A, and *B, to be used for O-ring models only.

NOTE: 1. 3'/2" Angle for model L14 - No angle for O-ring model 2. 3 Angle for model L40, L41 - No angle for O-ring model

DISC AND SEAT CRITICAL DIMENSIONS FOR RECONDITIONING PURPOSES

TABLE 1

Model

I Size

LCT-11

A l l

I 1 .300

LCT-13 LCT-14 & L14

A l l

.300 1 ~1 1 1 1.520 1 .680 1 -990 1.520 1 9680 1 0990 1

LCT-20 & LCT-30

3/4x1

.480 - 1 - .640

L40 & L41

L

- .950

3/4x1 3/4x2

- .480

1 . UUU 1.084 1.080 1.084 - .040 .080 .015 - .035 .095 - .I05 1.47

1x2 1x1 1/2

A 2

*A2

1 1 / 2 x 2 2x2

1x2 1x1 1/2

.640

- 5YU .395 .400 - .402

- I - 11.71 1 1 . 7 1 1 2 . 0 2 i

- 3bU .566

- .560 .566 - .040

s?!L -395 .400 .402

1 1/2x2 2x2

.950 -

I B 1 1 %

Min .

.080

.015 -

.035 -075 .085 1.22

- 3bU .564 .560 - .564

-

c2 1.42 -

- I l b .720

- .716 .720

- I lb .720 .716 .720

.080

.015

.035 B2

1 I -

.040 -

I .UUU 1.086 1.080 1.086

.025 - .080 .015 - .020 .085 - .095 1.47

.080 1 .080

.015 1 .015

- - .040 1 .040 .040 - .035 1 .035

.020

.075

.085 1.22

Min . C 3

I U 1

.015

.020 .020 .075 .085 1.22

*B2 1 -035 1 .045

.015

.020 - .035 .045 .84 Min .

c 1

-70 1 - 1.90 1 . 9 0 1 1 - 1 2 1 - I

- - 1 .96 1 .96 1 1.15

652 652 904 1 154 1 7 4 7 904

- .075 .085 1.22 .84

.654 1 .654 1 .903 1 1.153 1 1.746 1 .903 1 1.153 , * I 1 - I - I I.,._,.,

1.746 1

-

1 1 5 4

-

1 7 4 8

D2

D3

"

.500 1 - - - .SO0 1.706 1.900 1 1.350 1.706 1 - .go0 1 1.350 1

.504

.015

.020 El 1 .450

02 c

.696 1 .906 1.344

- .015 1 .025 1 ,030 f .030 1 .040 1 .060

.504 1 .700 1 .906 - - - .015 1 .015 1 .025 .020 / .030 1 .040

.460 *570 ,580

1.344

- .030 .060 1.215 - ,450 1 .640 - - .640 1 .810 I 1.215 1 .810 - -

.650

--- .805 .815

.460 - .570 .58O

.820 1.020

1.030

.650 - .805 .815

1.225 1.530 1 . 5 4 0 e

.820 1 1.225 - 1.020 1.030

1.538 1.540

Valve Diviwa,

Reassembly: Visually inspect all parts prior to assembly and remove all loose particles using air or oil free solvent. Pay particular attention to the seating surfaces on the base and disc (wipe seating surface with an oil free solvent and dry parts prior to assembly). 1. Secure base wrenching surface in a soft jaw vice.

Install guide onto base by turning clockwise until it contacts base seat.

2. Lower disc into guide carefully until it seats onto base seat.

3. Set guide position as shown in Fig. 4 for air, gas, and steam or Fig. 5 for liquid service.

4. Apply a small amount of anti-seize compound to bottom radius of the stem and install stem into disc.

5. lnstall top and bottom spring steps onto spring. Be sure steps do not bind on springs. Apply a small amount of anti-seize compound to bearing points on both spring steps and install spring assembly onto the stem.

6. Install bonnet gasket with suitable sealant onto gasket area of body. Apply anti-seize compound to threads on the base and lower bonnet over stem being careful not to jar stem or shift gasket. Turn bonnet clockwise until it locks onto base. Be sure gasket fits into recess of bonnet.

7. Thread compression screw locknut onto the compression screw with the chamfered side on top. Apply anti-seize compound to the bottom 1" of threads on the compression screw.

8. lnstall the compression screw in the bonnet. After contact is made with the upper spring step, turn the compression screw to the dimension measured at the time of disassembly.

9. Install guide pin with gasket into hole provided in the side of the bonnet, turn clock-wise to tighten. Be sure gasket seats into counterbore of the bonnet. After guide pin is tight, check guide side movement by placing a screwdriver into the valve outlet and engaging one of the guide notches.

NOTE: Changing set pressure may require more compression for higher pressures and less for lower pressures. Set pressure should not be changed more than plus or minus ten percent (10%) of the original setting without changing spring. Consult manufacturer's representative for any additional information.

STEAM, AIR AND GAS SERVICE GUIDE SETTING

GUIDE PORTHOLE

DlSC \ SEATFACE ,

DlSC

BASE

GUIDE

NOTE: Orientate disc seat face to guide porthole by turning guide (Position shown above).

(FIGURE 4)

LIQUID SERVICE GUIDE SETTING

DlSC SEAT FACE PORTHOLE, /

NOTE: Orientate disc seat face to guide porthole (Position shown above) by turning guide.

(FIGURE 5)

Setting and Testing: Valves should be tested on the medium for which they are to be used (using Air, Steam or Water). Prior to mounting the valve to the test stand, clean the test fixture and purge the system to remove any loose contaminates. Secure the valve inlet to the test fixture. Tighten the valve inlet using the wrench surface provided on the base. With the valve mounted on the test stand, bring system pressure up slowly until set pressure is reached or 1O0Io above set pressure. To increase set point, turn compression screw clockwise. To decrease set point, turn compression screw counter-clockwise. When adjusting set pressure, use guidelines as follows.

Set Pressure Adjustment: 1. Reduce system pressure 50% below set point or

isolate test valve. 2. Prevent disc from rotating on the nozzle by hold-

ing the stem while making adjustments. If the stem is allowed to rotate, it may cause galling of the disc and nozzle seat. Reduce system pressure 75% when making set pressure adjustments on valves which do not have protruding stems.

3. Tighten compression screw locknutafter each adjustment to prevent movement of adjustment while testing.

4. Tighten guide lock pin prior to popping valve to eliminate movement of guide position during testing.

To verify set point after adjustment, pop valve a minimum of two (2) times to check set pressure consistency.

Temperature Correction: L Series valves are sometimes used in systems which see temperatures above ambient. A temperature compensation is required for temperatures above 250°F. A correction factor is added to the valve set pressure when they are set at ambient tempera-

I Below 15 / 0 1 601-670 / 20 1

COLD SETTING TABLE

NOTE: L-Series valves specified for liquid service shall be adjusted for set pressure using water (no compensation for temperature).

ture. This set pressure is called "Cold Differential Set Pressure." Refer to Table 2.

Specified Set

Pressure

Example: Set Pressure Temperature Cold Differential Set Pressure

lncrease in

Setting

Specified Set

Pressure

Back Pressure Correction:

lncrease in

Setting

Back pressure may also require a correction to set pressure. This back pressure will be listed on the manufacturer's nameplate (if constant) and the corrected set pressure will be listed on the nameplate as Cold Differential Set Pressure.

EXAMPLE Set Pressure 200 PSI Constant Back Pressure 50 PSI Cold Differential

Set Pressure 150 PSI

Seat Tightness Test:

Air & Gas The recommended test fixture requires a 5/16 O.D. tube with a .035 wall thickness. One end of the tube will attach to the valve outlet and the other will be placed '/z" into a beaker of water. (Reference to API Standard 527) Prior to leak rate test, apply soap solution to all pressure boundaries. The pressure boundaries must be free of leakage (bubbles) in order to measure the actual seat leakage, if any. Allowable leakage is listed in the Table below. Test pressure should be 90% of set pressure.

NOTE: Before testing a test cap must be used when testing on Air or Gas.

Pressure boundaries include: 1. Cap to Body connection 2. Body to Base connection 3. Guide Pin to Body connection 4. Misc. DrainIVent Plugs (as applicable)

L Series valves with O-ring seat shall be tested as above except the test pressure shall 90% of the set pressure or 3 PSI below the set pressure, whichever is lower, and there shall be zero (0) bubbles.

ALLOWABLE LEAKAGE TABLE

Steam lncrease pressure to 90% of set pressure. Check for leakage by holding a cold steel bar at the top portion

Valve Model

L14

L40

Size

All

All

Max Leakage Bubbles

40

40

Allowable Leakage

0.6

0.6

RETAINING RINGS

CAP

STEM

LIFTING DISC

JAM NUT

GLAND HOUSING

SHAFT

PACKING GLAND

LEVER

L14 SERIES PACKED LEVER

(FIGURE 6)

of the discharge. Any noticeable condensation form- ing on the bar is considered leakage. Leak test duration is 15 seconds.

Liquid No visible signs of leakage at 90% of the valve set pressure. Fill body bowl with water up to the edge of the discharge port. Valve is considered tight if no water spills off edge of discharge while valve inlet is pressurized to 90%. Holding time is two (2) minutes.

L14 Packed Cap 1. Thread lifting disc and jam nut onto the stem.

lnstall lifting disc first. Thread both parts onto the stem halfway.

2. Place cap gasket with sealant onto the bonnet. Screw cap on by turning clockwise until it is hand tight.

3. Slide shaft into packing gland housing until cam rests against threaded end of the housing. With high side of cam down, mark top surface of the shaft to identify low side of cam when the shaft cam is hidden in the cap.

4. Place gasket with sealant over packing nut housing and thread housing into the cap wrench tight. Thread packing gland hand tight into packing gland housing.

5. With mark on the shaft up, lightly push shaft in until it touches the stem (be careful,not to bend stem), then back slightly. lnstall lever onto the shaft in the down position. Move lever upward until it contacts the lifting nut. Proper setting is 30-45" from vertical. (Fig. 6 )

6. To adjust lever setting, pull shaft outward until cam contacts inside of cap. Now cap can be removed by turning counter-clockwise. To reduce lever movement, turn lifting disc clockwise. To increase lever movement, turn lifting disc clockwise. To increase lever movement, turn lifting disc counter-clockwise.

7. Once proper lever adjustment is reached, remove cap assembly and lock jam nut against lifting disc to maintain lever adjustment.

8. With mark on shaft up and cam seating against inside wall fo the cap, re-install cap and tighten (be sure cap gasket is in place).

9. Remove packing nut and install packing, then compress packing by turning packing nut clockwise.

10. With mark on shaft up, place large diameter retainer ring onto large diameter of the shaft. Then slide liver onto end of shaft in down position. (Fig.6) lnstall small diameter retainer ring onto end of shaft and push shaft inward until distance between end of shaft and bonnet is dimension "A" (Fig. 6).

L40 Packed Cap 1. Insert yoke into cap thru bottom opening of cap,

convex surface of yoke in first. Line up hex hole of yoke with side opening of the cap. Insert shaft thru side opening, hex end first, engaging yoke, seat hub of shaft into bore at closed side of cap. Note: Milled flats at outer end of shaft should be almost vertical and

2. Slide collar over the shaft (with bevel facing out) into side opening of the cap until it seats completely into cap.

3. Thread lifting disc onto the stem, then thread on jam nut. Be sure lifting disc and jam nut threads are fully engaged on stem.

4. lnstall cap gasket with sealant onto bonnet. lnstall the cap assembly by holding the yoke shaft in the full counter-clockwise position and thread the cap onto the bonnet by turning the cap clockwise.

5. With the cap seating on the bonnet, rotate the yoke shaft clockwise until the yoke contacts the

lifting disc and nut. Proper adjustment will allow the shaft to move upward from vertical 20-30" (Fig. 7).

6. Once proper adjustment is obtained, remove cap assembly. Lock jam nut against lifting disc nut and reinstall cap assembly (yoke shaft must be turned counter-clockwise full movement for yoke to clear lifting disc nut). Wrench tight.

7. Insert packing into packing gland housing and compress by tightening packing gland nut clo,ckwise.

ACKING GLAND

GASKET, CAP Y l l Y'

(FIGURE 7)

CAP

SCREWED TYPE CAP WITH GAG SCREW

L40

GASKE; CAP j( 1 t/ Y

(FIGURE 8)

CAP, PLAIN LIFT CAP

L40 I

WASHERS SEAL & 1

LIFTING DISC

SEAL DETAIL

CAP SEATING

I/ VALVE OUTLET 0 (FIGURE 9)

Assembly Screwed Cap (Fig. 8)

1. Install the cap gasket (using sealant) onto the valve bonnet.

2. Screw cap on bonnet turning clockwise. Secure the cap, wrench tight.

Assembly Plain Lever (Fig. 9) 1. Install the lift disc and jam nut onto the stem until

each piece is fully engaged on the stem. Be sure the lift disc is installed first.

2. Install the cap onto the bonnet. Secure the cap by tightening cap set screws.

3. Slide the lever into cap opening. Insert the rivet through the lever and cap opening.

4. Check lifting disc clearance by lifting the lever until it contacts the lift disc. The minimum clearance between the lever and lifting disc is lhs".

5. If adjustment is required, remove the cap assembly from the bonnet and turn the lift disc and jam nut clockwise to shorten, and counterclockwise to increase clearance.

6. Once proper clearance is set, tighten jam nut. This will prevent any change. Reinstall the cap assembly. Tighten all cap set screws. Secure the rivet in place by a seal wire. Recheck clearance between the lever and lift disc to be sure clearance has not changed.

Back Pressure Leak Test: Back Pressure - Back pressure test is accomplished using a test fixture secured to the valve outlet through which a minimum of 50 PSI Air is applied. Using a soap solution while the valve is pressurized, check pressure boundaries (cap gear to body interface, base to body connection, guide pin) for leakage. There should be no visible signs of leakage (bubbles).

SLONERGAN'

L Series Safety and Relief Valve ~aintanance Manual

Required Order Information When ordering valve components (parts), include the following information:

QUANTITY LONERGAN MODEL DESIGNATION (See new model code designation in Lonergan L and D series catalog) INLETIOUTLET THREADED OR FLANGE RAT- ING AND FACING CONSTRUCTION MATERIAL (For non-standard materials, see new series designation) O-RING SEAT SEAL (See material and pressureltemperature limit charts)

SET PRESSURE BACK PRESSURE (Constant or variable) MAXIMUM INLET TEMPERATURE ALLOWABLE OVERPRESSURE SERVICE (Gaslvapor-molecular weight or specific gravity; Liquid-specific gravity and viscosity) REQUIRED CAPACITY ACCESSORIES: Packed lever, plain lever, Test gag. CODE REQUIREMENTS

LONERGAN P.O. Box 2360,8222 BLUFFTON ROAD, FORT WAYNE, IN 46801-2360

Printed in USA - 9-91

FORM P-4 MANUFACTURER'S PARTIAL DATA REPORT As Required by the Provisions of the ASME Code Rules, Section I TTB S / O #93X12516

I. Manufactured by Tulsa Tube Bending C O . ~ , Inc. 4194 S. Galveston, Tulsa, Oh (,,,,,. lNam and addres. of rnanufsctursrl

N/A

7: Manufactured for American Hydrotherm Corporation, New York, N Y P. 0. #2579-26056 (Name and eddrau of purchaser1

I I I I I I I

ingle pass single 1 1 , 3216A I E-10064-1 1 N / R N/ R 1 1993 1 4. The chemical ah~b~Ji ic~p~dpert ies of ail parts meet the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL

3. .Identification of Part(s)

CODE. The construction and workmanship conform to ASME Rules, Section I of the ASME Boiler and Pressure Vessel Code. 1992 , Addenda to NONE , and Code Cases

(Yew4 (Data) NONE

IN~nb.r.l

Nuno of Pan

6(a) Drums

~ndicate if (1) Seamless; (2) Fusion welded. "Indicate if (1) Flat; (2) Dished; (3) Ellipsoidal; (4) Hemispherical.

Cluantiw

61b) Boiler Tubes 6(c) Headers No. or (Box or sinuous or round. Mal'l. spec. no.; Thickmsal

L~ne No.

1 1 1 6ldl Staybolts (Mat'l. spec. no.; O~ameter; Size telltale; Net areal

Dlarneter

in. Net Area in.' MAWP - psi Pitch (Hor. and Ven.1 1Supponed by W bolt1

Mfr's. Identlfy~ng Numbers

Thickness Mat'l. Spec. No.. Grade

6(el Mud Drum or Heads or Ends Hydro. Test;.psi {For sect. header boilers. State Size; Shape; Mat'l. spec. no.; Thickness) (Shape; Mat'l. spec. no.; Thickness)

(1U91J This form (€00071) may be obtained f rom the ASME Order Dept., 22 Law Drive. 605 2300, Fairfield. NJ 07007-230Q.

aemIwr 6/92

Heads or Ends Hydro. Test, psi (Shepa; Mst'l. spec. no. Th~cknassl

Manufacturar'a Drawing No. CRN .

Nal~wlsi b u d No.

Ye# &Yll

Form P-4 (Back)

I I I I I I I I I 1 I I

9(a) Superheater Headers 9(b) Superheater Tubes I I I I I I I I i

lO(a1 Other Parts (1) (2) (3) . 1 O(b) Tubes for Other P a m

8(b\ Economizer Tubes 8(al Economizer Headers Heads or Ends

No.

I

2

a 1 Boiler I I I I M stamped on &urn b 1 Waterwall 1 1 heads.

Hydro. Tan. pu.

One SA106B/sb'ls 3" SX40 p ipe lcoi 1 conhis t i n g d f (1)oneJ 900 SA234WPB Welbel l c o i 7 s t i t c h welded f i r sd f o u r wraps 4" ldna w ~ l d s l ~ v e r ~ 1;(00. ~ h i b c o i l . . i r (<~rtq i n ! wter dsq

(3) FWAW (1!3"S/40 SA106B/smls P - F - (41 Feed O u t l e t (No.. aka. and type of noxaka or outlatsl (No.. Ju, ~ p . . yd bcatbn d WNWQWM)

' This heating surface not c ( Economizer I i to be used for

Meterial Spec. No.

Thickmu. in.

Diameter. m. s h . ~

, 3 c o i 1 section1 32168 t h make one ink-l ur l i t . I 1 1 . o p e n ~ n ~ s 11) SMSI (1)3"S/40 SA106B/smlq P - F . N n n ~ hv TTR

I n l e t (NO.. nze. a type of noubm or cutlatal (2) SefetY PJO.. nza. i;rd wp. of fmzxtw M OU~IOR)

' M.tr*l Spec. Na

t I

Thickmu. in.

Thickmu. In. SLe nd Sup.

, ( Heating surface to be 12

r I

Pkld Hydra. Test. p.l

Matarid w c . No.

d I Superheater I

Remarks: '

Murnurn AHow.ble Warlong R8rsura

300

CERTIFICATE OF SHOP COMPLIANCE 1 We certify the statements made in this Manufacturer's Partial Data Report to,be correct and that all details of material, construction, and work- & manship of this boiler part conform to Section I of the ASME BOILER AND PRESSURE VESSEL CODE. I

77 .7 .1 .1 I 1 599

Our Certificate of Authorization No. 7385 to use the ( m o r (S) S Symbol expires March 19 &

5-d- 93 Date Signed Name h l l sa bk R p n d ~ n g CO. . T ~ c - IM~ufacrurarl

Coda Par. andlor formula on Which MAWP is Based

I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors andlor the State or Province of Oklaharna and employed by Cornmercl a1 Union Insur-v

Boston, Mass have inspected the part of a boiler described in this Manufacturer's Partial Data Report on 3-3- 19 93, and state that to the best of my knowledge and belief, the manufacturer has constructed this

part in accordgnce with the applicable sections of the ASME BOILER AND PRESSURE VESSEL CODE.

By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the part described in this

Manufacturer's Partial Data Report. Furthermore, neither .the Inspector nor his employer shall be liable in any manner for any personal injury or

property damage or a loss of any kind arising from or connected wi th this inspection.

determining minimum

- - Data / 7 9 3

Shop Hydro. Test. p a

e 1 Other Parts 1

OK 758 Commissions (Authoriued inspectort INat'l. Board (incl. ondorumntsl. Stwe, Rovura. and No.] I

Heetlng Surface.

aq. tt.

450 safety valve capacity.

INSPECTOR DATE: 3 / f o 4 9 3 JOHN C. HOLDER (918) 4556593

BADGER S.B.C. MSpECTOR DATE; 3 - I) - JOHN C. HOLDER (918) 455-6593

FORM P-4 MANUFACTURER'S PARTIAL DATA REPORT As Required by the Provisions of the ASME Code Rules, Section I TTB S/O 8193x12516

1. Manufacturedby m a T u b e fb- ;Tnr 4184 S , Galv~q- lName and address of manufacturer1

K P-41DNo. N/A, 2. Manufactured for Arneri can Hydrotherm Corp. New York. NY P. 0. #2579 - 76056

[Name and address of purchaser1

3. Identification of Partls)

kinrJle pass s ing l le 1 /10@,111 32168 I I I I I I I

E-10064- 1 I N /R N / A 1993 1 4. T/&e&&ic~&ie physical prope&gf all parts meet the requirements of material spec~ficarions of the ASME BOILER AND PRESSURE VESSEL

Nama of Pan

CODE. The construction and workmansh~p conform.to ASME Rules, Section 1 of the ASME Boiler and Pressure Vessel Code.

lg9* , Addenda to NONE , and Code Cases NONE (Year) (Date1 INurnbwsI

6(a) Drums

Quantlty

'Indicate if (11 Seamless; (21 Fusion welded.

6(b) Boiler Tubes

L ~ n e No.

No.

1

2

3 4

"Indicate if ( I t Flat; (21 Dished; (3) Uk'psoidal; (41 Hemisphencal.

6(c) Headers No. or (Box or sinuous or round; Mat'l. spec. no.; Thickneul

Mfr's. Ident~fy~ng Numbers

I I I

lnslde D~ameter.

en.

Diameter Heads or Ends Hydro. Test. psi IShape. Mat'l. spec. no.. Thtckneesl

IMat'l. spec. no., Diameter: Size telltale; Net areal

Manufacturer's Draw~ng No.

lns~de Length ft ~n.

Th~ckness

Pitch in. Net Area in.' MAWP - pal ' IHor. and Vert.1 Isupported by one bolU

Mat'l. Spec. No.. Grade

6(e) Mud Drum or Heads or Ends Hydro. Teat, psi [For sect. header bo~lars. State Size; Shape; Mat'l. spec. no., Thlcknessl (Shape; Mat'l. spec. no.; Thcknersl

CRN

Shell Plates

National Board No.

I

Mat'l. Spec. No.. Grade

Y e u Bull1

Tubesheets

7(a) Waterwall Headers

Thlckness, tn.

Thickness, ln.

.Tube Hole bgarnont Effioency. %

(121911 This f o r m ( E 0 0 0 7 1 ) m a y b e o b t a ~ n e d f r o m t h e A S M E Order Dept., 22 Law Drive. Boy 2300, Fa~rfield, NJ 07007-2300.

RERaXNt 6 f i

l ns~de Radius. ~ n .

lnsde WIU, ~ n .

- Longltu- dm.(

Heads or Ends

No.

Cicun- f u m t ~ a l

7(bt Waterwall Tubes

,Shape Mater~al

Spec. No. Size and Shape Thickness,

fn. Mater~el

S p l . No. 1 I

Hydro Test. psi.

Th~ckness. ~ n .

I

Mater~al Spec. No.

hameter. in.

Th~ckneae.. n.

form P-4 (Back)

9(a) Superheater Headers 9(b) Superheater Tubes I 1 1''' I

1 1 I

- I I I I I I t I I J

None by TTB 1 1 . Openings (1) %m W3 I!?" 5/40 SA,06n/qmlq I P P - F INLET

(No.. au6. and type of nozzles or outlets1 (2) Safety Vahm (No.. &a. and typo 01 nod88 or wtim81

- -

I

1 1 I One SA106B/smls 2 1 321GA i n s e r t s 9 1

(3)-&%Wf (1)31/3(1/qmlq P - F (4) Feed (No., sue, and type of noulei or outletrl (No., .iu. type. Md location of cmlnutbrul

Code Par. andlor Heet~ng . h i m u m Allowable formula on Which Shop Hydro. Surtece.

12 WorCing Remure MAWP is 8.sed Tea. prr . sq. n. I , , ( Heating surface to be

1 1 1 I I Iota) Other Parts (1) (2) (3) 10(bl Tubes for Othsr Part8

stamped on drum heads.

This heating surface not to be used for determining minimum safety valve capacity.

f*ld Hydro. T.U. pU

3 1/2" S/40

I CERTIFICATE OF SHOP COMPLIANCE

We certify the statements made in this Manufacturer's Partial Data Report tq be correct and that all details of material, construction, and work- f manship of this boiler part conform t o Section I of the 4SME BOILER AND PRESSURE VESSEL CODE. I

i n t o p ipe co i ' cons isd inq o f ( 5 ) 90° I ~ - s A ~ ~ ~ w P B weldel 's. C o i l

(RQXor (Sl -2 Symbol explres March 30 19 94

Date Name Tulsa Tube Bendinq Co., Inc. (Manufacturer1

t h i s c o i l s e c t i o i

I - --

CERTIFICATE OF SHOP INSPECTION SI ned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors andlor the State or Province

of a oma 'I the u6RY R

and employed by Comnierci a1 Union Insurance Company Boston, Mass have inspected the part of a boiler described in this Manufacturer's Partial Data Report on

3 - r - 19 , 9 3 and state that to the best of my knowledge and belief, the manufacturer has constructed this

part in accordance with the applicable sections of the ASME BOILER AND PRESSURE VESSEL CODE.

By signing this certificate neither the lnspector nor his employer makes any warranty, expressed or implied, concerning the part described in this

Manufacturer's Partial Data Report. Furthermore, neither the lnspector nor his employer shall be liable In any manner for any personal injury or

property damage or a loss of any kind arising from or connected with this inspection.

t o makd (1) one

Date 3 - 3 7 / g 93

commissions OK 258 1

INst'l. Boud lincl. endor-tal. State. ROVIM. Md Nal

i n t e r q a l u n i t . 1

BADGER S.Q.C. INsPEC~R DATb 3- 10 - 9 3 JOHN C. H O W (918) 455-6593,

FORM P 4 MANUFACTURER'S PARTIAL DATA REPORT As Required by the Rovhions of the ASME Code Rules, Section I TTB S/O 4'93x12516

Ler t l f l e d ii I. Manufactured by Tulsa Tube Bending Co., Inc. 4194 S. Galveston, Tu l sa , OF4 ,,

{Nan8 8M .ddnu ot muululuri N/ A

q nutactured for Anleri can Hydrotherm Corporat ion, New York, NY P . 0. #2579-26056 I W m 8 M . d O n u 0 t p r d v u l

I I I

~ n g l e pass s ing le 1 0 1 , 3 2 1 7 ~ I E-10064-1 I N / R N/ R I 1993 1 4. The chemical W E b ; i ~ i c S O p s of all pans meet the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL

Nwrr 01 P r t

CODE. The consuuction and workmanship conform to ASME Rules. Section I of the ASME Boiler and Pressure Vessel Code. 1992 , Addenda to NONE . and Code k c

I Y W l 101181 NONE

I N ~ I

O w u t v

-

' ate if (1) Seamless; (2) Fus~on welded.

6(b) Boiler Tubes

r

No

1

2

"lnd~cate if (1 ) Flat: (2) Dished: (3) Ell~paoidal; (4) Hemispherical.

6lct Headers No. or lBor or unuous or round: Mat'!. apoc. no.: T M m u l

Lrr No.

MW8. Id.ntltwng Numb.rs

3 1 4 1

lnud. b8m.W.

n.

/ D-er I Thacknsrr / Met'i. b c . No.. G r m r

1 I

Pitch in. Net Area in.' MAWP - psi lkor. 8nd Vm.1 l5upponed by m Wltl

I

1 " ; ; " y

Heads or Ends Hydro. Test, psi 1Slupr:~Mat'l. w c . no.. T h c r n u c l

I I I I 6(dl Stavbolts

61el Mud D N ~ or Heads or Ends Hydro. Test, PO/ 11% ucr. M.r bu4mrs. SUU Sua; Shap8; Mat'!. w c . M.: T-ul IShW: Mw'l. w c . no.: T h u m v l

M r u t u n n n ' r Drawma No

~ongnuduul tnun. h n t S JOlIlxS H ~ W S

NO. t E ~ I . NO. i EHO- ~ 1 . 1 . S-C. NO.. RUINS ~nhwr n v d r w WPc -v 1VW WV G r a m of Duh No. Sue T m . pu

2 I R

r k I

Uwll Rat88

i

, h t ' l . Swc. No.. Gram

IMar'l. .PC. no.: Dumter ; Sue rWW; Na1 uul

- -

U(rJ

' Tub..h..ts

N e W l w B o d No. &.I

I

Tluckmu. n

Thf*nou. n

Tub. nd8 humt 1

E W w . %

7(a) Waterwall Headers

hwh W r . n.

l a u d 8 R.du8. n. d*ul

LonOnv,

1121B11 Thu tom (EOOO711 mmy be oburnsd from UIO ASME Order Dept.. 22 Law D m . Box 2300. F w M . NJ 07007-2300.

mxwr 6/92

I

trarlwl --

Heads or Ends

No.

7(b) Waterwall Tubes

Shlpa Mm~mel

b.c. No. s u e and Shme T h d m s s .

m. .

1

M . d &JU. NO.

Hvdro. T u t . p.i.

T t n c k n u . m.

Metmai Spc. NO.

Dunwur. m

T h c t m u . n.

I I t I I I I I I I

I I I 916) Superheater Headers 91b) Suwha te r Tuber

I I I I 1

L I I , I I I I

10(a) Other Parts (1 (2) (3) , 10(b) Tubs fQr 0 t h ~ PVU

8(al E#wmuar Hekr.d.n

i I One SAlOGB/smls 3" Sl40 p ipe \ c o i l c o n $ i s t i n q df ( l ) o n e ( 900 SA234WPB Welhel l c o i l s t i t c h ' I

2 1 welded f i r s d fou r w r a ~ s 4" 1 d n o , Th i k c n i 1 i d q ~ r t q in1 q l l t~r n a q q . . I I

I 11. openings (1) ** U!3"S/40 S-1s P - E -

In le t (ha.. $lM. Ud tYg. 01 mzXnS Ol o M U ) (2) sew "aiVe )

mo.. am. hp. lwmon d o a c ~ 1 1

Heat~ng surface to be stamped on drum heads.

This heating sutfaca not to be used for deternunlng minimum safety valve capacny.

T)ranrr. m.

Heads or Ends

CERTIFICATE OF SHOP COMPLIANCE

We certify the statements made in this Manufacturer's Pen~al Data Repon to be correct and that ell details of material, consuucuon, and work-

manstup of th~s boiier pan conform to Secuon I of the ASME BOILER AND PRESSURE VESSEL CODE. I

- 8ibl Economizer Tubes

u.rrw &I= no. Mo.

, Our Certificate of Authorizat~on No. S Symbol expires March 19 %

3&& Signed Date Name J u l ~ a ~ l & d . m d i n ~ h.. Tnc. ( M m u t a c ~ ~ n l

&-a. T..L pl. tL.ndSh.0

1, the undersigned, holding a valid commission issued by the ~ational ~o>rd of Baler and Pressure Vessel Inspectors andlor the Sate or Province of Oklahama and ctmp~oyed by B r c 1 ,a 1 Un 3 on Ins u r a n c e Q a ~ z ~ m ~

Boston, Mass have inspected the pan of a boiler described in th~s Manufacturer's Partial Data Repon on 19 93, and state that to the best of my knowledge and belief. the manufacturer has CO~uucted this

pan in accordance with the applicable sections of the ASME BOILER AND PRESSURE VESSEL CODE.

By signing this certificate n e m r the Inspector nor his employer makes m y warranty, expre~sed or implied. concerning the pan described in th~s

h*ura. m.

Manufacturer's Part181 Data Repon. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal lnJUry or

property damage or a Loss of m y kind anling from or connected with thu inspectJon.

YmrW sS.r ha.

omaumc. h.

INSPECTOR DATE: 3- 154 93

l-ldmu. a

YnrW sac. no.

FORM P-4 MANUFACTURER'S PARTIAL DATA REPORT As Required by the Provisions of the ASME Code Rules, Section I TTB S / O A(93X12516

C e r t i f i e d & 1. Manufactured by h 1 S a T u h ~ ~~ndlngLcn-T.n..inr4184 S , G a l v ~ z t a n , T u l ~ a : 0

INam and address ol manutanurnl K P-4 ID No. N/A

Manufactured for American Hydrotherm Corp . New York, NY P. 0. 67579-76056 IN- and address ot purchawrl

3. Identification of Pan(sl

Mtr's. IdentiWlng I Manulacturer's Nauwul Numbers Drawma No. I CRN I BOvd No. 1 % I

CODE. The construction and workmanship conform to ASME Rules, Section I of the ASME Boiler and Pressure Vessel Code.

992 , Addenda to NONE , and Code Cases . NONE IYau) IDatel lNumbwsl

1

6(a) Drums

i n c j l e pass singlle 1 ) lo@, 111 321/B

'Indicate if (1) Seamless; (2) Fusion welded. "Indicate if (1) Flat: (21 Dished; (3) Ellipsoidal; (4) Hemispherical.

4. Tlke&i l)hic~~ak& physical p r o p e a g f all parts meet the requirements of material specifications of the ASME BOILER AND PRESSURE VESSEL

E- 10064- 1 1 N / R

1 1 1 6ldl Staybolts ihi.1'1. PWC. no., Olemeter; Stre telltale: Net area)

N / A 1 1993

6(b) Boiler Tubes 61c) Headers No. or lBax or stnuou$ or round, Mat'i. spec. no.. Th~cknessl

Pitch ' in. Net Area in.' MAWP - psi IHor. and Ven.1 (Supported by one ban)

6(el Mud Drum or Heads or Ends Hydro. Test. psi Ifor sea. h e h r bodsrs. State Sue; Shape: Mat'l. spec. no.; Thaknessl [Shape. Maf'l. spec. no.. Th~ckneul

This form (€00071) may be obtained from the ASME Order Dept.. 22 Law Drive, ~ox'2300. Fairfield. NJ 07007-2300. REPRINT 6/92

Heads or Ends Hydro. Test, psi IShape: Mat'l. spec. ,no.; Thlcknessl

Mat'l. Spec. No.. Grade D ~ m t n

I I Th~ckness

Form P 4 (8scWl

9(al Superheater Headers 9(bl Superheater Tubes

I I 1 I I I I I I I

10(a) Other Parts (1 (2) (3) 10(b) Tubes for Other P G ~

-

1 1 . openings (1) (1!3 1!3" 7/40 S A U b E U d q P F None by TTB INLET

(NO.. r u r , u~ type of nozzles or outktal (2) Safety Vm (NO.. a~za. and wpe ot m u ~ n or OUIIOUI

I

2 3

(3) i w ~ f (1)3 s!40 7 A W q m l q P - F - 14) Feed

OUTLFT (No.. uza. and wpe of m u m s or MnUtal (No.. mu. NP.. and loutw ot conmuwl

Remarks:

p i ~ e coil consisdinq of ( b ) 90° l d . ~ ~ 2 3 4 ~ ~ 9 welde14s. Coil sectioh to makd (1) onelinterqal unit.

One SA106B/(smls 3 1!2" S/40

d I Superheater I

CERTIFICATE OF SHOP COMPLIANCE I fl We certify the statements made in this Manufacturer's Partial Data Report t0 be correct and that all details of material, construction, and work<

manship of this boiler pan conform to Sect~on 1 of the ASME BOILER AND PRESSURE VESSEL CODE. I

3217A insdrts into

Heattng Surf-.

Heating surface to be stamped on drum

This heating surface not ) to be used for

Our Certificate of Authorization No. S) .& Symbolexplres March 30 19 94

Date 3- Idg3 Signed Name Tulsa Tube Bending Co., Inc. IMmufanwerI

this coil

Shop Hydro. Ton, PSI

300

SI ned, holding a valid commission Issued by the National .~oard.of Boiler and Pressure Vessel Inspectors andlor the State or Province 1 :"eu6flaRoma andemployedby Commerc~al Un~on Insurance Company Boston, Mass have inspected the part of a boiler described in this Manufacturer's Partial Data Report on

Code Par. andlor tonnula on Whlch MAWP I. B.ud

u~in 3 7 . 3 1.1

I 3- 15- 9 3 19 , and state that to the best of my knowledge and belief. the manufacturer has constructed this I

Maxnnwn A I l o w W Workbng R e u w e 1 2 .

determining mlnimum

1135

pan in accordance with the applicable sections of the ASME BOILER AND PRESSURE VESSEL CODE. By signing this certificate neither the lnspector nor his employer makes any warranty, expressed or ~mplied, concerning the pan described in this

Manufacturer's Partial Data Report. Furthermore, ne~ther the Inspector nor h ~ s employer shall be liable in any manner for any personal injury or

property damage or a loss of any kind arising from or connected with this inspection.

a

b

c

e 1 Other Parts ]

I , /+re- A-d trup.aort ~ornmissions OK 258 INat'l. Bovd (ncl. Mdorwmanrl. Suta. Rouma. .nd No.1

Boiler Waterwall

Economizer

safety valve capacity.

R 'S..Q.C, INSPECTOR DATE; 3& f 9 3

Allen-Bradley Co. 1747 Series Software APS Release 2.01

Documentation Utility Processor Config

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G.

Processor File: m 2 5 7 9 . A C H March 2 9 , 1993 - 12:20

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 1 P-~cessor Config Processor File: AM2579.ACH

1/0 CONFIGURATION FOR: AM2579

Rack 1 = 1746-A7 7-slot Backplane

SLOT CATALOG # CARD DESCRIPTION

0 1747-L514 5/01 CPU - 4K USER MEMORY 1 1746-IM16 16-Input 200/240 VAC 2 1746-IM16 16-Input 200/240 VAC 3 1746-OW16 16-Output [RLY] 240 VAC 4 1746-OW16 16-Output [RLY] 240 VAC 5 ***** NOT CONFIGURED ***** 6 ***** NOT CONFIGURED *****

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 2 xessor Config Processor File: AM2579.ACH Summary

REPORT OPTIONS SUMMARY

Insure Valid X-Ref Info: ~raphics Mode: Page Width: Page Length:

+-------------------------------------------------- +

Allen-Bradley Co. 1747 Series Software APS Release 2.01

Documentation Utility Program Listing

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By-:R.G.

Processor File: AM2579.ACH March 29, 1993 - 1 2 : 1 9

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 1 Program Listing Processor File: AM2579.ACH Rung 2: 0

Rung 2: 2 I LOWER SWIT~

Rung 2: 1

CONDENSATE I

UPPER SWIT CH LOCATED ON CONDENS ATE STORAG E TANK

CONDENSATE AVAILABLE IF LATCHED UNAVAIL.FO R UNLATCHD

LSH 012 13.0 ~3 ---- ] [--------------------------------------------------------------- (L) -----

4 1

CH LOCATED ON CONDENS ATE STORAG E TANK

AVAILABLE IF LATCHED UNAVAIL. FO R UNLATCHD

Rung 2: 3 CONDENSATE AVAILABLE IF LATCHED UNAVAIL.FO R UNLATCHD

B3 +TON--------------- + ---- 1 [--------------------------------------------- +TIMER ON DELAY +- (EN) -

LSL 012 13.0 ~3

- - I ............................................................... (U) ----- 5 1

1 Timer T4 : 0+- (DN) Time Base Preset :;:;I Accum 0

+------------------ +

BADGER D E S I G N & CONSTRUCTORS I N C . A M - 2 5 7 9 B y : R . G . M a r c h 2 9 , 1 9 9 3 Page 2 , T g r a m L i s t i n g Processor F i l e : A M 2 5 7 9 . A C H R u n g 2 : 4

~ ~ n g 2 : 4 CONDENSATE A V A I L A B L E I F LATCHED UNAVAIL . F O R UNLATCHD

B 3 +TON--------------- + ----]/[--------------------------------------------- + T I M E R ON DELAY +- ( E N ) -

1

R u n g 2 : 5 LOW FLOW THRU H T R C O I L # 1

F S L 0 0 1 1:T.o +TOE'--------------- + ---- 1 [--------------------------------------------- + T I M E R O F F DELAY +- ( E N ) -

R u n g 2 : 7

I

T i m e r T 4 : 1+- ( D N ) T i m e B a s e Preset A c c u m

;16::1 o

0

~ u n g 2 : 6 LOW FLOW THRU H T R C O I L # 2

F S L 005 1 : Z . o +TOF--------------- f ---- 3 [--------------------------------------------- + T I M E R O F F DELAY + - ( E N ) -

+------------------ +

T i m e r T 4 : 2+- ( D N ) T i m e B a s e 0 . 0 1 Preset 500 1 A c c u m 0

1

LSLL I 1 : l . O

+------------------ +

T i m e r T 4 : 3+- ( D N ) T i m e B a s e Preset A c c u m

O;::I 0

LOW-LOW L E V E L SECOND H T R E X P . TANK ON OR O F F

+------------------ +

TWO O R HOT O I L T H R E E PUMP S U P P L Y RUN VALVE

LOW FLOW H T R C O I L 1 DELAY 5 S . E C

LOW FLOW H T R C O I L 2 DELAY 5 S E C

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. D~ogram Listing Processor File: AM2579.ACH

March 29, 1993 Page 3 Rung 2 : 7

SECOND HTR ON OR OFF

Rung 2: 8

TWO OR THREE PUMP RUN

1:l.O 1:l.O ----- I/[-------- ] [-----

0 2

Rung 2:9

HIGH TEMP HEATER COIL # 1 TSH 019 TSH 020 SS 2 ROS HIS

~3 1:1. o 1:i. o 1:2.0 1:l.o 1:l.o

OPERATING TEMPERATUR

HEATED GAS CUTOFF OTC

BURNER HIN GE INTL'K SWITCH

HIGH TEMP. HEATER COIL # 2

RECYCLING INTERLOCKS

HEATER START-STOP

SS 4 TIC 015 CR 2 ~3 1:2.0 I:?-. o 0: 3 .-Sj ---- I [-----+---- ] [----------------------+---- ] [-------------------- ( ) -----

HEATER START-STOP REMOTELY

8 0 4

+---- I r-------- ] [------ I E--+

I 12 1 DN I

11

AUTO SS-4

CONDENSATE AVAILABLE IF LATCHED UNAVAIL . FO R UNLATCHD

I:2.0 B3 T4 : 0

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. - Tgram Listing Processor File: AM2579.ACH

AUTO SS-4 I:2.0


B3 T4 : 1

LSL 012 I 1:2.0 1:i.o

+---- I [-------- I / r ------ ] [--+ 12 1 DN

March 29, 1993 Page 4 Rung 2: 9

CONDENSATE SS-4

LOWER SWIT CH LOCATED ON CONDENS ATE STORAG E TANK

Rung 2:10 CONDENSATE AVAILABLE IF LATCHED JNAVAIL . FO

. - ! UNLATCHD B3 +TOF--------------- + ---- I/[--------------------------------------------- +TIMER OFF DELAY +- (EN) -

LOW PRESS HEATED GAS PSL 004 1:Z.o

1

HEATED GAS

Timer T4 : 4+- (DN) Time Base 0.01 Preset 1500 1 Accum 0

HIGH PRESS HEATED GAS

+------------------ +

SS 4 PSH 003 1:2.0 1:y. 0

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 5 Program Listing Processor File: AM2579.ACH Rung 2:11

Rung 2:12 I I I

+

CONDENSATE SS-4

Rung 2:13

I

I +---- I E-------- I / [ ------ I r ---------- I [-------- I [----- + 12 1 DN 2 3

AUXILIARY SWITCH ON BLOWER MOT OR STARTER

BURNER CONTROLLER CONDENSATE TERMINAL M SS-4

BC M 1:l.C I:2.0

LOW PRESS CONDENSATE

ATOMIZ.AIR COMPRESSOR

AAC 0:3.0

LOW PRESS ATOMIZ.AIR

PSL 002 PSL 007 I:2.0 1:Z.o 1:T.o

+---- ] [ -------- ] [ -------- ] [--------------------------- 13 4 6

AB PSL 003 CR 3 B3 1:l.O 1:2.0 0:3.0

--I [----- I [-------- ] [---------------------------------------------- ( I----- 5 14 5 1

LOW PRESS COMB. AIR

AUTO SS-4

NON RECYCLING INTERLOCKS

CONDENSATE AVAILABLE IF LATCHED UNAVAIL.FO LOW PRESS R UNLATCHD CONDENSATE

LOW PRESS ATOMIZ-AIR

PSL 002 PSL 007 I:2.0 B3 T4 : 0 I:?. 0 1:Z.o

+---- I r-------- I C- - - - - - I [---------- I [-------- I r----- + 12 1 DN 4 6

AUTO SS-4

PSH 003 PSL 004 I:2.0 B3 T4:l 1:'Z.o 1:'Z.o

CONDENSATE AVAILABLE IF LATCHED UNAVAIL . FO HIGH PRESS R UNLATCHD HEATED GAS

LOW PRESS HEATED GAS

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 6 ,ogram Listing Processor File: AM2579.ACH Rung 2:13

AUTO SS-4 I:2.0


B3


CONDENSATE SS-4

NON

+---- ] / [ -------- ] [---------------- + 0 13



CONDENSATE SS-4

CR 2 0: 3 .o I:2.0 B3

AUTO SS-4

CONDENSATE AVAILABLE IF LATCHED UNAVAIL . FO R UNLATCHD

+---- ] / [ -------- ] [---------------- + 1 13

NON RECYCLING INTERLOCKS

AUTO SS-4

CONDENSATE AVAILABLE IF LATCHED UNAVAIL. FO R UNLATCHD

k [I] P( a:

[I] -4 W d n

u i i i j r l >( W * * U E 0 w z PI; H

I I

[I] I C7 % 1 z w m I H O 1 0 1 I - i

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W E 0 1 w a I P; H I

I

O I l n N W U q u

H PI; w4:- o x 0 1

!2 $ I I

I w ol I

I $ i s m I 4 O O l N 3 a o .-

Im Z E 3 * - - H d W O l

2 F W I I I I I I I I I I

[I] I

[I] I C3 x I Z U N I H O 1010 d d f f i P : u

U & U O > w * * - U E - ( 0 1 W Z I Lx H I

I

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 8 "-ogram Listing Processor File: AM2579.ACH Rung 2:16

i

BURNER CONTROLLER CONDENSATE TERMINAL 7 SS-4

BC 7 1:l.O I:2.0

1 NON MAIN VALVE CONDENSATE


ESV 001 0:T.o I


CR 2 CR 3 0:3.O 0: 3 -5

Rung 2: 17

I

---- 3 [ ----- + ---- ] [----------------+---- ] [--------------- ( )----- I E-------- 11

BURNER CONTROLLER TERMINAL 7

BC 7 1:l.C +TON--------------- + ---- 1 [--------------------------------------------- +TIMER ON DELAY +- (EN) -

+---- I C--- - - - - - I C----- + 12 1

11

Rung 2: 18

0 1 3 13

Timer T4 : 6+- (DN) Time Base 0.01 Preset 6000 1 Accum 0

AUTO SS-4

+------------------ +

MAIN VALVE STABILIZER

CONDENSATE AVAILABLE IF LATCHED UNAVAIL. FO R UNLATCHD

SS 3 BC 7 PSH 006 PSL 006 ESV 004 1:2.0 1:l.C T4:6 1:T.o 1:Z.o 0:Z.o

---- ] [-------- ] [------ ] [ -------- ] [------------------------ ( ) ----- I [----- 10 11 DN 7 8 4

LOW PRESS STABILIZER

STABILIZER OFF-ON

I:2.0 B3

BURNER CONTROLLER HIGH PRESS TERMINAL 7 STABILIZER

I I I

PC I

E r lcn I d o 1 U J

E-cffi*O W lrl

H W O E I X X U I

I

PC I

E N O I N O l I'

EP:=+kO W Id

X € 4 d X - * n W ~ H W H I H W O E I X X U I

I

E r lcn I d o 1 U J

i- + I I

N l a ) I c n N u U . . m m \ N a n a n

I I rn I I c +- + =r I P; -

I +- + I I

m l o o I c n N u u . . m C)

N m n a - I I

D I I G +- +

! Z I

I I 10 I l l Ud u d

& cn P( P: 0 E+ U 5 P: E cn Z 0 U

a tr c

Z -d w c , H in V] .d Wil a

E P: a W k u tr a o 2 PF

I +- I

+ I

r-i I W I f - - m Qt-1 -4 . . PI m N a m f a n

I I D-l I I G +- + 7 -. I ---

I I I I I I I I I I I

W I ro .9 I Q4CY I w m o o l w K Z O * - PC PI ICY ad * - -

3 z m ~ I O O P I I 4 u I

I +- I

CO 1

I e I in' rl U N '--a . . rl m \ N m-- m-,

I I F I I C f- 3-

2 I

DG' DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 14 O ~ L .Ail Listing Processor File: AM2579.ACH Rung 2:39

Rung 2:41 ALARM SILENCE

PB 2 B3 1:2.?j

.ng 2:39 ALARM SILENCE

PB-2 B3 I:2.0 B3

-+--I [--+----]/[-------------------------------------------------------- ( I - -

2 4 I 1 4 2 5 1 B3 +--I [--+ 2 5

tung 2 : 4 0

I LOW PRESS COMB. AIR PSL-003 1 B3 I:2.0 B3 -+-- 1 [----- ] [---2-+------------------------------------------------------ ( 1- -

2 6 I 26 B3 T4:7

+--I I--- ] / I-------+ 26 DN

(

LOW PRESS COMB. AIR PSL-003

B3 I:2.0 +--I / I----- ] I-----+

27 1 B3 T4:7 1 +--I/[---]/[------- +

2 7 DN

BFP"ER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 15 "- ram Listing Processor File: AM2579.ACH Rung 2 : 4 2

Rung 2 : 4 1

LOW PRESS ATOMIZ.AIR PSL 007 1:T.o ----- 3 [----- -I--

8 T4:5 1

---I/[------- + 8 DN

LOW PRESS ATOMIZ.AIR PSL 007

1:T.o I

Rung 2 : 4 3 ALARM SILENCE

PB 2 B 3 1 : 2 . 0 B3

-+--I [--+----]/[-------------------------------------------------------- ( I - -

2 8 I 14 29 I 8 3 +--I [--+ 2 9

HIGH PRESS STABILIZER PSH 006

B 3 1:Z.o B3 -+--I [--+---- 1 [-------------------------------------------------------- ( ) - -

3 0 I 7 30 I B3 +--I / [--+

31

;ER :SIGN & CONSTRUCTORS I N C . AM-2579 By:R.G. March 29, 1993 Page 17 jran L i s t i n g P roces so r F i l e : AM2579.ACH Rung 2:49

Rung 2 : 5 1

I

ALARM HORN AH

B3 0 : 4 . 0 -+--I [--+------------------------------------------------------------ ( ) -----

3 4 I 7 J B3 +--I [--+

1 8 3 35 1 +--I [--+ 36

BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 18 'ram L i s t i n g P r o c e s s o r File: AM2579.ACH Rung 2:52

Rung 2 : 5 2

Rung 2:53

HEATER ON L 12

B3 0: 3-0 -+---- 3 [-----'------------------------------------------------------- ( I-----

HIGH TEMP HTR COIL 1

L 13 0: 3,0

4 LAMP TEST

PB 3 1 : 2 . 5

1 I LAMP TEST 1

6

Rung 2 :54 I

+---- ] [----- -+ 15

I B3 B3 +--I / [ -------- I/[-------- i + 8 9 / LAMP TEST 1

HIGH TEMP HTR COIL 2

L-14 0 :3 .0 .......................................... ( I-----

8

>AD' P DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 29, 1993 Page 19 '-o, dm Listing Processor F i l e : AM2579.ACH Rung 2:55

{ung 2 : 5 5 BURNER HINGE SWITCH

L 15 S:4 B 3 B3 0 : 3,0

-+--I [-------- ]/[---I [--+------------------------------------------- ( )-----

5 10 l1 I 9 1 B3 B 3

+--I/[-------- I/[-------- + 10 12

LAMP TEST PB 3

1:2.5 B 3 +---- 3 [------ ] [-------- +

1 5 1 0

Rung 2:56

I FLAME FAILURE

I-+--] [-------- I/[---] [--+------------------------------------------- ( ) ----- 5 12

l3 I 10

i B3 B 3 +--I/[-------- I/[-------- +

12 13 LAMP TEST

PB- 3 I:2.0 B 3

Rung 2:57 LOW LOW LEVEL EXF . TANK

1-17 S:4 B 3 B 3 0: 3 . 0

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BADGER DESIGN & CONSTRUCTORS INC. AM-2579 By:R.G. March 2 9 , 1993 Page 25 Pr ram Listing Processor File: AM2579.ACH Summary

kLPORT OPTIONS SUMMARY

Insure Valid X-Ref Info: Graphics Mode: Page Width: Page Length:

Starting File: Ending File: Power Rail: Address Comments: Address Display: Rung Comments: Ladder Cross Reference:

2 2 YES YES YES NO NONE

The Getting Started Guide for APS (Catalog Number 1747-PA2E)

User's Manual

Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. "Application Considerations for Solid State Controls" (Publication SGI- 1.1) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will the Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited.

01992 Allen-Bradley Company, Inc

We want our manuals to be the Best! You can help. Our manuals must meet the needs of you, the user. This is your opportunity to make sure they do just that. By filling out this form you can help us provide the most useful, thorough, and accurate manuals available. Please take a few minutes to tell us what you think.

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Using This Guide Chapter 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 HardwareRequirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Overview of the Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 IntendedAudience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setting Up Your Equipment Chapter 2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Styles 2-2 ........................................ Setting Up a Demo Kit 2-3

Setting Up a Field-Wired Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Connecting the Controller to a Personal Computer . . . . . . . . . . . . . . . . . . 2-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Computer Requirements 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Software 2-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RunningAPS 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APS Display Format 2-9

Control Basics Chapter 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SLC 500 File Concepts .. ..... . . . 3-1 How External I/O Devices Communicate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with the Processor 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Addressing External 110 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ladder Logic Concepts 3-5

Creating a Processor File Chapter 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration of SLC 500 Controllers 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating a Processor File 4-4

Online Operations. Quick Chapter 5 Edit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

. . . . . . . . . . . . . . . . . . . . . . . . Restoring (Downloading) a Processor File 5-2 TestingtheProgram .......................................... 5-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Editing the Program with QuickEdit 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Data Files 5-8

Creating and Printing Reports

Chapter 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CreatingReports ............................................. 6-2 PrintingReports ............................................. 6-4

Additional Ladder Program Appendix A Exercises Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Entering an Input and Output Branch ............................. A-2 Entering a Timer Instruction .................................... A-4

Troubles hooting Errors Appendix B Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 APS Error Messages .......................................... B-1 System LED Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Processor Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Glossary

Getting Started Guide for APS

Introducing the SLC 500 Family of Small Logic Controllers

Preface

Welcome! We in the SLC 500 product group are excited that you have made Allen-Bradley your company for small logic controllers. We are confident that you will find this decision to be the right one.

The SLC 500 programmable controller is not only the solution for today's small control applications, but its higNy versatile design allows for continual upgrading to meet future industrial challenges.

While you have acquired an invaluable technological resource, you have also enlisted a team dedicated to helping you tap this resource.

Committed to Sewing YOU Our goal is to anticipate, rather than react to, your industrial control needs by providing upfront information and support. That is why we offer:

The Allen-Bradley application support hotline 1-800-289-2279 (or 1-800-289-ABSW), which you can call when you have questions concerning your SLC 500 controller or APS software. SLC 500 training from distributors and sales offices.

Our relationship with customers is by no means one way. We encourage you tqsuggest ways that we can better serve you. In fact, the Getting Started ~ u i d e for APS was created as a result of customer suggestion and input. So your comments do count.

The Getting Started Guide This guide is an introductory document, designed to allow you to install APS and begin programming in the shortest time possible. It does this by focusing on a simple controller and a simple program. Basic concepts are presented, but only with enough detail to get you started and let you know that there is more to be learned. Read chapter 1 first. It will acquaint you with the rest of the guide.


Preface

Introducing the SLC 500 Family of Small Logic Controllers

Welcome! We in the SLC 500 product group are excited that you have made Allen-Bradley your company for small logic controllers. We are confident that you will t-md this decision to be the right one.

The SLC 500 programmable controller is not only the solution for today's small control applications, but its highly versatile design allows for continual upgrading to meet future industrial challenges.

While you have acquired an invaluable technological resource, you have also enlisted a team dedicated to helping you tap this resource.

Committed to Sewing YOU Our goal is to anticipate, rather than react to, your industrial control needs by providing upfront information and support. That is why we offer:

The Allen-Bradley application support hotline 1-800-289-2279 (or 1-800-289-ABSW), which you can call when you have questions concerning your SLC 500 controller or APS software. SLC 500 training from distributors and sales offices.

Our relationship with customers is by no means one way. We encourage you tazuggest ways that we can better serve you. In fact, the Getting Started Guide for APS was created as a result of customer suggestion and input. So your comments do count.

The Getting Started Guide This guide is an introductory document, designed to allow you to install APS and begin programming in the shortest time possible. It does this by focusing on a simple controller and a simple program. Basic concepts are presented, but only with enough detail to get you started and let you know that there is more to be learned. Read chapter 1 first. It will acquaint you with the rest of the guide.


Using this Guide

Hardware Requirements

Read this chapter first. It covers:

Hardware requirements Overview of the Guide Intended audience Related publications

This guide provides task-oriented procedures that introduce you to APS and SLC controllers through hands-on practice. To perform these tasks we recommend the following hardware:

An SLC 500 modular or fixed controller with external inputs and outputs. An SLC 500 demo unit would be ideal. The programs and examples used in this guide are based on using a modular controller demo unit (catalog no. 1747-DEMO 3 or 1747-DEMO 4). A compatible personal computer (PC). A list appears on page 2-6. An RS-232lDH-485 Interface Converter (catalog no. 1747-PIC).

A communications cable for connecting the Interface Converter to the controller (catalog no. 1747-C10). This cable is supplied with the Interface Converter. A compatible printer, if you choose to use the "Print Reports" capability described in chapter 6.

Overview of the Guide

Intended Audience

Related Publications

The table below provides a brief overview of the guide.

The Getting Started Guide is intended as an introduction of APS software to first-time users. The simple tasks and practice exercises in this guide do not include important user information for actual control applications.

Chapter

1

2

3

4

5

6

Appendix A

Appendix B

The table below is a partial list of publications that contain information about installation, programming, and operation of SLC 500 controllers.

Title

Using this Guide

Setting up Your Equipment

Control Basics

Creating a Processor File

Online Operations, Quick Edit


Additional Ladder Program Exercises

Troubleshooting Errors

Purpose

An overview of the manual.

Shows you how to set up a controller, connect your PC to the controller, and install APS software on your PC.

Presents basic information you will need to know before you can begin programming with APS.

Shows you how to create a processor file, enter a ladder program and add a rung comment

Shows you how to restore (download) your processor file to the controller, monitor and test the program, and use Quick Edit.

Guides you through creating and printing reports. These include program listing, cross reference, processor configuration, and data tables.

introduces you to branching of instructions and the timer instruction.

Provides a listing of error messages that you may encounter while working through the guide. Also, offers possible solutions for these errors.

Glossary Provides a listing of terms used throughout this guide.

Description

Detailed information on programming with APS

Detailed information on installing, wiring, and operating fixed controllers

Detailed information on installing, wiring, and operating modular controllers

Name

APS User's Manual

SLC 500 Fixed Hardware Style Installation and Operation Manual

SLC 500 Modular Hardware Style Installation and Operation Manual

CataloglPublication Numbers

Catalog Number 1747-NM002 Series A

Publication 1747-800

Publication 1747-804

Overview

Getting Started Guide I for APS

Setting up Your Equipment

This chapter briefly describes SLC 500 controller styles, then shows you how to set up your equipment in preparation for the exercises in later chapters. Topics:

Controller Styles Sening up a Demo Unit Sening up a Field-Wired Controller Connecting the Controller to a Personal Computer Personal Computer Requirements Installing the Software Running APS APS Display Format

Controller Styles The SLC 500 comes in two different styles: modular and fixed. These styles are illustrated below. The modular controller consists of a rack, power supply, Processor (CPU), and InputlOutput (UO) modules. The fixed controller consists of a power supply, processor (CPU), and a fixed number of U 0 contained in a single unit. An expansion rack can be added to the fixed controller.

Processor Output Module

SLC 500 Modular Controller

slot 0 1 2 3

Output Terminals

I

ill slot 0

SLC 500 Fixed Controller

Further information on hardware is found in the Installation and Operation Manuals, Pub. 1747-800 (fixed controllers) and 1747-804 (modular controllers).


Setting Up a Demo Unit

SLC 500

SLC 500 demo units are available with either a fixed controller or modular controller. This guide assumes you are using a modular controller demo unit for all the programming exercises. If you use a fxed contioller demo unit, you will need to use different configuration information and I/O addresses in the exercises. This is explained later.

The figure below shows an SLC 500 modular controller demo unit. It is completely wired, with 12 external inputs (six push buttons and six selector switches) and 8 external outputs (pilot lights).

In setting up your system, place the demo unit near your personal computer. Note the OnIOff Power Switch and the Power Supply Receptacle on the demo. Make certain that the power switch is Off, then insert one end of the power cord into the power supply receptacle and the other end into an electrical socket.

Modular Controller

Pilot Light'Pushbuttons - Selector Switches

Setting Up a Field-Wired Controller

The details of installing and wiring the controller and external inputloutput devices is beyond the scope of this guide.

If you are using a field-wired fixed or modular controller, refer to the Installation and Operation Manuals, Pub. 1747-800 (fixed controllers) and 1747-804 (modular controllers), for information on installation and wiring of the controller and external inputfoutput devices. We recommend that your controller have at least two external input devices and two external output devices connected to complete the exercises in this guide.

Connecting the Controller TO connect the controller to a personal computer, you will require a to a Personal Computer communications cable, catalog number 1747-CIO, and an R S - ~ ~ Z I D H - ~ R ~

interface converter, catalog number 1747-PIC. Procedure:

1. Locate the Communications Port of the controller. The figure below shows where it is located on modular and fixed controllers.

SLC 500 Fixed Controller n Processor Module (Modular Controller)

(Communications Port) u 2. Insert one end of the 1747-C10 cable into the communications port of

your controller.


3. Insert the other end of the 1747-C10 cable into the DH-485 connector of the 1747-PIC interface converter. The DH-485 connector is shown below.

DH-485 Connector

Personal computer Interface converter

RS-232 Connector

4. Insert the RS-232 connector (see figure above) of the interface converter into the serial communication port of your computer.

If your computer has a 9-p* serial port, use the 9-25 pin adapter provided with the interface converter.

The figure below shows a modular controller connected to a personal computer.

SLC Controller

174741 0 Cable *r0JRW2 Personal Computer

Personal Computer Requirements

Installing the Software

The Advanced Programming Software (APS) can be used with an Allen-Bradley T45, T47, or T50 terminal, an IBM-AT or XT, a Compaq Portable, Portable 11, Deskpro 286,386/SX, 386, a Tandy 3000HL, or Toshiba 3 100E personal computer. Your computer must have:

640 KBytes of RAM (extended or expanded memory is recommended, but not required) 10 MBytes fxed-disk drive (APS requires a minimum or 2.5 MBytes of free disk space) DOS version 3.1 or higher

Before you actually install the software, complete the prepaid postage Software Updates registration card and return it to Allen-Bradley. This is very important, since it confirms your registration.

We assume that you have installed DOS in your computer. If you have not, do this now, following the instructions supplied with your computer.

To determine if your computer has enough memory for the software, at the DOS prompt type: CHKDSK, then press [ENTER]. The screen displays the memory configuration of your computer. Check the last line of the display "XXXXXX bytes free". You must have at least 525 KEiytes of free memory to execute the APS software.

Important: Make sure your CONFIG.SYS file contains the following statements (to check this, type TYPE CONFIG.SYS at the DOS prompt):

FILES = 30

BUFFERS = 30

Important: These are minimum values. If your CONFIG.SYS file contains FILES and BUFFERS statements with greater values, there is no need to change the file. Be aware that these statements may conflict with the CONFIG.SYS requirements for other software packages you have installed on your programming terminal.

To change this file, follow the instructions supplied with your computer.

If you change the CONFIG.SYS file, you must re-boot the system to initialize the file. You can do this by pressing Ctrl +Alt +Del at the same time.

The APS software, Catalog No. 1747-PA2E, is supplied on 5- 114 inch disks and also on 3- 112 inch disks.


To install the APS software, do the following:

1. Insert the disk labeled Disk 1 into the appropriate disk drive (either drive A or drive B). For this example, we are using drive A.

2. Type: A:INSTALL, then press Enter].

During the installation process, instructions appear on the screen to prompt you through the procedure. Follow the instructions and type in the information requested.

If this is the first time you have installed the software, the system prompts you for your name, the name of your company, and the serial number of your software. This is also the case for any software updates you may install.

Important: During the installation process you are asked for the serial number of your software. The serial number is not found on the disks. The serial number is located in several places:

1. On the spine of the software manual binder.

2. On the software registration card.

3. On the registration change card.

4. On the outside of the shipping carton.

Important: If you enter the serial number incorrectly or enter the wrong serial number and accept the entry, you will be unable to correct this situation later. Verify your entry carefully, before committing your work. The serial number you enter is used to personalize the software.

Running APS To run APS, follow these steps:

1. If necessary, change the drive specifier to the drive where the software is installed (typically C). To do this, type

C: and press [Enter].

2. If you are using the default directory (and did not speclfy a different directory path during the install procedure), at the DOS prompt, type

CD UPDS\ATTACH\SLCSOO and press [Enter].

If you specified a different directory path, change to that directory and press Enter].

3. Q p e APS and press IEnter].

The APS menu will appear:

Display area: SLC-500 ADVANCED PROGRAMMING SOFTWARE - RELEASE 3.00 Allen-Bradley Company, Copyright 1991

174 7-PA2E

All Rights Reserved

This software is licensed to: Your name Your company name 0000000000 1

I Tue Jul 24, 1991 Current Offline File: 09 11:03:09 am I ---

Terminal Address: 0 Current Device: 1747-PIC (DH-485) Proc Address: 1

Message: Prompt: Press a function key

Data entry: Status:

Main Functions: SYSTEM

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

Exiting the System: You can exit APS software and return to DOS by accessing the APS menu, shown above, and pressing function key F10, Exit System.


APS Display Format The APS screen is divided into three areas:

Display area Message, prompt, data entry, and status lines Main functions

The figure below indicates what appears in these areas.

Display area: The five APS displays appear here -the APS menu, offline program directory (shown here), offline monitor file, online program directory, and online monitor file. Various option windows overlay these displays, depending on the function you are accessing. Also, the status data file and other data files, force tables, and the memory map appear in thi area. t

DIRECTORY FOR PROCESSOR : OSTEST

NAME TYPE S I Z E (words ) 0 s y s t e m 217

Message: Prompt: P r e s s a key , e n t e r f i l e number o r f i l e name

Data entry: Status: 4 o f f l i n e SLC 5/02 S e r i e s B F i l e 05TEST

Message line: Error codesldescriptions and information concerning terminal or processor operation appears here.

Prompt line: Indicates action you should take.

Data entry line: Information entered from the terminal keyboard appears on this line.

~ a i n functions: APS functions appear here. They are accessed by terminal keys F1 to F10. Pressing a main function key calls up sub-functions and sometimes option windows.

Status line: Status information concerning the processor and program file appears on this line.

Getting Started Guide

Overview

SLC 500 File Concepts

for APS

Control Basics

This chapter introduces you to basic concepts essential for understanding how the SLC 500 controller operates. It covers:

SLC 500 file concepts How external 110 devices communicate with the processor Addressing external LIO Ladder logic concepts

The CPU, or processor, provides control through the use of a program you create. The program you create is called a processor file. This file contains other files that break your program down into more manageable sections. These sections are:

Program Files - provide storage and control of the main program and subroutines. Data Files - contains the status of inputs, outputs, the processor, timers, counters, and so on.

Processor Files: Each CPU can hold 1 processor file at a time. The processor file is made up of program files (up to 256 per controller) and data files (up to 256 per controller).

Processor File

Processor files are created in the offline mode using APS. These fdes are then restored, also referred to as downloaded, to the processor for online operation.

Program Files: Program files contain controller information, the main control program, and any subroutine programs. The first three program files are required for each processor file. These are:

File0 This file stores the controller configuration and other system information. File 1 This file is reserved for internal controller use. File 2 This file stores the main control program. Files 3 -255 These files are optional and used for subroutine programs.

Most of your work with program files will be in file 2, the main program file, This f ie contains your ladder logic program which you create to control your application.

Data Files: Data fdes contain the data associated with the program files. Each processor fde can contain up to 256 data files. These files are organized by the type of data they contain. Each piece of data in each of these files has an address associated with it that identifies it for use in the program file. For example, an input point has an address that represents its location in the input data file. Likewise, a timer in the timer data ffle has an address associated with it that allows you to represent it in the program file.

The first 9 data files (0 - 8) have default types. You designate the remainder of the files (9 - 255) . The default types are:

File 0 - Output Data This file stores the state of the output terminals for the controller. File 1 -Input Data This file stores the status of the input terminals for the controller. File 2 - Status Data This file stores controller operation information. Files 3 -7 These files are pre-defined as Bit, Timers, Counters, Control and Integer data storage, respectively. File 8 This file is reserved for internal use. Files 9 -255 These files are user-defined as Bit, Timer, Counters, Control and Integer data storage.

Most of your work with data files will be in files 0 and 1, the output and input files. Refer to Appendix A for an example of the Timer data file.


How External 110 Devices Communicate with the Processor

The figure below applies to a modular controller demo unit having an input module in slot 1 and an output module in slot 3. See page 2-2 for a diagram of the slot location. To simplify the illustration, only pushbutton 0 and pilot light 0 of the external YO are shown.

Each of the external input circuits is represented by a status bit in the input data file of the processor file. Each of the external output circuits is represented by a status bit in the output data file of the processor file. During controller operation, the processor applies the input data to the program, solves the program based on the instruction you enter, and energizes and de-energizes external outputs.

Input Module in slot 1

Pushbunon 0 is wired to terminal 0. Pressing pushbutton 0 will cause the corresponding status bit in the input data file to go from 0 to 1.

l n ~ u t Data File

address data 1:1 0000

Status bit 0 corresponds to terminal 0 of the input module in

slot 1.

Closing an external input circuit changes the corresponding status bit from 0 to 1.

Opening an external input circuit changes the corresponding status bit from I to 0.

Output Module in slot 3

Pilot light 0 is wired to terminal 0. The pilot light will be energized when the processor has completed evaluation of the program and transfers the OrJlOFF status to the outputs.

I

Output Data File - -

address data

Status bit 0 corresponds to terminal 0 of the output module in

slot 3.

When an output data file status bit has been solved as a I, the corresponding extemal output circuit will be energized (ON).

When an output data file status bit has been solved as a 0, the corresponding external output circuit is de-energized (OFF).

Addressing External I/O AS pointed out in the last section, external inputs and outputs are linked to the input data file and output data file of the processor file. Each status bit in these files has an address. You specify the appropriate address when you enter an instruction in your ladder program.

For our purposes, input addresses have the form I : e /b where I = Input data file : = Element or slot delimiter e = Slot number of the input module / = Bit or terminal delimiter b = Terminal number used with input device

Similarly, output addresses have the form 0 : e/b where 0 = Output data file : = Element or slot delimiter e = Slot number of the output module / = Bit or terminal delimiter b = Terminal number used with output device

Examples: I : 1 /0 = Input, slot 1, terminal 0 I : 2/0 = Input, slot 2, terminal 0 0 : 3 / 0 = Output, slot 3, terminal0 0 : 3/7 = Output, slot 3, terminal 7 0 : 0/7 = Output, slot 0, terminal 7 (fixed controllers only because of slot 0) I : 0/4 = Input, slot 0, tenninal 4 (fixed controllers only because of slot 0)

Eventually, you will be addressing other data files, such as Status, Bit, Timer, Counter, Integer, and Control. Addressing of these files is discussed in the APS programming manual.

APS display of instructions/addresses: APS displays I/O addresses as shown below.

When you enter an XIC instruction (defined later) and the address I : 1/0, APS will display the address with the instruction as follows:

Explanation: /'

Input data file, slot 1, word 0

1:l.O ---I F- / O - Terminal 0

XIC instruction


Ladder Logic Concepts AS we mentioned earlier, the program files you create contain the program used for your controlling application. The programs are written in a programming language called Ladder-Logic. This name is derived from its ladder-like appearance.

A ladder logic program consists of a number of rungs, on which you place instructions. Instructions each have a data address associated with them and based on the status of these instructions the rung is solved.

The figure below shows a simple I-rung ladder program. The rung includes two input instructions and an output instruction. Note, in the example below each instruction has a name (Examine if Closed), a mnemonic (XIC), and an address (I: 110).

Input Instructions Output Instruction

OTE pr: -1- I0 0 : 3 . 0 1 1 0 4

XIC = Examine if Closed Address I:l/O XI0 = Examine if Open Address I:1/1 OTE = Output Energize Address 0:3/0

A simple rung, using bit instructions.

TrueRalse Status: The data file bits that these instructions are addressed to will be either a logic 0 (OFF) or a logic 1 (ON). This determines whether the instruction is regarded as "true" or "false":

If the data file bit is

Logic 0

Logic 1

The status of the insttuction is

XIC Examine if Closed + +

False

True

XI0 Examine if Open +/+

True

False

OTE Output Energize

---t P

False

True

Logical Continuity: During controller operation, the processor evaluates each rung, changing the status of instructions according to the logical continuity of rungs. More specifically, input instructions set up the conditions under which the processor will make an output instruction true or false. These conditions are:

When the processor finds a continuous path of true input instructions in a rung, the OTE output instruction will become (or remain) w e . We then say that "rung conditions are true". When the processor does not find a continuous path of true input instructions in a rung, the O'IE output instruction will become (or remain) false. We then say that "rung conditions are false".

The figure below indicates the data file conditions under which the rung is true:

Input Instructions I Output Instruction

lnput Data File

address data 1:l 0001

status bit 1:111 is a Status bit I:1/0 is a

logic 0, making the logic making the XIO instruction true XIC instruction true

I Output Data File

I address data 0: 3 0000 0001

The processor changes status bit 0:310 to I a logic 1, because a continuous path 01

I true input instructions exist in the rung.

In the above example, if the input data file was 0000, then the rung would be false and the output data file would read as 0000 0000.

Getting Started Guide 1 for APS

The Processor Operating Cycle: The diagram below indicates the events that occur during the processor operating cycle. This sequence is repeated many times each second.

The status of external input circuits is

The ladder program is executed. The input data file is evaluated, the ladder rung is solved, and the output data file

Output Data File

address The output data file information is

0000 0001 transferred to the external output circuit, thus energizing or de-energizing it.

Communications with the programming

Communications terminal and other network devices

Ovetview


for APS

Configuration of SLC 500 Controllers

Creating a Processor File

In this chapter you create a processor file. The tasks you will perform:

For modular controllers: Make a record of the processor module catalog number, the rack catalog number(s), the I/O module catalog numbers, and the slot locations of 110 modules. Or, for fixed controllers: Make a record of the controller catalog number (and YO module catalog numbers and slot locations if you are using the 1746-A2 expansion rack). Run APS software and initiate the creation of a processor file Name the processor file GETSTART

Enter the controller configuration Enter a l-rung ladder program

Add a rung comment Save the processor file to disk

The following paragraphs briefly describe SLC 500 controllers and indicate the location of catalog numbers on the devices. This information wiIl help you when you create a processor file and enter the specific controller configuration that will run the file.

To make the best use of this guide, you should have access to an SLC 500 Demonstration Unit, which includes completely wired external inputs and outputs. For the exercises in this guide, we arbitrarily assumed that you are using a Demo unit using a modular controller with the components listed on page 4-4.

Controller Styles As previously mentioned, SLC 500 controllers are available in two styles -the fixed controller and the modular controller. Examples are shown in the figure below.

SLC 500 Fixed Controller SLC 500 Modular Controller

~rocessor & Expansion Rack Power supply \ Power

7- Processor / slot rack

Slot 0 1 2 Slot0 1 2 3 4 5 6

The fixed controller combines a power supply, processor (CPU), and a fixed number of I/O points in a single unit. You have the option of adding a 2-slot expansion rack if you want to add I/O points.

The modular controller consists of a power supply, 1-3 I/0 racks, a processor module which you insert in slot 0 of the first rack, and various I/O modules which you insert in the remaining slots of the racks.

Slot Numbers: Note that slot numbers are indicated in the figure above. In fixed controllers, slot 0 applies to the processor and fixed I/O points; slots 1 and 2 apply to 110 modules located in the expansion rack. In modular controllers, slot 0 is always reserved for your processor module; the remaining slots apply to the various 110 modules you have inserted.

Catalog Numbers When you configure your controller, you must specify the processor catalog number, rack catalog numbers, and UO module catalog numbers as required. The location of the catalog number on the various components is shown in the following figures.

Make a record of controller components: We recommend that you make a list of the processor, rack, and YO catalog numbers, and also the rack numbers assigned to the racks and the slot locations of all I/O modules. You can then refer to this list as you configure your controller.


Catalog Number Location - SLC 500 Fixed Controllers

Label for Processor Catalog I and Serial number

Processor 0 7

Catalog Number , 0

/ /A The catalog number for the expansion rack is 1746-A2. It appears on side of the rack.

I Side View

Catalog Number Location - SLC 500 Modular Controllers

Processor (CPU) Modules Label for Processor Cat-

- Side View

Racks

I @ SLC 500 1 1747-L W Processor /

Catalog Number /

,----- .rr/)

Label for Rack Catalog and Serial no.

C -------.

I10 Modules

e catalog number and serial number for VO modules also appears on the side of the module.

10 SLC 500 I

I 4 Rack Catalog Number 0

-CdR

." _--- Side View L

Arbitrary Controller used in this Guide In the following procedures, we have arbitrarily assumed that the controller you are configuring in your processor file is a modular demo unit including the following components:

Rack 1746-A4,4-slot rack

Processor 1747-L5 1 1 in slot 0

Input module 1746-IA4 in slot I

Input module 1746-IA8 in slot 2

Output module 1746-OA8 in slot 3

The ladder program shown on page 4-8 contains I/O addresses which are consistent with the configuration indicated above. If you are using some other controller configuration, keep in mind that these addresses may not be valid for your controller.

Creating a Processor File A processor file is always created offline, in the terminal workspace. In creating the processor file, you will:

Name the file and configure the controller

Enter a ladder program

Add a rung comment

Save the processor file to disk

If you are not already running APS, refer to "Running APS", page 2-8. The following procedure begins at the APS menu display.


Name the processor file and configure the controller

Complete the following steps:

1. Access the Create Processor File window

Press , , then . The display shown below will appear. F4 F6

PROCESSOR - INPUTS - OUTPUTS

1 7 4 3 - L 5 1 4 5 / 0 1 CPU - 4 K USER MEMORY 1 7 4 7 - L 5 2 4 5 /02 CPU - 4K USER MEMORY 1 7 4 7 - L 2 0 A 1 2 - 1 1 5 VAC 8-RLY 1 7 4 7 - L 2 0 B 1 2 - 1 1 5 VAC 8-TRIAC 1 7 4 7 - L 2 0 C / F 12 -DC SNK 8-RLY

CREATE PROCESSOR F I L E

NAME : F 2 P r o c e s s o r : 1 7 4 7 - L 5 1 1 I 5 / 0 1 CPU-1K USER MEMORY

L ESC e x i t s / A l t - U abor ts c h a n g e s I Message:

Prompt: P r e s s a F u n c t i o n key o r E n t e r F i l e Name Data entry:

Status:

Main Functions:

2. Enter the name GETSTART The prompt line asks you to enter a file name. Type "GETSTART", then press [Enter]. GETSTART appears in the Create Processor File window.

3. Enter the appropriate processor catalog number The Create Processor File window lists the default processor, 1747-L5 11. This is correct for our controller. If you are using a different processor, use the cursor keys to locate the appropriate processor in the upper option

window, then press . F2

Fixed controllers without an expansion rack: If you have selected a fried controller and are not using an ex~ansion rack, the controller configuration is - complete at this point. Press and go to step 7.

4. Configure the racks of your controller

. The following option window appears. Note that rack 1 is F5

specified as 1746-A4, the default selection. This is correct for our controller.

If you are using a different rack, press , then . Select the F4 F1

appropriate rack, using the cursor keys, and press [Enter]. If you are using more than one rack, follow the same procedure for racks 2 and 3.

Display area: r 1/0 CONFIGURATION F0R:GETSTART 1

I RACK 1 = 1746-A4 4-SLOT Backplane RACK 2 = NOT INSTALLED RACK 3 = NOT INSTALLED

SLOT CATALOG # CARD DESCRIPTION I

Message: Prompt: p r e s s a function key

Data entry: Status:

Main Functions:

Note the asterisks next to slots 0 thru 3. This indicates that we have configured these slots and can now configure I/O modules. Slot 0 is already configured with our processor.

5. Configure the I/O modules

The cursor is located on slot 1. To configure it, press . The F5

following option window appears:


Display area:

Message: Prompt: Press ENTER to select I/O Module

Dataentry: Enter Module ID Code > $j$: Status:

Main Functions:

This window allows you to select a module for slot 1. Use the upldown cursor keys to place the cursor on the appropriate module catalog number,

. This returns the display to the If0 configuration F2

window with the selected module indicated. Cursor down to the next open slot and repeat the configuration steps. For our controller, the completed option window will appear as follows:

Display area: 1/0 CONFIGURATION F0R:GETSTART

RACK 1 = 1746-A4 4-SLOT Backplane RACK 2 = NOT INSTALLED RACK 3 = I NOT INSTALLED

SLOT CATALOG # CARD DESCRIPTION *0 1747-L511 5/01 CPU - 1K USER MEMORY *1 1746-IA4 4-Input 100/120 VAC

4 5 6 7 8

ESC exits


Data entry: Status:

Main Functions: 1 1 I I Ml F4 F5 F6 F7 F8

6. Create the archive file GETSTART

Press , then . Archive f i e GETSTART is created on F8 F8

your computer hard disk and placed in the Offline Processor File window.

7. Return to the APS menu

Press . The file GETSTART is in the terminal workspace, and you F8

have returned to the APS menu.

Enter the Ladder Program

The following rung consists of an XIC input instruction and an OTE output instruction. The addresses conform to the controller configuration indicated on page 4 4 . If you have entered a different controller configuration, make certain that the addresses are consistent with your configuration. It is also important that you have an external input, such as a pushbutton, and an external output, such as a pilot light, at the terminal addresses used. You will be using these external devices in later chapters of this guide.

P1.- 0 : 3 . ~

The rung can be entered by completing the following steps:

1. Access the Program Directory of file GETSTART

Press m. 2. Monitor Program File 2

Press

3. Insert a rung

Press ,then m.


4. Enter the Input instruction on the rung

F4 F1

then press [Enter].

5. Enter the Output instruction on the rung

Press , then . Type the address "0:310". then press F1

[Enter].

6. Accept the rung

Press [Esc], then , then [Esc].

Add a Rung Comment

Complete the following steps to add a rung comment:

1. Configure the display so that rung comments will be visible

Press , then [Esc]. The display is now configured so that rung F10

comments are visible.

2. Add the rung comment

Press , then . Type the comment "Input pushbutton F5 F1

turns on output pilot light".

3. Accept and save the comment

Your completed ladder program and m g comment should look like this:

Display area: Input pushbutton turns on output pilot light

1:l.O ..... p::3 .... . q . .... . . . . ... ... . . . . . . . 0

Message: Prompt: P r e s s a f u n c t i o n , , k e y

Data entry: ( f i l e 2 , r u n g 0);::; . . ...: Status: o f f l i n e no f o r c e s

Main Functions:

F i l e GETSTART

1 1 piq UTILITY MONITOR

Save the Processor File

Complete the following steps to save the processor file to disk:

1. Return to the Program Directory

2. Save the file to disk

Press . Accept the default Save options by pressing Em 3. Return to the APS menu

Overview


Online Operations, Quick Edit

In this chapter you will complete the following tasks:

Restore (download) processor file GETSTART Monitor the ladder program in the run mode Test the program

* Edit the program using Quick Edit Test the edited program Monitor the input and output data files

Restoring (Downloading) a There are two tasks to complete in restoring processor file GETSTART to the Processor File processor :

Check the Online Configuration parameters

Go online and restore (download) processor file GETSTART

The procedures begin at the APS menu display.

Check the Online Configuration parameters Complete these steps:

1. Access the Online Configuration window

Press . The display shown below will appear. F2

Display area: - ONLINE CONFIGURATION I F1 Port COMl F2 Current Device 1747-PIC (DH-485) F3 Baud Rate 19200 F4 Terminal Address 0 F5 PROC Address 1 F6 MAX Node Address 3 1

F9 Save to File I - ESC exits/Alt-U aborts changes


Data entry: Status:

Main Functions: DEVICE

2. Verify the parameters The default values are shown for items F1 to F6. If you used the COMl port of your computer and used a catalog 1747-PIC Interface Converter when connecting your computer to the controller, chances are that you will be able to establish processor-computer communications. If any of these default parameters are incorrect, change them with the function keys, then:

Press , then Fsc]. This returns the display to the APS menu. F9


Go Online and restore (download) processor file GETSTART Complete these steps:

1. Access the Restore File window

F1

If the message MESSAGE TIMEOUTS - LOSS OF COMMUNICATIONS appears, one or more of the Online Configuration parameters is incorrect and/or there is an improper connection between the computer and the processor. Refer to appendix B.

Once you establish communications w& the processor, the program directory display will appear. Do one of these three things:

a) If the default program directory appears, (the directory is named

DEFAULT, and only the system file is listed) press . F2

b) If a file exists in the processor, and no matching disk file is found on the computer harddisk, you will be asked "Read Processor Program?". Press

c) If a file exists in the processor, and a matching disk file is found on the 0 .

computer harddisk, press , then .

After you have done a), b), or c), the following display appears:

Message: Prompt: Press a F u n c t i o n Key o r E n t e r F i l e N a m e

Data entry: ij:i:ji +:.:..

Status: p r o g r a m S L C 5/01 S e r i e s A FRN 1

Display area:

Main Functions:

- \IPDS\ARCH\SLC5 00

Name S i z e D a t e

'..,'.,.,.,~.' :.:.;.: ........... " ................................... .... , , : , - , ~ ~ ~ ; & ~ ~ $ ~ ~ ~ > ~ ~ ~ ~ ~ : : ; ; : : ~ : i : ~ : : : : : i _ : : ? ~ ~ i ~ ; ~ ~ ::

PROC A d d r 1

RESTORE FILE

F3 F i l e Name:

ESC e x i t s / A l t - U aborts c h a n g e s

Restoring (Downloading) a 2. Select and accept file GETSTART P ~ O C ~ S S O ~ File (continued)

The cursor is located in the righthand window, which lists all of the processor files saved on disk. Move the cursor to the file GETSTART if it is not

already there. Press . GETSTMT appears in the Restore File F3

window. Then press . If the processor is in the program mode, the FB

file will be restored (downloaded). If the processor is in the run mode, you

will be asked "Change Processor Mode to Program?". Press . File F8

GETSTART will then be restored (downloaded).

When the restoring (downloading) process is complete, you will be asked to "Press Any Key to Continue". After you press any key, the program directory for file GETSTART will appear:

- PROGRAM DIRECTORY FOR PROCESSOR: GETSTART

F I L E NAME T Y P E SIZE (words) 0 system 7 2 1 reserved 0

Message: Prompt: Press a key, e n t e r f i l e number o r f i l e name

Data entry: iK Status: program SLC 5/01 S e r i e s A FRN 1 PROC Addr 1

Testing the Program To test the ladder program you entered in chapter 4, we will now monitor program file 2, and change the processor mode from program to run. Then activate the external input having address I:O/O and observe the effect on the external output at address 0310.

Begin at the program directory display for processor file GETSTART.


1. Monitor program file 2 and enter the run mode

Press . The ladder program will appear.

Press 8 1 , then , then . (Note that the status line F1 F3 F8

now indicates RUN instead of program.) If you get a fault code on the status line, refer to appendix B to clear the fault.

2. Test the program The following diagram shows the rung you entered if you are using the modular controller demo unit discussed on page 4-4. If you are using some other controller configuration, make certain that your external input device and output device are wired to the controller input and output that you addressed in your ladder program.

Address 1:1.010 corresponds to pushbutton

0 of the demo unit

Address 0:3.010 corresponds to pilot light

0 of the demo unit

To test the program, press pushbutton 0. Pilot light 0 should go on. The display should show both the XIC and OTE instructions highlighted to indicate that they are true.

Processor operation: When you pressed pushbutton 0, the input instruction went from false to true. This resulted in a path of true input instructions in the rung, causing the output instruction to go from false to true.

Now release the pushbutton. Pilot light 0 should go off. Neither instruction in the rung should be highlighted. When you released pushbutton 0, the input instruction went from true to false; this broke the path of true input instructions, causing the output instruction to go from true to false.

Editing the Program with The QuickEdit feature of APS software allows you to move quickly from QuickEdit online monitoring to offline editing, then back to online monitoring. To give

you experience at doing this, we will edit the program by adding an input instruction on the rung. The effect of the edit: Selector switch 6 must be on (closed) to allow pushbutton 0 to turn on pilot light 0.

We will place an XIC instruction in series with (to the right of) the XIC instruction already entered. It will have address I:2/2, corresponding to selector switch 6 of the demo unit. See the figure below.

Add this instruction

Complete the following six steps to edit and test the edited program. The starting point for this procedure is the online monitor file display, with the processor in the run mode:

Display area: I n p u t p u s h b u t t o n t u r n s o n o u t p u t p i l o t l i g h t pl. , , o:" . ..

END

Message: -ProlIlpt: P r e s s a f u n c t i o n , , k e y

Data entry: ( f i l e 2 , rung 0 1 i?$2 .... Status: RUN no " f o r c e s PROC Addr 1

Main Functions: 1 ~ ' " " " " ~ ~ ~ ~ MONITOR

F 1 F2 F3 F6 F7 F8 F9 F10

1. Go offline and edit the disk version of the file

Press , then . Note that the status line of the display now F10 F3

indicates that you are offline, at file GETSTART.

2. Select Modify Rung and position the cursor

Press . We want to append an instruction to the XIC instruction, so F5

use the cursor key to position the cursor on the XIC instruction.

3. Enter an XIC instruction, address I:U2

F3 F1 F l

Qpe the address "1:2/2", then press [Enter], then [Esc].

4. Accept the rung


5. Save the edit and go back online

. Accept the default Save options by pressing Em Before the software restores the program it asks "Change Processor Mode to - -

hogram?". Press . When the program is successfully restored, the

software asks "Change Processor Mode to Run?". Press . F8

You are now back online with the edited program, in the run mode.

6. Test the edited program The following diagram shows the rung you have modified if you are using the modular controller demo unit discussed on page 4-4. If you are using some other controller configuration, make certain that your external input devices and output device are wired to the controller inputs and output that you addressed in your ladder program.

Address 1:1.010 Address 1:2.0/2 Address 0:3.0/0 corresponds to pushbutton corresponds to selector corresponds to pilot light

0 of the demo unit switch 6 of the demo unit 0 of the demo unit

\ i I 1:l.O I:2.0 0 : 3 . 0

0 2

END

To test the program, first turn selector switch 6 to the on position. Note that the corresponding input instruction in the rung is highlighted, indicating that it is true. Now press pushbutton 0. Pilot light 0 should go on. The rung should show all instructions highlighted to indicate that they are true.

Processor operation: When you pressed pushbutton 0, the corresponding input instruction went from false to true. This resulted in a path of true input instructions in the rung, causing the output instruction to go from false to true.

Now turn selector switch 6 to the off position. Note that the corresponding input instruction in the rung is no longer highlighted, indicating that it is false. Press pushbutton 0. Note that the corresponding input instruction is highlighted, but the output instruction does not go from false to true. This is because a continuous path of true input instructions does not exist in the rung.

Monitoring Data Files In this procedure, you will monitor the input data file and the output data fde. These files include a status bit for each of the configured YO terminals of the controller. You will monitor data file changes as you operate pushbutton 0 and selector switch 6. To end the exercise, you will go offline to the APS menu.

The starting point is the online monitor file display with the processor in the run mode:

Display area: Input pushbutton turns on output pilot light r l l o I"O , , o:~?

( . ..

H f

END

Message: Prompt: P r e s s a f u n c t i o n - . k e y

Data entry: ( f i l e 2, rung o):% Status: RUN no .."forces PROC Addr 1

Main Functions: 1 "I prl MONITOR

F1 F2 F3 F6 F7 F8 F9 F10

1. Position the ladder cursor and access the input data file Use the cursor key to vosition the cursor on the XIC instruction having - . - address I: 1.010, then press . The input data file appears, with the

F8 cursor located on status bit I: 1.0/0. This is shown below.

Display area: address 1 5 d a t a 0 a d d r e s s 1 5 d a t a 0 1:1 &$ 1:2 0000 0 0 0 0

Message: Prompt: P r e s s a key o r e n t e r v a l u e

Data entry: I : 1. o/o = ;.-:i .... .... .... Status: RUN .... no f o r c e s b i n a r y d a t a d e c i m a l a d d r PROC Addr 1

Main Functions:

F1 F5 F6 F7 F8

2. Monitor input data changes resulting from input device operation Press pushbutton 0. Note that the status bit goes from 0 to 1, as the instruction goes from false to true. Now turn selector switch 6 to the on position. Note that status bit 1:2.012 goes from 0 to 1, as the instruction gees from false to true.


3. Access the output data file The output data file precedes the input data file in the data table. Press

. The output data file appears. Since we didn't specify a particular F8

bit address, the cursor is located on the status bit having the lowest address, 0:3.0/0. This is also the status bit for pilot light 0 in our program. This is shown below.

Display area: address 0:3

data 0

0000 OO@Q address data

Message: Prompt: Press a key or enter value

Data entry: 0 : 3 .0/0 - . i : ~ . . . .... .... Status: RUN

..., .... no forces binary data decimal addr PROC Addr 1

4. Monitor output data changes resulting from input device operation Press pushbutton 0 with selector switch 6 in the on position. Note that status bit 0:3.0/0 goes from 0 to 1, as the output instruction of our program goes from false to true.

Continue to press pushbutton 0, as you turn selector switch 6 to the off position. Note that bit 0:3.0/0 goes from 1 to 0. This is because there is no longer a path of true input instructions in the rung, causing the output instruction to go false.

5. Return to the APS menu Press [Esc]. This returns you to the online monitor file display.

Press . This returns you to the online program directory display.

, This takes you offline, returning you to the APS menu F3

display.


3. Access the output data file The output data file precedes the input data file in the data table. Press

. The output data file appears. Since we didn't specify a particular FB

bit address, the cursor is located on the status bit having the lowest address, 0:3.0/0. This is also the status bit for pilot light 0 in our program. This is shown below.

Display area: address 0 : 3

data 0 0 0 0 0 o o g i

address data

Message: Prompt: Press a key or enter value

Data entry: o : 3 . 0 1 0 = :%: .... .... .... Status: RUN .... .... no forces binary data decimal addr PROC Addr 1

Main Functions: ADDRESS MONITOR

4. Monitor output data changes resulting from input device operation Press pushbutton 0 with selector switch 6 in the on position. Note that status bit 0:3.0/0 goes from 0 to 1, as the output instruction of our program goes from false to true.

Continue to press pushbutton 0, as you turn selector switch 6 to the off position. Note that bit 0:3.0/0 goes from 1 to 0. This is because there is no longer a path of true input instructions in the rung, causing the output instruction to go false.

5. Return to the APS menu Press [Esc]. This returns you to the online monitor fde display.

Press . This returns you to the online program directory display.

. This takes you offline, returning you to the A P S menu F3

display.

Overview


for APS


This chapter shows you how to create and print reports.

The following four hard copy reports can be created and printed:

Program Listing - This can include a) the main program file and all subroutine files, b) a single file, c) a range of files, or d) a range of rungs.

a Cross Reference - This provides an alphabetical list of addresses and their rungs, in either address or symbol order.

Processor Configuration - This details the configuration of the processor and associated hardware in the system. Data Tables - This details the contents of the offline or online data files.

If you do not have a printer set up in your system, we suggest that you go through these procedures anyway, to familiarize yourself with report capabilities.

Creating Reports A report can be created at the program directory display, either offline or online. In the following procedure, reports are created offline. The starting point is the APS menu.


1. Access the documentation (reports) and options windows

. This accesses the program directory display.

. The following windows appear in the display area:

Display area: PROGRAM L I S T I N G O P T I O N S 1 S t a r t i n g F i l e : R u n g 2 E n d i n g F i l e : R u n g 2 I P o w e r R a i l YES A d d r e s s C o m m e n t s YES A d d r e s s D i s p l a y SYMBOL R u n g C o m m e n t s YES L a d d e r C r o s s R e f e r e n c e ALL

Save t o F i l e I - E S C e x i t s / A l t - U abor ts c h a n g e s

8 WCUMENTATION 1 :v:::::g:s~q*ajijjgg$gg@q:$$$;i)i; .::.:.::. ......... ... . . . . .

C r o s s R e f e r e n c e P r o c e s s o r c o n f i g D a t a T a b l e s

ESC e x i t s

Message: Prompt: P r e s s a f u n c t i o n key o r press ENTER t o p e r f o r m o p e r a t i o n

Data entry: Status: o f f l i n e S L C 5/01 Series A F i l e GETSTART

Main Functions:

F2 F3 F4 F5 F6 F8

2. Specify Documentation The "Documentation" window lists the four reports you can create. The cursor is located on the "Program Listing" report. Options for the Program Listing are shown in the window at the left. Function key F5 allows you to change items in the options window.

Move the cursor to "Cross Reference", then "Processor Config", then "Data Tables". Note that as you do this, the option window changes to match the report the cursor is located on.

An explanation of the various options is beyond the scope of this guide. For our purposes, the default options are suitable.

Now press . In doing this, you have selected all four reports. This FZ

is verified by the appearance of asterisks at the left of each report in the Documentation window.

Getting Started Guide I for APS

3. Specify a title and create the reports

Press . Type "getprint" in the window that appears. F8

Press Enter] to accept the title. Then press [Enter] to perform the create reports operation. When the reports have been created, DOCUMENTATION COMPLETE appears in the display area, and PRESS A KEY TO CONTINUE appears on the prompt line.

Press any key. The program directory appears.


Press . You will be asked "Save Current Work?' Since we have

not changed the ladder program in any way, a Save is not required.

Press . The APS menu will appear.

Printing Reports Printing reports is done from the APS menu.


1. Access file GETSTART in the Report Directory

Press . The report directory appears. It lists the processor file F8

names for which reports have been created:

Display area: PROCESSOR

........ :.:.:.:.:.. '... .., '.'.....' "'.'../.: i:;:i:ls~Tg@a~T<;:

Message: Prompt: P r e s s a F u n c t i o n Key, S e l e c t o r E n t e r a P r o c e s s o r F i l e Name

Data entry: Status:

Main Functions:

Use the upldown cursor key to move the cursor to GETSTART, then press [Enter]. The display shows the reports you have created for file GETSTART:

Display area: r PRINT GETSTART

R e p o r t S i z e D a t e I

Data T a b l e 3657 01-04-92 P r o c e s s o r Conf ig 1739 01-04-92

L ESC e x i t s I Message:

ProllIpt: P r e s s a f u n c t i o n key or p r e s s ENTER t o pe r fo rm o p e r a t i o n Data entry:

Status:

Main Functions: PROCESS


2. Configure the printer and prepare it for operation

. Change configuration parameters if necessary, then press F5

Enter]. Prepare the printer for operation.

3. Select the reports to be printed and initiate printing

Press . Your choice is verified by the appearance of asterisks at the

left of the four reports you have created. Press to perform the F7

printing operation.

If your printer is not ready for some reason, PRINTER NOT READY will appear on the message line. The prompt line asks "Continue Printing?" You

can correct the problem and press , or you can cancel printing by

After the printing operation, you can return to the APS menu by pressing [Esc] .

APS Getting Started Guide for APS

Overview

Entering an lnput and Output Branch

Additional Ladder Program Exercises

This appendix lets you apply what you have learned in the previous chapters. It covers:

Entering a program with a I/O branches Entering a program with a timer instruction

The important feature of this program is the output and input branch. The input branch is based on what is called OR or parallel logic. This means that if either input #O OR input #1 is true, then output #O and #1 turn on.

Exercise 1 Entering an lnput and Output Branch

1. We are assuming you have created a new file, configured it and you are now ready to begin entering an instruction. See chapter 4 for help with the above. Begin offline at the edit screen.

2. Enter the rung and XIC instruction

I,

1:l.O I1

:I - Press , then , then , then 11

II F4 F4 F1 F1 I , address "I: 110" then press [Enter], then [Esc]. I ,

I, ., . I 1 I 1

,I 1 ,, 3. Enter a branch and another XIC instruction. Il I ,

Cursor left once, so your cursor is on the XIC instruction. Press ,

, then m , t h e n m ,

then , then . Type the address "I: l i ly ' then press [Enter]. ,I 1:l.O 0 : 3 . 0 " : 3-4: F l F1

0 01 I 1

,, 4. Enter an OTE instruction ,a Cursor up, then cursor right so your cursor is at the far right power rail. Press

F1 F3

press [Enter], then [Esc].

5. Enter a branch and another OTE instruction

Cursor left once so you are on the OTE instruction. Press , then

F1 F3

press [Enter], then [Esc].

6. Accept the rung

Press , then [Esc]. FlO

7. Enter the rung comment

Press . Type the comment "Either input F5 F l

pushbutton #O or #I turns on output pilot lights #O and #I".

8. Accept and save the comment

Your completed ladder program and rung comment should look like this:

Message: Prompt: P r e s s a f u n c t i o n , > k e y

Dataentry: ( f i l e 2, r u n g o 1%; Status: o f f 1 i n e n o f o r c e s

Display area: E i t h e r i n p u t p u s h b u t t o n #O o r #1 t u r n s on o u t p u t p i l o t l i g h t s #O and #1

1:l.O 0 : 3 . 0 I [

F i l e GETSTART

0

1:l.O

Main Functions: p?ziEq y l //EYIUUL(J WLIN MONITOR ) pi71 F2 F3 F5 F6 n F8 F9 F10

0 : 3 . 0

i r 1 1

1 IENDl 13 1






Press . Accept the default Save options by pressing


Test the Ladder Program

Complete the following steps to test the processor file:

1. Go online with your processor and restore the new file. Refer to chapter 5 for help.

2. Monitor the file. Refer to chapter 5 for help. 3. Place the processor in the RUN mode. See chapter 5 for help. 4. Press pushbutton #O. Outputs #O and #1 turn ON. 5. Release pushbutton #O. Outputs #O and #I turn OFF. 6. Press pushbutton #l. Outputs #O and #1 turn ON. 7. Release pushbutton #I. Outputs #O and #1 turn OFF.

Entering a Timer Instruction

In exercise 2, you enter a timer instruction with a time delay of 10 seconds. Two different types of timer status bits activate output pilot lights #O and #l. The first type, called a ''timer timing" status bit turns on output #O for 10 seconds. The second type, called a "done" status bit, turns on output #1 afer 10 seconds.

Exercise 2 Entering a Timer Instruction

1. We are assuming you have created a new file, configured it and you are now ready to begin entering an instruction. See chapter 4 for help with the above. Begin offline at the edit screen.

2. Enter a rung and an XIC instruction

F3 F4 F1 address "I: 1/0" then press [Enter].

3. Enter the timer instruction

F2 F1 Type the address "T4:O" then press [Enter]. This is the T i e r Address.

T i m e Base 0.01 Type "1000" then press [Enter]. This is the Timer Preset Value in hundredths Preset of a second. Accum

Q p e "0" then press [Enter]. This is the Timer Accumulated Value. ENDt-

4. Accept the rung

5. Enter a second rung and an XIC instruction

, then , then . ?)ipe the address F4 FI F1

"T4:OIT then press [Enter]. "TI''' represents the timer timing bit.

6. Enter an OTE instruction

Press , then . Type the address "0:3/0.', then press F1 11 [Enter].

7. Accept the rung

Press [Esc], then m.


8. Enter a third rung and an XIC instruction

F4 F1 F1

"T4:O/DN7', then press [Enter]. " D N represents the timer done bit.

9. Enter an OTE instruction

F1

press [Enter].

10. Accept the rung

Press [Esc], then , then [Esc].

11. Exit the edit mode Press [Esc]. Your completed ladder program should look like this:

Display area: TIMER O N DELAY

T i m e B a s e P r e s e t A c c u m

Message: Prompt: P r e s s a f u n c t i o n k e y

Dataentry: ( f i l e 2, r u n g O f $ $ : Status: off 1 i n e no f g r c e s

Main Functions:

File GETSTART





Press . Accept the default Save options by pressing


Test Your Ladder Program

Complete the following steps to test the timer instruction file:

1. Go online with your processor and restore the new file. Refer to chapter 5 for help.

2. Monitor the file. Refer to chapter 5 for help.

3. Place the processor in the RUN mode. See chapter 5 for help.

4. Press pushbutton #O for at least 10 seconds. During the first 10 seconds, output #O turns ON and #1 stays OFF.

5. After 10 seconds, output #O turns OFF and output #1 turns ON.

6. Release pushbutton #O; the timer resets and both outputs #O and #I turn OFF.


Overview

APS Error Messages

for APS

Troubleshooting Errors

This appendix shows you how to identify and correct errors that you may encounter while working through this guide. They include:

APS error messages System LED'S status PTocessor error codes

Table B.A details APS error messages:

Device type in F2 "Online Config" should I Wrong device n i p 1 g ,747-PIC.

Table 6.A APS Error Messages

I Incompatible or wrong Select different COM port in F2 "Online computer Serial Port 1 Config"; verify PC COM port works.

Error Message

APS Timeout - Loss of Communications

Bad cable Check continuity in 174741 0 cable; contact local Allen-Bradley distributor for replacement.

Cause

Wrong baud rate

Wrong processor node address

I Bad 1747-PIC I Contact your local Alle~Bradley distributor for replacement

Corrective Action

Select different baud rate in F2 "Online Config"; CPU default is 19200.

Select different processor address in F2 "Online Config"; CPU default is 1.

I I

I Consult PC manual for Serial Por! tvm

I need a null-modem adaptor. -

incompatible 4-25 Pin Adaptor

, , (DCE or DTE); 9-25 Pin Adaptor supplied with 1747-PIC is for a DTE Serial port. If serial port is DCE, you may

Not 1747-PIC enough to Check line power to SLC power supply; check position of power supply jumper for mdular systems.

Database Read Error Fiies and buffers are not set up correctly

Use a word processor or DOS Edline to verifylchange your CONFIG.SYS file to contain Files = 30 and Buffers = 30. If file is modified, re-boot PC.

Table 0.A APS Error Messages (continued)

Enor Message I Cause

Fatal Communication Hardware Error

Incompatible or nonexistent Serial COM port on PC

Illegal Data or Parameter Value

Maximum node address of the processor exceeds 31

110 Address Not Configured

Processor1system configuration does not match entered addresses

No Matching Disk File Found

Processor program do, not exist on hard disk

No Or Not Enough Load Communication Driver

I match your hardware

PC does not have enough free RAM

to continue

Incompatible Processor Type

Corrective Action

configuration of the program you are restoring does not

Select different COM port by pressing F2 "Online Config; verify COM port works.

Reduce the maximum node address of the processor to 31 by pressing F5 'WHO"; F5 'Who Active"; F7 "Max Address".

Verify correct address format (I:slot/terminal or 0:slotlterminal); verify system configuration by pressing F3 "Offline PrglDoc"; F1 "Procssr Functns"; F1 "Change Procssr"; F5 "Configr IIO".

To read the processor program (upload), press Fa "Yes"; othe~wise press F10 "No" to continue with other online activities

Verify your PC has >525K of free RAM to execute APS; exit APS and type "CHKDSK at DOS prompt Last line should read 'S525K bytes free". If not, disable TSR's, drivers, menus, shells, etc. loaded in AUTOEXEC.BAT or CONFIG.SYS that may be running in background. Re-boot PC.

Verify that processor configuration of your program matches your hardware by pressing F3 "Offline PrglDoc"; F 1 "Procssr Functns; F1 "Change Procssr".

Getting Started Guide for A P S

Sjstem LED Status The System LED's are located at different places on the modular system and the SLC fixed controller. Refer to the Installation and Operation manual for more information on system LED status. See Figure B .l.

Figure B.l System LED's

Modular System n

SLC 500 Fixed Controller

Table 6.B LED Status - Error Conditions

Processor LED

POWER

CPU FAULT

CPU FAULT

BATTERY LOW

Corrective Action

Verify line power within range. Verify wiring and grounding. Check power supply fuse. For modular system, verify power supply jumper is positioned correctly and that the power supply has been sized properly for loading in the rack.

Verify that position of notch in processor firmware chip matches processor board diagram. See corrective action for Power LED.

See Status File (S:6) by pressing F8 "Data Monitor" while monitoring your ladder diagram. Correct the problem based on the error message. Press F10 "Clr Maj Fault" and return proces- sorto RUN mode. See processor error codes.

Replace 1747-BA and do not remove processor power; or add 1747-BA to retain RAM memory; or add LED jumper to prevent the LED from lighting.

Status of LED

Off

Steady

Flashing

Steady

Cause

No DC power to backplane

Bad CPU or firmware improperly installed

Processor major fault

Battery voltage fallen below thresh- old to retain RAM memory; or no battery present; or LED jumper is

missing

Processor Error Codes Table B.C derails some of the processor error codes. Refer to the APS manual for a complete list of error codes and troubleshooting information.

Table 6.C Processor Error Codes .

Corrective Action

Checkwiring, layout, grounding. If using a 4KCPU, verify that a battery is installed to retain RAM memory when power isremoved. SeeCPU FAULT- Flashing under system LED status. Restore the program using APS or an HHT. - Checkwiring, layout, grounding. If using a 4K CPU, ver i i that a battery is installed to retain RAM memory when power isremoved. See CPU FAULT- Flashing under system LED status. Restore the program using APS or an HHT.

Verify that processor configuration matches you hardware by pressing F3 "Offline PrgfDoc"; F1 "Procssr Functns"; F1 'Change Procssr"; F5 "COP figr I/O"; See CPU FAULT-Flashing under the s p tem LED status.

Verii that rack configuration in your program matches your hardware by pressing F3 "Offline Prgl Doc"; F1 "Procssr Functns"; FI "Change Proc F5 "Configr 110". If multiple racksystem, verify p, er installation of rack interconnect cable. See CPU FAULT - Flashing under system LED status. -

Error Code

0001

0012

XX50, XX51, XX52 XX53, XX54, XX55

(xx = slot #)

0056

Cause

RAM program is corrupt due to noise, lightning, improper grounding or loss of capacitor or battery back-up.

RAM program is corrupt or RAM itself is bad due to noise, lightning, improper grounding, or loss of capacitor or battery back-up.

It0 module configuratiodconflict or runtime problem.

Rack configuration error.


Glossary

The following terms are used throughout this manual. Refer to them while working in this manual.

address: A character string that uniquely identifies a memory location. For example, I:1/0 is the memory address for the data located in the Input file location 110.

APS (Advanced Programming Software): Software used to monitor and develop SLC 500 ladder logic programs.

bit: The smallest storage location in memory that contains either a 1 (ON) or a 0 (OFF).

branch: A parallel logic path within a rung of a ladder program.

comment: Text included with a program to explain what the program is doing. Comments do not affect the operation of the program in any way.

communication scan: A part of the SLC's operating cycle. Communication with other devices, such as APS on a personal computer, takes place.

con troller: A device, such as a programmable controller, used to monitor input devices and control output devices.

CPU (Central Processing Unit): The decision-making and data storage section of a programmable controller.

cross reference: A report listing addresses, instructions, and their rung numbers where used.

data file: An area within a processor file that contains the status of inputs, outputs, the processor, timers, counters, and so on.

data table report: A report documenting the contents of the data files.

DOS: The operating system used to operate a personal computer.

edit: To create or modify a ladder program.

expansion rack: A 2-slot rack used only with fixed controllers.

false: The status of an instruction that does not provide a continuous logical path on a ladder rung.

file: A collection of information organized into one group.

fixed controller: A controller with a power supply, CPU, and I/O integrated into a single package.


Glossary

The following terms are used throughout this manual. Refer to them while working in this manual.

address: A character string that uniquely identifies a memory location. For example, I: 110 is the memory address for the data located in the Input file location 110.




comment: Text included with a program to explain what the programis doing. Comments do not affect the operation of the program in any way.


con troller: A device, such as a programmable controller, used to monitor input devices and control output devices.










fixed controller: A controller with a power supply, CPU, and I/O integrated into a single package.


Glossary

The following tenns are used throughout this manual. Refer to them while working in this manual.

address: A character string that uniquely identifies a memory location. For example, I: 110 is the memory address for the data located in the Input file location 110.




comment: Text included with a program to explain what the program is dohig. Comments do not affect the operation of the program in any way.


controller: A device, such as a programmable controller, used to monitor input devices and control output devices.










fixed controller: A controller with a power supply, CPU, and 110 integrated into a single package.


function keys: Keys on a personal computer keyboard labeled F1, F2 and on. The operation of each of these keys is defined by APS.

harddisk: A storage area in a personal computer that may be used to sav processor files and reports for future use.

hardware: The components that comprise a programmable controller, sucha Input modules, Output modules, and the CPU.

I/O (Inputs and Outputs): Consists of input and output devices whichprovid andlor receive data from the programmable controller.

input device: A device, such as a pushbutton or a switch, that supplies dat through input circuits to a programmable controller.

input scan: A part of the SLC's operating cycle. Status of the input module are loaded into the Input data file.

instruction: A mnemonic and data address defining an operation to b performed by the processor. A rung in a program consists of a set of input an output instructions. The input instructions are evaluated by the SLC as bein true or false. In turn, the SLC sets the output instructions to true or false.

interface converter: An Allen-Bradley device, Catalog Number 1747-PIC used to establish communication between the personal computer and an SLC 500 programmable controller.

ladder logic: A program written in a format resembling a ladder-like diagm The program is used by a programmable controller to control devices.

modular controller: SLC 500 system consisting of a power supply, rack CPU, and input and output modules.

module: An interchangeable plug-in device that may inserted into a rack.

network: A series of devices connected by a communication medium.

off line: Describes devices not under direct communication. For example when programming in APS.

online: Describes devices under direct communication. For example, whe APS is monitoring the program file in a SLC.

operating cycle: The sequential order of operations performed by the processc when in the run mode.

OTE (OuTput Energize): An instruction that energizes when arung is true an de-energizes when a rung is false.

output device: A device, such as a pilot light or a motor starter coil, th; receives data from the programmable controller.

output scan: A part of the SLC's operating cycle. During this scan the outp data file information is transferred to the output modules.

processor: See CPU.

processor configuration: Areport detailing the configuration of the processor.

processor file: The set of Program and Data Files used by the SLC to control output devices. Only one processor file may be stored in the SLC at a time.

processor overhead: An internal portion of the operating cycle used for house-keeping and set-up purposes.

program file: The area within a processor file that contains the ladder logic program.

program listing: A report containing a range of program files or a range of rungs.

program mode: When the SLC is not executing the processor file and all outputs are de-energized.

program scan: A part of the SLC's operating cycle. During the scan the ladder program is executed and the Output data file is updated based on the program and the Input data file.

rack (chassis): A hardware assembly that houses devices such as I/O modules, processor modules, and power supplies.

read: To acquire data from a storage place. For example, the processor READS information from the input data file to solve the ladder program.

report: A printable document containing information about a processor file. For example, aladder listing, a cross reference, the data tables, and the processor configuration.

restore: To download(transfer) a program from a personal computer to a SLC.

run mode: When the processor file in the SLC is being executed, inputs are read, the program is scanned, and outputs are energized and de-energized.

rung: Ladder logic is comprised of a set of rungs. A rung contains input and output instructions. During Run mode, the inputs on a rung are evaluated to be true or false. If apath of true logic exists, the outputs are made true. If all paths are false, the outputs are made false.

save: To upload (transfer) a program stored in memory from a SLC to a personal computer; OR to save a program to a computer harddisk.

SLC (Small Logic Controller): A controller that comes in 1 of 2 styles: fixed or modular.

slot: The area in a rack that a module plugs into.

software: Executable programming package used to develop SLC ladder diagrams.


status: The condition of a circuit or system, represented as logic 0 (OFF) q 1 (ON).

terminal: A point on an YO module that external YO devices, such as r pushbutton or pilot light, are wired to.

true: The status of an instruction that provides a continuous logical path on& ladder rung.

write: To copy data to a storage device. For example, the processor WRITEp the information from the output data file to the output modules.

examine If Closed (XIC): An input instruction that is logically true when the status of the bit located at its address is a 1; false when it's a 0.

examine If Open (XIO): An input instruction that is logically true when the status of the bit located at its address is a 0; false when it's a 1.

m m

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Mounting Plate #TQCBMPAl

GL Equipment Grounding Lug General ~lectric (Eleven 14-8 "AWGU CU #TGL2

F I N A L W H E N S T A M P E D AS F I N A L A N D S IGNED B Y PROJECT E N G I N E E R

DWG. NO.

A- 3699-2

Page 3 of 7

S C A L E

,

D A T E

3/15/93 C H E C K E D B Y

A P P R O V E D B Y


470 PARKAVE. SOUTH, N.Y., N.Y. 10016

PROJECT N O

1114-2579 O R A W N B Y

RG S U B M I T T E D

e 0

2 (D .-

m

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03A/HS-101A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


HOUSTON. TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER "A"

TAG QTY DESCRIPTION MFG & CAT #

SS-1 3 Selector switch, NEMA Allen-Bradley SS-2 type 4/4X, 2-positions #800H-HR2D1 SS-3 with one (1) N.O.

maintained contact and legend plate as shown on dwg D-3662

SS-5 1 Same as Above Allen-Bradley except with two (2) N.O. #800H-HR2A2 maintained contact and legend plate as shown on ~ w g 0-3662

SS-4 1 Selector switch, NEMA Allen-Bradley type 4/4X, oil-tight, #800H-JR2KC7AAXX heavy duty, three (3) positions maintained type, two (2) N.O. & two (2) N.C. contacts with legend plate as shown on dwg D-3662

TB 120 Terminal blocks, 300 V Quincy Connector medium duty tubular screw #ST-76 or equal type, phenolic barrier

W.D. As Wire duct, plastic Electrovert Required 1-1/2" (W) x 2" (H)

As Nameplates and legend Shop Fabricated Required plates as shown on

Dwg. D-3662 white letters on black background

FINAL WHEN S T A M P E D A S F I N A L A N D S I G N E D B Y P R O J E C T E N G I N E E R

DWG. NO.

A-3699 -2

Page 4 of 7


3/15/93 C H E C K E D B Y :




P R O J E C T N O . :

AM-25 79 D R A W N B Y :

RG S U B M I T T E D :

BADGER PURCEASE ORDER NO.: BH-2831-H01-10 2001-F-03A/HS-l01A KHZWOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


HOUSTON. TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER I1A1@


Window 1 Stainless steel with a Hoffman brushed finish window kit A-PWK53NFSS NEMA 914Xn for outdoor application corrosion-proof and water-tight window size 5"x3" frame size 7+"x53"

AAC AB BC DTI-009 DT1-014 ESV-003 ESV-005,006 ESV-001,002 ESV-004 FCV-001,002 FSL-001 FSL-005 HFS HIS IT LFS M PSH-003 PSL-004

SEE BURNER EOUIPMENT LIST FOR THERMAL LIOUID HEATER

MODEL 1700-3.5/3.0-2D-94-17/20

Atomizing Air Compressor Combustion Air Blower Flame Program Control Digital Display Heater Stack Temp.

II 11 11 Inlet Temp. Main Gas Solenoid (Heated Gas) Pilot Gas Solenoids Oil Shutoff Solenoids (Condensate) Main Gas Solenoid (Stabilizer) Butterfly Heated Gas and Condensate Valves Low Flow Cutoff Heater Coil #1

II II " Heater Coil #2 Hi-Fire Switch - Air Purge Switch Hinge Interlock Switch Pilot Ignition Transformer Low Fire Switch Modutrol Motor Hi-Gas Pressure Cutoff (Heated Gas) Low Gas Pressure Cutoff (Heated Gas)

F I N A L WHEN STAMPED AS F I N A L A N D S IGNED B Y PROJECT ENGINEER

PROJECT NO.: D A T E : SCALE:

XMERICAN HYDROTHERM AM-2 5 79 3/15/93 DWG. NO.

CORPORATION D R A W N B Y : CHECKED B Y :

RG A- 3699-2

470 PARK AVE. SOUTH, N.Y., N.Y. 10016 SUBMITTED: APPROVED B Y : Page 5 of 7

SEE BURNER EQUIPWENT LIST FOR THERMAL LIOUID HEATER

MODEL 1700-3.5/3.0-2D-94-37/20 (Continued)

(D m r! = %-

Hi-Gas Pressure Cutoff (Stabilizer) Low Gas Pressure Cutoff (Stabilizer Low Combustion Air Cutout Low Oil Pressure Cutout (Condensate) Low Atomizing Air Cutout Infrared Scanner 48PT2 Thermocouple Type "JW for Stack Temp. Thermocouple Type "JW for Heater Inlet Temp. Thermocouple Type "JW for Hi-Temp. TSH-019 Thermocouple Type "Jtt for Hi-Temp. TSH-020 Thermocouple Type ltJW for Heater Temp. Controller Heater Temperature Controller Hi-Temperature Cutoff Heater Coil #1 Hi-Temperature Cutoff Heater coil #2



HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER BfiAIl


PSH-006 PSL-006 PSL-003 PSL-002 PSL-007 SC TE-009 TE-014 TE-019 TE-020 TE-015 TIC-015 TSH-019 TSH-020

F I N A L W H E N STAMPED A S F I N A L A N D S I G N E D B Y P R O J E C T E N G I N E E R

DWG. NO.

A- 3699-2 Page 6 of 7


3/15/93 C H E C K E D B Y :


r




AM-2579 D R A W N B Y :

RG SUBMITTED:

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03A/HS-lOl.A KHANOM ONSHORE FACILITIES TEE PETROLEUM AUTHORITY OF THAILAND KBANOM, THAILAND

AM-2579 BADGER DESIGN & CONSTRUCTORB INC.

HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER "A"

TAG OTY DESCRIPTION XFG L CAT #

BY CUSTOMER

AAC AB E/S E/S-1 ELS-A LSLL-006 PP-102A PP-102B PP-102C AB

LSH-012 LSL-012 ROS-A

Motor Starter for Atomizing Air Compressor Motor Starter for Combustion Air Blower Emergency Stop Push-Pull Button Local Emergency Stop Contact Closure Remote End Limit Switch MTD on Hot Oil Supply Valve Lo-Lo-Level Switch Contact - MTD on Expansion Tank Auxiliary Contact MTD on Motor Starter of PP-102A Auxiliary Contact MTD on Motor Starter of PP-102B Auxiliary Contact MTD on Motor Starter of PP-102C Auxiliary Contact MTD on Motor Starter of Combustion Air Blower

Upper Level Switch MTD on Condensate Storage Tank Low Level Switch MTD on Condensate Storage Tank Remote Operating Switch Heater Start-Stop Power Supply for Main Header Hot Oil Supply Valve HOV-A

F I N A L W H E N S T A M P E D AS F I N A L A N D S I G N E D B Y PROJECT E N G I N E E R

DWG. NO.

A-3699-2

page 7 of 7

SCALE:

,

D A T E :

3/15/93 C H E C K E D B Y :




PROJECT NO. :

AM-2579 D R A W N B Y :

RG S U B M I T T E D :

BADGER I i

PURCHASE ORDER NO.: BH-2831-H01-10 2 0 0 1 - F ~ 0 3 B / H S - 1 0 1 B ,., c :< .i 3 194J KHANOM ONSHORE F A C I L I T I E S

i

TBE PETROLEUM AUTHORITY OF THAI- - . i: ,-' !C.YY KHANOM, THAILAND 5 ~;.IG'N~:ER!WG D@r-

,< - -,,7m -n*zFLt--t---- -

AM-2579 BADGER DESIGN h CONSTRUCTORS INC.

HOUSTON, TEXAS

ELECTRICAL B I L L OF MATERIAL EOUIPMENT LISTED FOR HEATER "B"

TAG

AH

CPT

CR- 1 thru CR-9 CR-A CR-B CR-C

ECP

OTY DESCRIPTION XFG & CAT I

Alarm Horn, vibratory type, 22'0 VAC, 50 Hz operat ion

Wheelock #31T-220-S

Control Power Transformer Wesco 1000 VA, 12Ox208/240/277VAC HS12FlAS primary, 120/240 V secondary, 50 Hz, equipped with electrostatic shield

12 Control Relay, plug-in Grainger type, 3 form "CU, 10 Amp Stack #4A066 rating contacts, 240 VAC Socket operating coil, 11-pin Stock #6X156 screw terminal type Potter Brumfield relay socket #KRPA-14AG-240

Electrical Control Panel Hammond enclosure NEMA If4lf size: #1418N4R10 4811 (H) x3OW (W) xlOn [D) complete with interior subpanel size: 45"x27" epoxy painted semi gloss gray

Fuseholder, 1 pole, 250 V, 30 Amp

Bussman H25030-1C

Fuse, 8 Amp, 250V Bussman dual element, Fusetron FRN-8

F I N A L W H E N S T A M P E O A S F I N A L A N 0 = N E D - 4 P R O J E C T E N G I N E E R

S C A L E :

,

D?715/93 C H E C K E D B Y :

A P * R O V E D B v :


470 PARK AVE. SOUTH, N.Y.. N.Y. too16

DWG. NO.

A- 3707-2 gage 1 of 7


AM-2579 D R A W N B Y :

RG SuBMITTEO:

PURCHASE ORDER NO.: BH-2831-HOX-10 200 l-F-03B/HS-l01B , <r~ ,.c: 1 , . , b +, *<)Q: j ; , -a

KHANOM ONSHORE FACILITIES i i THE PETROLEUM AUTHORITY OF THAILAND , ., ,. :, ;, ,': -32 :t<63Fe+ *

3 , F

KHANOM, THAILAND E , \;! ?jE r,;%i%$G $EW?- %..- - - - " , - *<-~ . . . -~- -~A

TAG

L-1 thru L-2 8

MOV-1 thru MOV-9

PB- 1

AM-2579 BADGER DESIGN h CONSTRUCTORS INC.

HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER "B"

28 Pilot light unit NEMA Allen-Bradley 4/4X full voltage 240 VAC 1 pc WHITE lens with lens and legend #dOOH-QR20W plate as shown on 6 pcs GREEN lens d ~ g . 0-3662 #800H-QR20G

1 pc AMBER lens #800H-QR20A

18 pcs RED lens #800H-QR20R

1 pc BLUE lens $800H-QR20B

1 pc CLEAR lens #800H-QR20C

9 Metal oxide varistor f8MOV1i General Electric type, transient surge V430MA7B protector

1 Pushbutton, NEMA type 4/4X Allen-Bradley bootless flush head push- #800H-AR6D1 RED button (RED) with one (1) N.O. Momentary contact with legend plate marked "RESET"

2 Pushbutton, NEMA type 4/4X Allen-Bradley with BLACK booted head push- #800H-R2D1 button with one (1) contact block with one (1) N.O. momentary contact and legend plate marked (1) "LAMP TESTtf and (1) "SILENCEn

a m

n L)

F I N A L W H E N S T A M P E D A S F I N A L A N D S I G Y E O B Y , R R O J E C T ENG1NEE.R



S C A L E :

DWG. NO.

A- 3707-2 Page 2 of 7


AM-2579 D R A W N B Y : RG

SUeM'TTED:

D A T E :

3/15/93 C H E C K E D B Y :

APpROVEDBY:

PURCHASE ORDER NO.: BE-2831-H01-10 2001-F-03B/HS-101B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND -OMl THAILAND

0 m

2 0 .- .

AM-2579 BADGER DESIGN b CONSTRUCTORS INC,

HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER fifiBfifi


SLC 1 Programmable Logic Controller Allen-Bradley Type SLC 500 modular hardware SLC 500 style. Consists of: - CPU SLC 5/01 with 4K

user instruction capacity Cat. #1747-L514

- Power Supply 170-265 VAC, 50 Hz, 5 Amp @ 5 V DC and 0.96 Amp @ 24 V DC Cat. #1746-P2

- 2 Input Modules 16 points 200/240 V AC Cat. #1746-1M16

- 2 Relay Output Modules 16 points (2x8) 10-250 V AC 110-125 V DC Cat. #1746-OW16

- 7-Slot Rack-Modular Hardware Style Cat. #1746-A7

- Memory Module EEPROM 4K User Instructions Cat. #1747-M2

- 2 Modular Card Slot Fillers Cat. #1746-N2

CB-1 1 Circuit Breaker, single General Electric pole, 15 Amp, 240 V AC #THQC1115WL

Mounting Plate #TQCBMPAl

GL 1 Equipment Grounding Lug General Electric (Eleven 14-8 "AWGW CU #TGL2

F I N A L WHEN STAMPED AS F I N A L A N D SIGN-ED BY_PROJECT ENGINEER

DWG. NO.

A- 3707-2 Page 3 of 7

D A T E . SCALE

3/15/93 CHECKED BY

APPROVED BY:



PROJECT N O

, AM-2579 D R A W N B Y .

RG SUBMITTED:

PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/BS-101B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND

, ~

AM-2579 BADGER DESIGN L CONSTRUCTORS INC.

HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EQUIPMENT LISTED FOR HEATER "B"

DESCRIPTION MFG & CAT #

0 Q

$1 0 ,- .

Selector switch, NEMA Allen-Bradley type 4/4X, 2-positions #800H-HR2D1

SS-3 with one (1) N.O. maintained contact and legend plate as shown on dwg D-3662

SS-5 Same as Above Allen-Bradley except with two (2) N.O. #800H-HR2A2 maintained contact and legend plate as shown on Dwg D-3662

SS-4 Selector switch, NEMA Allen-Bradley type 4/4X, oil-tight, #800H-JR2KC7AAXX heavy duty, three (3) positions maintained type, two (2) N.O. & two (2) N.C. contacts with. legend plate as shown on dwg D-3662

TB 120 Terminal blocks, 300 V Quincy Connector medium duty tubular screw #ST-76 or equal type, phenolic barrier

W.D. As Wire duct, plastic Electrovert Required 1-1/2"(W) x 2"(H)

As Nameplates and legend Shop Fabricated Required plates as shown on

Dwg. D-3662 white letters on black background

F I N A L WHEN STAMPED A S F I N A L A N D S IGEED BY-P-ROJECT ENGINEER


470 PARKAVE. SOUTH, N.Y.. N.Y. 10016

SCALE

,

DWG. NO.

A- 3707-2 Page 4 of 7

PROJECT NO.:

AM-2579 D R A W N B Y :

RG SUBMITTED:

D A T E

3/15/93 CHECKED B y .

APPROVED B Y .

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 i l d .

2001-F-03B/HS-101B .,.* x,ir. 3 % :P-T XEANOM ONSHORE FACILITIES t r I ~9.r i

TEE PETROLEUM AUTHORITY OF THAILAND 1

-OM, THAILAND


HOUSTON, TEXAS



Window 1 Stainless steel with a Hoffman brushed finish window kit A-PWX53NFSS NEMA I14X1l for outdoor application corrosion-proof and water-tight window size 511x31t frame size 7$1rx5$11

AAC AB BC DTI-009 DT1-014 ESV-003 ESV-005,006 ESV-001,002 ESV-004 FCV-001,002 FSL-001 FSL-005 HFS HIS IT LFS M PSH-003 PSL-004


MODEL 1700-3.5/3.0-2D-94-17/20

Atomizing Air Compressor Combustion Air Blower Flame Program Control Digital Display Heater Stack Temp.

11 . II II Inlet Temp. Main Gas Solenoid (Heated Gas) Pilot Gas Solenoids Oil Shutoff Solenoids (Condensate) Main Gas Solenoid (Stabilizer) Butterfly Heated Gas and Condensate Valves Low Flow Cutoff Heater Coil #1

11 II Heater Coil #2 Hi-Fire Switch - Air Purge Switch Hinge Interlock Switch Pilot Ignition Transformer Low Fire Switch Modutrol Motor Hi-Gas Pressure Cutoff (Heated Gas) Low Gas Pressure Cutoff (Heated Gas)

F I N A L WHEN STAMPED AS F I N A L A N D SlGDLEO S Y S R O J E C T ENGINEER

DWG. NO.

A- 3707-2 Page 5 of 7

SCALE:


470 PARK AVE. SOUTH, N.Y., N.Y. 1001s

PROJECT NO.:

AM-2579 D R A W N BY:

RG SUBMITTED:

D A T E :

3/15/93 CHECI(ED BY:

APPROVED BY:

PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-101B ;&;&.: ; 9 ::;$;?

KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND A%<.& -(;A ,;~,t, :: : J ~ ~ J T S E P - M ~ -OM, THAILAND 3 , $ + 4 1. ,,, . ,.,.--...~.-...-..-------.-*- - 7 i c


HOUSTON, TEXAS




MODEL 1700-3.5/3.0-21)-94-17/20 ( Cont inuedl

Hi-Gas Pressure Cutoff (Stabilizer) Low Gas Pressure Cutoff (Stabilizer Low Combustion Air Cutout Low Oil Pressure Cutout (Condensate) Low Atomizing Air Cutout Infrared Scanner 48PT2 Thermocouple Type I1Jgv for Stack Temp. Thermocouple Type "JW for Heater Inlet Temp. Thermocouple Type "JV1 for Hi-Temp. TSH-019 Thermocouple Type tvJ1l for Hi-Temp. TSH-020 Thermocouple Type "JM for Heater Temp. Controller Heater Temperature Controller Hi-Temperature Cutoff Heater Coil #1 Hi-Temperature Cutoff Heater Coil #2

0 a 2

F I N A L W H E N STAMPED AS F I N A L A N D S I G ~ E O BY-PROJECT ENGlNECR

DWG. NO.

A- 3707-2 Page 6 of 7

SCALE: D A T E :

3/15/93 CHECKED BY:

APPROVED BY:


470 PARK AVE. SOUTH, N.Y.. N.Y. 10016

PROJECT NO.:

AM-2579 D R A W N BY:

RG SUBMITTED:

PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-lOlB LA&\. 2 3 $v2 i P-: j

KBANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND : ,! , . ,$ : ; e . t d : T b s i : ;*b.;

KaANOM, THAILAND : , ' ;\ ic?fit~<: OF%?, - ...- '-..--9 >-w. ---- -.- <w:+

m-2579 BADGER DESIGN L CONSTRUCTORS INC.

HOUSTON, TEXAS

ELECTRICAL BILL OF MATERIAL EOUIPMENT LISTED FOR HEATER '*B**


AAC AB E/S E/S-1 ELS-B LSLL-006 PP-102A PP-102B PP-102C AB

LSH-012 LSL-012 ROS-B

BY CUSTOMER

Motor Starter for Atomizing Air Compressor Motor Starter for Combustion Air Blower Emergency Stop Push-Pull Button Local Emergency Stop Contact Closure Remote End Limit Switch MTD on Hot Oil Supply Valve Lo-Lo-Level Switch Contact - MTD on Expansion Tank Auxiliary Contact MTD on Motor Starter of PP-102A Auxiliary Contact MTD on Motor Starter of PP-1O2B Auxiliary Contact MTD on Motor Starter of PP-102C Auxiliary Contact MTD on Motor Starter of Combustion Air Blower

Upper Level Switch MTD on Condensate Storage Tank Low Level Switch MTD on Condensate Storage Tank Remote Operating Switch Heater Start-Stop Power Supply for Main Header Hot Oil Supply Valve HOV-B

F INAL WHEN STAMPED A S FINAL AND S I G ~ ~ O BYPROJECT ENGINE€

DWG. NO.

A- 3707-2

Page 7 of

SCALE: D A T E :

3/15/93 CHECKED BY:

APPROVED BY:


470 PARK AVE. SOUTH, N.Y., N.Y. lo016

PROJECT NO.:

AM-2579 D R A W N B Y :

RG SUBMITTED:

BADGER PURCmSE ORDER NO.: BE-2831-H01-10 2001-F-03A/HS-101A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND

BURNER EOUIPMENT L I S T AM-2579 P a g e 1 of 7

THERMAL LIOUID HEATER H S l O l A - MODEL 1700-3.5/3.0-2D-94-17/20

NORTH AMERICAN - BURNER # 6 1 3 1 FOR HEATED GAS (STREAM # 5 ) . CONDENSATE (STREAM #8) , STABILIZER OVERHEAD (STREAM #12)

TAG OTY DESCRIPTION MFGR AND/OR MODEL

B-A 1 Dual Fuel Burner North American #6131-FA 2/P-1

HIS-A 1 Hinge Interlock Switch N.A. #R830-4028

PILOT GAS TRAIN

NP-A 1 Gas Pilot Assembly N.A. 131-0450 Nat. Gas

HV-4-A 1 Gas Valve Part of Pilot

ESV-005-A 2 Pilot Gas Solenoids Asco #8215G20 -006-A 1/2" - 220V, N.C.

PCV-025-A I Pilot Gas Regulator N.A. #7344-01, 1/2"

PCV-028-A 1 Pilot Gas Regulator N.A. #7345-01-HI 1/2"

HV-3-A 1 Pilot Gas Cock Crane #254, 1/211

PI-008-A 1 Pressure gage N.A. #8735-HM 0-32 oz, 2-3/4" dial

HV-10-A 1 Gas Cock Part of Pilot

AIR-LINE TRAIN

AB-A 1 Air Blower

M-A 1 Modutrol Motor

Integral with Burner 380/3/50, 20 HP 2900 RPM, TEFC

Honeywell M7284C, 30 sec. 90°, 4-20 mA

LFS-A 1 Low Fire Switch Hon. #Q607A, Mtd. in M

FINAL WHEN STAMPED AS FINAL AND SIGNED BY PROJECT ENGINEER

IPROJECT NO.: 1 DATE: 1 SCALE: 1

- .

I page I or

=AWN BY: lcnr AMERICAN HYDROTHERM b~-2579 1 2/18/93

470 PARK AVE. SOUTH, N.Y., N.Y. 10016 - "7

_ CORPORATION

DWG. NO.

A- 3698-3 -

HS 1 &?z: SUBMITTED: (APPROVED BY:

BADGER PURCHASE ORDER NO,: BH-2831-H01-10 2 0 0 1 - F - 0 3 A / H S - l 0 1 A KHANOM ONSHORE F A C I L I T I E S THE PETROLEUM AUTHORITY O F THAILAND KHANOM, THAILAND

BURNER EOUIPMENT L I S T AM-2579 Page 2 of 7

THERMAL LIOUID HEATER H S l O l A - MODEL 1700-3 ,5 /3 .0-2D-94-17/20

NORTH AMERICAN - BURNER # 6 1 3 1 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM # 1 2 )


AIR-LINE TRAIN - cont. HFS -A 1 Air Purge Switch Part of M

BAS -A 1 Burner Air Shutter Integral with Burner

PSL-003-A 1 Low Combustion Air Cutout

ATOMIZER AIR-LINE TRAIN

AAC-A 1 Atomizing Air Compressor Set

Hon. #C437F 1-16 oz, N.O.

D-240, 5 HP, 780 RPM, TEFC 380/3/50

PRV-001-A 1 Pressure Control Valve Circle Seal #559 Set at 40 psig

PSL-007-A 1 Low Atomizing Air Cutout Ashcroft B424BXFM60 0-60 psig

PSV-018-A 1 Compressor Safety Relief Valve

Part of AAC, 1/211 Kingston Fig. 112C Set @ 60 psig

CFH-A 1 Compressor Flexible Part of AAC Hose

PI-024-A 1 Pressure Gage N.A. #8735-P 0-100 psig

HEATED (STREAM #5) GAS-LINE TRAIN

PCV-033-A 1 High Gas Pressure Regulator Fisher #630, 2" NPT Set at 15 psig

FINAL WHEN STAMPED AS FINAL AND SIGNED BY PROJECT ENGINEER

DWG. NO.

A- 3698-3 Page 2 of 7

SCALE:



PROJECT NO.: D A T E :

AM-2579 b/18/93 D R A W N B Y :

HS SU WITTED: ,$ ,.

CH%;<~:

APPROVED B Y :

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-O3A/HS-l01A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM* THAILAND

BURNER EOUIPMENT LIST AM-2579 Page 3 of 7

THERMAL LIOUID HEATER HSlOlA - MODEL 1700-3.5/3.0-20-94-17/20 NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


HEATED (STREAM #5) GAS-LINE TRAIN - cont.

PCV-026-A 1 Low Gas Pressure Regulator Fisher #133L, 211 NPT Set at 1.5 psig

FCV-001-A 1 Butterfly Gas Valve Integral with Burner

PSH-003-A 1 High Gas Pressure Ashcroft #B24BXFM15 Cutoff 0-15 psig

PSL-004-A 1 Low Gas Pressure Ashcroft #B424BXFM30t1 Cutoff 0-30" W.C.

PI-014-A 2 Pressure Gages N.A. #8735-HM -015-A 0-32 02

2-3/4" dial

PI-045-A 1 Pressure Gage N.A. #8735-S 0-160 02 2-3/4" dial

ESV-003-A 1 Main Gas Solenoid G-C H117AL114, 3"

HV-6-A 1 Test Cock Crane, 1/8"

HV-1-A 1 Main Gas Cock Walworth #1797F 4" Flg.

HV-2-A 1 Main Gas Cock Walworth #I750 2" N.P.T.

PCV-027-A 1 Pressure Reducing N.A. #7349-7-SY Gas Regulator 4" N.P.T.

FINAL WHEN STAMPED AS F I N A L A N D S IGNED B Y PROJECT

PROJECT N O . D A T E SCALE.

AMERICAN HYDROTHERM 2/18/93 DWG. NO. A

CORPORATION DRAWN BY: cn KEO B Y .

HS &{- A- 3698-3 470 PARK AVE. SOUTH, N.Y., N.Y. 10016

b

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03A/HS-l01A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


THERMAL LIOUID HEATSR HSlOlA - MODEL 1700-3.5/3.0-2D-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


CONDENSATE (STREAM #8)-LINE TRAIN

HV- 5 -A 1 Gate Valve 2" S.W.

ESV-001-A 2 Oil Shutoff Solenoids N.A. #R8266C219L -002-A X/2It, 220V

PSL-002-A 1 Low Oil Pressure Cutout Ashcroft #B424BXFM100 0-100 psig

PCV-024-A 1 Fuel Oil Pressure N.A. #R690-6105, 1/2It educing Valve

ST 1 Fuel Oil Strainer N.A. #8553, 3/4"

PI-005-A 3 Pressure Gages N.A. #8735-M 0-100 psig 2-3/4" dial

PI-003-A 1 Pressure Gage N.A. #8735-Y 0-200 psig 2-3/4" dial

DPI-004-A 1 Diff. Pressure Gage Ashcroft #45-1125-02L 0-10 psid

FCV-002-A 1 Sensitrol Oil Valve N.A. #11-3354-4

FINAL WHEN STAMPED AS F I N A L A N D S IGNED BY PROJECT IZNGiNEER

DWG. NO.

A- 3698-3 Page 4 of 7

SCALE:

,

D A T E :

2/18/9 cn KED BY:

k c - APPROVED BY:


470 PARK AYE. SOUTH, N.Y., N.Y. 1001s

PROJECT NO.:

,AM-2579 D Y ~ N BY:

I T T E D : ',"Fa-



THERMAL LIOUID HEATER HSlOlA - MODEL 1700-3.513.0-2D-94-17/20 NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5). CONDENSATE (STREAM # a ) . STABILIZER OVERHEAD (STREAM #I21


STABILIZER OVERHEAD (STREAM #12)

PCV-029-A 1 Main Gas Pressure Fisher #Y750, l1I NPT Regulator Set at 1 psig

PSH-006-A 1 High Gas Pressure Ashcroft #B424BXFM15 Cutoff 0-15 psig

PSL-006-A 1 Low Gas Pressure Ashcroft #B424BXFM3O1I Cutoff 0-30" W.C.

PI-016-A 2 Pressure Gages -043-A

N.A. #8735-HM 0-32 oz 2-3/4It dial

ESV-004-A 1 Main Gas Solenoid Hon. #5055C w/4055D 3/4"

HV-6A-A 2 Gas Cocks -6B-A

Walworth #7796, 3/4"

HV- 6 -A 1 Test Cock Crane, 1/8"

CONTROLS

TIC-015-A 1 Temperature Controller Hon. #DC300K

TSH-019-A 4 High Temperature Hon. #DC200H -020-A Cutoff

FSL-001-A 2 LOW Flow Cutoff U.E. #H105K, 0-20 psid -005-A

FE-001-A 1 Flow Orifice 3 -1./2"

FE-005-A 1 Flow Orifice 3 I#

FINAL WHEN STAMPED AS FINAL AND SIGNED B Y PROJECT LNGlNEER

DWG. NO.

A- 3698-3

Pase 5 of 7

SCALE: DATE:

2/18/93 CHE,CXEO BY:

f~c-fi' 4 - APPROVED BY:



PROJECT NO.:

AM-2579 DRAWN B Y :

HS

~ ~ ~ , ~ ~ '

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03A/HS-l01A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND

BURNER EOUIPMENT LIXT AM-2579 Page 6 of 7

THERMAL LIOUID HEATER HSlOlA - MODEL 1700-3.5/3.0-20-94-17/20 NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM # 8 ) r STABILIZER OVERHEAD (STREAM #12)

TAG OTY DESCRIPTION MFGR AND/OR MODEL -

CONTROLS - cont. --

DPI-010-A 2 Differential Midwest #I20 -011-A Pressure Gages 2-1/2", 0-10 dpsi

DPI-012-A 2 Differential Midwest a120 -013-A Pressure Gages 2-1/211, 0-50 dpsi

BC-A 1 Flame Program Control Fireye Monitor E200

SC-A 2 Scanners Fireye 48PT2-9003

IT-A 1 Pilot Ignition Trans. N.A. #4066-5N4-6A 220F/6000V

TE-015-A 1 Thsrmocouple Assembly T.E. 2D1/2x1/2, 3/4 S.W. -2-ADSL/4JGP

TE-019-A 2 Thermocouple Assembly -020-A

STACK TEMPERATURE INSTRUMENTS

TE-009-A 1 Thermocouple Type l1JU

DTI-009-A 1 Digital Display Heater Hon. #DC2001 Stack Temperature

TI-046-A 1 Thermometer Ashcrof t #50E160E060 200-1000°F

W-7-A 7 1/2" - 600# Gate S.W. Valve W-8-A 2 3/411 - 600# Gate S.W. Valve

F I N A L WHEN STAMPED AS F I N A L A N D SIGNED BY PROJECT ENGINEER

DWG. NO.

A- 3698-3 Page 6 of 7

SCALE D A T E

2/18/93 C H K E D B Y AE- APPROVED B Y :

AMERICAN HYDROTHERM CORPORATlON


PROJECT NO.

1114-2579 D R A W N B Y .

HS

?"%r;: -

b

BADGER PURCHASE ORDER NO*: BH-2831-H01-10 2001-F-03A/HS-101A KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


THERMAL LIOUID HEATER HSlOlA - MODEL 3700-3.5/3 .0-20-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM #8). STABILIZER OVERHEAD (STREAM #I21


HOT OIL INLET TEMPERATURE INSTRUMENTS

PI-017-A 1 Pressure Indicator Ashcroft #451279RS046XPD 4-1/2", 1/211 B.C. 0-160 psig

TE-014-A 1 Thermocouple Type llJw

DTI-014-A 1 Digital Display for Hon. #DC2001 Heater Inlet Temperature

TI-045-A 1 Thermometer Ashcroft #50E160E060 100-800" F

TW-014-A 2 Flanged Thermowells Ashcroft 045-A #15W0200HF26CR300

1-1/211-300# R. F.

RELIEF VALVES

PSV-14-A 1 Safety Relief Valve Lonergan #L4 0LCD20, ASME, 3/4"-300# R.F. Set at 150 psig

PSV-15-A 1 Safety Relief Valve Lonergan #L4 0LCD20, ASME, 3/4"-300# R.F. X 111-150# R.F. Set at 150 psig

ST-A 1 Stack

HV-9-A 1 3" - 300# C.S. Gate B.W. Valve HV-11-A 1 4" - 300# C.S. Gate B.W. Valve

FINAL WHEN STAMPED A S F I N A L A N D SIGNED BY PROJECT

DWG. NO.

A- 3698-3 Page 7 of 7

SCALE: D A T E

2/18/9

cx%?z HPPROVED W .



PROJECT N O

AM-25 79 D R A W N BY:

HS

'I i *

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-l01B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAM) KHANOM, THAILAND


THERMAL LIOUID HEATER HSlOlB - MODEL 1700-3.5/3.0-2D-94-17/20 NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5), CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


B-B 1 Dual Fuel Burner North American #6131-FA 2/P-1

HIS-B 1 Hinge Interlock Switch N.A. #R830-4028

PILOT GAS TRAIN

NP-B 1 Gas Pilot Assembly N.A. 131-0450 Nat. Gas

HV-4-B 1 Gas Valve Part of Pilot

ESV-005-B 2 Pilot Gas Solenoids Asco #8215G20 -006-B 1/2" - 220V, N.C.

PCV-025-B 1 Pilot Gas Regulator N.A. #7344-01, 1/2"

PCV-028-B 1 Pilot Gas Regulator N.A. #7345-01-H, 1/2"

HV-3 -B 1 Pilot Gas Cock Crane #254, 1/2"

PI-008-B 1 Pressure gage N.A. #8735-HM 0-32 02, 2-3/4" dial

HV-10-B 1 Gas Cock Part of Pilot

AIR-LINE TRAIN

AB-B 1 Air Blower Integral with Burner 380/3/50, 20 HP 2900 RPM, TEFC

M-B 1 Modutrol Motor Honeywell M7284C, 30 sec. 90°, 4-20 mA

LFS-B 1 Low Fire Switch Hon. #Q607A, Mtd. in M

FINAL WHEN STAMPED A S F I N A L A N D S I G N E D BY PROJECT

DWG. NO.

A- 3708-3 Page 1 of 7

SCALE.

,

D A T E .

2/18/93 C H

A P P ~ O V E D BY

I



PROJECT N O

14M-~579 D R A W N 8 Y :

HS SUI) I T LO:

BADGER PURCIUWE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-101B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND IQ?ANOM, THAI LAND


THERMAL LIOUID HEATER HSlOlB - MODEL 1700-3.5/3.0-2D-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5), CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


AIR-LINE TRAIN - cont. HFS-B 1 Air Purge Switch Part of M

BAS-B 1 Burner Air Shutter Integral with Burner

PSL-003-B 1 Low Combustion Air Cutout

ATOMIZER AIR-LINE TRAIN

AAC-B 1 Atomizing Air Compressor Set

Hon. #C437F 1-16 oz, N.O.

D-240, 5 HP, 780 RPM, TEFC 380/3/50

PRV-001-B 1 Pressure Control Valve Circle Seal #559 Set at 40 psig

PSL-007-B 1 Low Atomizing Air Cutout Ashcroft #B424BXFM60 0-60 psig

PSV-018-B 1 Compressor Safety Relief Valve

CFH-B 1 Compressor Flexible Hose

PI-024-B 1 Pressure Gage

Part of AAC, 1/2It Kingston Fig. 112C Set @ 60 psig

Part of AAC

N.A. #8735-P 0-100 psig

HEATED (STREAM #5) GAS-LINE TRAIN

PCV-033-B 1 High Gas Pressure Regulator Fisher #630, 2" NPT Set at 15 psig

F I N A L W H E N STAMPED AS F I N A L A N D S IGNED BY PROJECT ENGINEER


AMERICAN HYDROTHERM DWG. NO.

CORPORATION APPROVED BY:

A- 3708-3 470 PARK AvE. SOUTH, N.Y.. N.Y. 1-1. '~~~~~ page 2 of 7

' B2mGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-101B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAM> KHANOM, THAILAM>


THERMAL LIQUID HEATER HSlOlB - MODEL 1700-3.5/3.0-2D-94-17/20 I NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #I21

TAG OTY DESCRIPTION MFGR AND/OR MODEL I HEATED (STREAM #5 1 GAS-LINE TRAIN - cont. I

PCV-026-B 1 Low Gas Pressure Regulator Fisher #133L, 2" NPT Set at 1.5 psig I

FCV-001-B 1 Butterfly Gas Valve Integral with Burner I PSH-003-B 1 High Gas Pressure Ashcroft #B24BXFM15

Cutoff 0-15 psig I PSL-004-B 1 Low Gas Pressure

Cutoff

PI-014-B 2 Pressure Gages -015-B

PI-045-B 1 Pressure Gage

Ashcroft #B424BXFM3OW 0-30" W.C. I N.A. #8735-HM 0-32 oz 2-3/4" dial

N.A. #8735-S 0-160 oz 2-3/411 dial

ESV-003-B 1 Main Gas Solenoid G-C H117AL114, 3" I HV-6-B 1 Test Cock Crane, 1/8" I HV-1-B 1 Main Gas Cock

HV-2-B 1 Main Gas Cock

PCV-027-B 1 Pressure Reducing Gas Regulator

Walworth #1797F 4" Flg. I Walworth #I750 2" N.P.T.

N.A. #7349-7-SY 4l' N.P.T. I

F I N A L W H E N STAMPED AS F I N A L A N D S IGNED BY PROJECT ENGINEER

[PROJECT NO.: IDATE: I SCALE: i

AMERICAN HYDROTHERM DWG. NO.

CORPORATION A- 3708-3

470 PARK AVE. SOUTH, N.Y., N.Y. 10016 Page 3 of 7

BADGER PURCHASE ORDER NO.: BE-2831-H01-10 200l-F-03B/HS-l01B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


THERMAL LIOUID HEATER HSlOlB - MODEL 1700-3.5/3.0-20-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM # 5 ) , CONDENSATE (STREAM #8), STABILIZER OVERHEAD (STREAM #12)

TAG QTY DESCRIPTION MFGR AND/OR MODEL

CONDENSATE ( STREAM #8 1 -LINE TRAIN

HV-5-B 1 Gate Valve 2It S. W.

ESV-001-B 2 Oil Shutoff Solenoids N.A. #R8266C219L -002-B 1/2", 220V

PSL-002-B 1 Low Oil Pressure Cutout Ashcroft #B424BXFM100 0-100 psig

PCV-024-B 1 Fuel Oil Pressure N.A. #R690-6105, 1/2It Reducing Valve

ST-B 1 Fuel Oil Strainer N.A. #8553, 3/4"

PI-005-B 3 Pressure Gages N.A. #8735-M 0-100 psig 2-3/4" dial

PI-003-B 1 Pressure Gage N.A. #8735-Y 0-200 psig 2-3/4" dial

DPI-004-B 1 Diff. Pressure Gage Ashcroft #45-1125-02L 0-10 psid

FCV-002-B 1 Sensitrol Oil Valve N.A. #11-3354-4

FINAL WHEN STAMPED AS F I N A L A N D S IGNED BY PROJECT ENGINEER

I - PROJECT NO.: D A T E : SCALE:

AMERICAN HYDROTHERM AM-2579 2/18/93 DWG. NO.

CORPORATION , A - 3 7 0 8 - 3 I T E D : APPROVED BY:

470 PARK AVE. SOUTH, N.Y., N.Y. 10016 T& c- Page 4 of 7

BADGER PURCHA8E ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-101B KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


THERMAL LIOUID HEATER HSlOlB - MODEL 1700-3 .5 /3 .0-2D-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5), CONDENSATE (STREAM #8), STABILIZER OVERHEAD (STREAM #12)


STABILIZER OVERHEAD (STREAM #I21

PCV-029-B 1 Main Gas Pressure Fisher #Y750, 1" NPT Regulator Set at 1 psig

PSH-006-B 1 High Gas Pressure Ashcroft #B424BXFM15 Cutoff 0-15 psig

PSL-006-B 1 Low Gas Pressure Ashcroft #B424BXFM30n Cutoff 0-30" W.C.

PI-016-B 2 Pressure Gages N.A. #8735-HM -043-B 0-32 oz

2-3/4" dial

ESV-004-B 1 Main Gas Solenoid Hon. #5055C w/4055D 3/4"

HV-6A-B 2 Gas Cocks Walworth #7796, 3/411 -6B-B

HV-6-B 1 Test Cock Crane, 1/8"

CONTROLS

TIC-015-B 1 Temperature Controller Hon. #DC300K

TSH-019-B 4 High Temperature Hon. #DC200H -020-B Cutoff

FSL-001-B 2 Low Flow Cutoff U.E. #H105K, 0-20 psid -005-B

FE-001-B 1 Flow Orifice 3-1/2"

FE-005-B 1 Flow Orifice 3 It

F I N A L WHEN STAMPED AS F I N A L A N D S IGNED BY PROJECT ENGINEER I

PROJECT NO.: D A T E SCALE:

AMERICAN HYDROTHERM AM-25 79 2/18/93 DWQ. NO. DRAWN BY: cn

CORPORATION HS A-3708-3 sUBMITTCD: APPROVED BY:

470 PARK AVE. SOUTH, N.Y., N.Y. 10016 A% 44 *c Page 5 of 7

BADGER PURCHASE ORDER NO.: BH-2831-H01-10 2001-F-03B/HS-101B -OM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND


THERMAL LIOUID HEATER HS101B -- MODEL 1700-3.5/3.0-2D-94-17/20 NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5), CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


CONTROLS - cont. PDI-010-B 2 Differential Midwest #I20

-011-B Pressure Gages 2-1/2", 0-10 dpsi

PDI-012-B 2 Differential Midwest #I20 -013-B Pressure Gages 2-1/2", 0-50 dpsi

BC-B 1 Flame Program Control Fireye Monitor E200

SC-B 2 Scanners Fireye 48PT2-9003

IT-B 1 Pilot Ignition Trans. N.A. #4066-5N4-6A 220F/6000V

TE-015-B 1 Thermocouple Assembly T.E. 2D1/2x1/2, 3/4 S.W. -2-ADSL/4 JGP

TE-019-B 2 Thermocouple Assembly -020-B

STACK TEMPERATURE INSTRUMENTS

TE-009-B 1 Thermocouple Type "JI8

DTI-009-B 1 Digital Display Heater Hon. #DC2001 Stack Temperature

TI-046-B 1 Thermometer Ashcroft #50E160E090 200-1000°F

HV-7-B 7 1/2" - 600# Gate S.W. Valve HV-8-B 2 3 /4" - 600# Gate S.W. Valve

~ ~ N A L WHEW STAMPED A S F I N A L A N 0 S I G N E D BY PROJECT C N G l N L g R

PROJECT NO.: P A T E : SCALE:

AMERICAN HYDROTHERM . AM-25 79 2/1*/9 3 DWG. NO.

CORPORATION A P P R O V E D BY:

A- 3708-3 470 PARK AVE. SOUTH, N.Y., N.Y. 10016 ZM6- Page 6 of 7 .

J

BADGBR PURCHASZ ORDER NO.: BE-2831-H01-10 2001-F-03B/HS-101B KBANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND

BURNER EOUIPMENT LIST AM-2579 Page '2 of 7

THERMAL LIOUID HEATER HS101B - MODEL 1700-3.5/3.0-20-94-17/20

NORTH AMERICAN - BURNER #6131 FOR HEATED GAS (STREAM #5) , CONDENSATE (STREAM # 8 ) , STABILIZER OVERHEAD (STREAM #12)


HOT OIL INLET TEMPERATURE INSTRUMENTS

PI-017-B 1 Pressure Indicator Ashcrof t #451279RS046XPD 4-l/2l1, l/2lf B.C. 0-160 psig

TE-014-B 1 Thermocouple Type "JW

DTI-014-B 1 Digital Display for Hon. #DC2001 Heater Inlet Temperature

TI-045-B 1 Thermometer Ashcroft #50E160E090 100-800" F

TW-014-B 2 Flanged Themowells Ashcroft 045-B #15W0200HF26CR300

1-1/2"-300# R.F.

RELIEF VALVES

PSV-014-B 1 Safety Relief Valve Lonergan #L40LCD20t ASME, 3/4"-300# R.F. X 1" - 150# R.F. Set at 150 psig

PSV-015-B 1 Safety Relief Valve Lonergan #L40LCD20, ASME, 3/4"-300# R.F. X 1" - 150# R.F. Set at 150 psig

ST-B 1 Stack

HV-9-B 1 3 11 - 300# C.S. Gate B.W. Valve

HV-11-B 1 4" - 300# C.S. Gate B.W. Valve F l N A L WUEN STAMPED AS F I N A L A N D S IGNED BY PROJECT ENGINEER


AMERICAN HYDROTHERM ,AM-2579 2/18/93 DWG. NO.

CORPO~ATiON A- 3708-3 470 PARK AVE. SOUTH, N.Y., N.Y. 10016 Page 7 of 7

J

.FULL. WELD

P

TOP Rl't.lG.-DETAIL

STACK TO f3 E PAINTED WITH T W O (2) COATS

I E ALUMINuM P/?\\Nt

BADGER

BADGER DESIGN & DATE REC'D

CONSTRUCTORS. INC.

ACTION STATUS I I I

Reviewed wltnout comments. Reviewed with comments.

A Subm~l FINAL drawing. C Resubmit tor further review. Proceed w ~ t h fabrlcatlon. proceed with fabrlcatlon

I

Reviewed with comments. Reviewed wlth comments. incorporate comments and D Resubm~t tor further revlew. B submit FINAL drawing. HOLD for fabricallon. Proceed w~ th fabricallon.

Information Only. F Approved Final i Approval Not Required.

1 REVISIONS

AMERlCAN PPYDROTI-IERM CORPORATION


GADGER, DESIGN $ C~NSTRUCTC~~~;S , INC.

PURCHASE ORDER NO.: BH-283 1-H0 1-10 f)Sri~iz&&cffI.~::I.0:&B 2 0 . 0 1 - 1: - ~ ~ A ] I ! J - / e r f i 4 z do I -F- i i 3 f i / i / 5 - 01

ICHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND PROJECT No.:

P E .

ImANOM, THAILAND - a , , = ..,$%" .,.. .. : - . ., , . , t s Ij TliZ $PCPEKW CF P,!!ECICA!I tIY :ROTIiER:l CCRPOR;?TjO?( A!iD IS TQ OE RETIjRtlED UPOtl REQUEST. I T CO:ITAIllS COIlFlDENTlAL It(EOR!.tATIOti ;'/HIGH f.IUST 1.101 EE DISCLOSED TO ANYONE \YITIICUT Pn18R ;VRITTEN CONSEN'I: IT I S 1 ~ ~ t ; r 3 ' . " , , . I ~ . . , - i fi:C t,'.l.T:ZZZ ,%Gf'E1tC:iT TIiRT I t i E D24;'l!t!G A113 i?:F9n!dAT!:!4 TllER5O:l ,\$'ILL FIor. D l i ? E ~ l . Y OR I ~ ~ D I R E ~ L Y , DE nEPfiODUCED! COPIED OR OfllERVIISE',DISPOSED OF. O R BE USED I!{ i'1'IHOLE OR PhRr TO r I S I i S T I N I l IA l . IP.(T; OR TO FURNISH ANY I!~FORt.fATlO!~ FOn i i lE ' f !A: i l? iG CF C5AY;fIIGS. P I : I ! ~ T S ~ ~ ~ Q T I ? ~ ~ C3CCCUtTIC! lS T)lCCcQf', OR CF APPARATUS OR P;\l?YS TiIEREOP. OR Foil ANY OTtlER PUI?POI;C. WITIiOUT PRIOR WRITTEIf COIISEIJT. T l l E ACCEPTAIlCE OF THIS DRAVO'ING CONSTITUTES ACCEPTAHCE OF ,. ..-. P C ; * , ~ - . . , . ' - -'C,,r"'* . . - . . , . . t A : . J . . . .&4 . -1 ,*

E L E C T R I C A L COI?l.ITROL PA NE L " ECP-A"& "E CP- B*'

Sl NGLE DOOR NEMA TYPE -4'' ENCLOSURE S \ Z E : . ~ ~ * M x ~ O ' ~ J ) K I O " ( D ) - ------ ----

W E . N \ N G PLATE Y E L L O W WIRES IND\CATE VOLT4GE FROEA EXTERNAL POW EP. SQURCE

.-*-

r -,

PROVICE m~ .EC. CUFP02,T TO BRING (BRriCr.5l DIGI~AL R E A C C ] ~ T OP FLAT€

CLOSE 10 Et~ciQsuRE D O P \.;lrlr?oyJ.

J * -. -

ALLEN%~NEI "Fl R'EY E'

FLAME MONITOR E 2 0 0

\ --

- - - -- pv .

I W I N D O W I N O T E ' . ALL E?~UIP~.AENT MOUhlTED O N FACE OF PAhlEL S H O U L D B E bIEATHERPROOF (GAS\CET E D) At4D CORP,OSIOI.lPROOF.

I -- ---.-

S P A R E T E R M I N A L BLOCVS - I

. . ..... I --... . I _ . .-.J L * - i

W I R E DUCT SIZE: 2 " - (~1)r l;,s1'(w) (TY P) / j

I '"A c4c4 LOf..7{2 I LUJ 7 - 5 L O T RACK r 1746-A7

CIJST'S EQUIPMEIJ'I ---- G N D BARE \.J\F?E COPPER. *I2 " AWG"

I - - -

2 ?$I/?! ~4 R E ~ J I C E ? P C ' : C ~ ~ ~ ~ ' ~ . C / ) I ( E ~ I T S

I ?il;/3! P c, nrr_ I I ~ , F = _ ~ . PEP CUST'S C O ~ ~ ~ ? F P I T S

, I r) I,??,:: D . ~ , . 1t.q IJI:~-\ ~ 3 f 3 q : ~ ~ ~ ' ~ r ,c)?d.r~r-rl t5 4 ,

0 DATE B Y DESCRIPTION

DOOR V I E \ /

L EGEtJD AND IJAMEPLATE DESCRI --.----.--- P7-1 O!dC 2-

EMERGEMCY A C T 1Q4.r ED .1.-21 LO-PP.ESS FUEL HEATED G45

HTR C\KC PUMP PP-102A L-22 Lo- PP.ESS FUEL cot4bEr\lSh"lE

H7R ClRC PUMP PP-1020 L-23 L O --PY,EFS C U ' O ~ A B U S T I C ~ ~ I A \ R

q T i ? . L \ R C PUMP p P - \ 0 2 ~ - L O - PRESS ATotA\z \NG A \ R

MAlkd ' d E 4 D E S V A L V E 3PEhI 1-25 \ A \ - PR.ESs< 5Tb,B\L\zE.f-'

MA\N HEADER vAWE CLOSE L&-PRESS 57491L\ZER

C a h l ~ K o ~ POWER OEf \:%'7 cor.\U:,- t1t,;nTE ~\/A\LABLF_

CONDENSATE MOT A'JAl LABLE L-28 \EA.\EE 5 - r ~ ~ R G I ~ O T E C ' ~

HEATED GAS BURMING PB , I r LL,,AE F^A.\LLIRE RESET

CONDEUSATE BURI.IIF\IG PP-2 !\LA?-\/? ~ \LE' , \C.E

STABILIZER VALVE OPE E.J PB-Z) LAUP -1 EST

HEATER O U 55-1 C Q I \ \ ' ~ R ~ L P'-'\AIR 3 ~ ~ - 0 r \ l

H\-TEt.1? HTR COIL* I 55-2 \4EATEp. 2,5lhP,l-,STc)P

HI-TEMP HTP, COILG! r; .>>-!: r $TAB\L \ZEP. Q F F -- qk.1

I REVISIONS

I THIS DRAWING IS THE PROPERTY OF AMERICAN I HYDROTHERM CORPORATION AND IS TO BE RETURNED I UPON REQUEST, IT CONTAINS CONFIDENTIAL INFOA- MATION WtllCI4 MUST NOT BE DISCLOSED TO ANYONE 1 553-5 HEATER ENABLED

'ECP-A' FOR c lF47~R"A" EcP- B" F O R MHEAXER's

A - : > G ~ ? E ~ \ . F ~ Y - l ? \ ~ A . I . F T ! L l - :yF \ , \ h ! : . ' t d \ , / \ , \ - H ~ P , ( , IT IS LOANED WITH THE EXPRESS AGREEMENT THAT I THE DRAWING AND INFORMATION THEREON WILL NOT.

A - " 7 ' 1 ' \ I F , i . l f l r : , , \ t \ - r t - D \ / \ x \ - t \ - i R 'b" DIRECTLY OR INDIRECTLY. BE REPRODUCED. COPIED - I_ -- OR OTHERWISE DISPOSED OF. OR BE USED I N WHOLE OR PART TO ASSIST I N MAICING OR TO F l lRNlSH ANY

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NOTE ACTUAL PANEL COIdDLIIT PENETR&TIOt\IS A N D RUfJS SMALL BE D E T E R M I N E D DURING SHOP FABP.lCATIC)N AidD FIELD I~JSTALL&TID~I.

COLOR OF PAUEL T-0 BE: EPOXY PA11 lTED SEI~A\ G l - 0 3 ~ <<P,X~' --... --- ...... -- --- .---- -- A -- - I THE ACCEPTANCE O F THIS DRAWltJG CONSTII'UTES ACCEPTANCE O F THE FOREGOING AGREEhlENT. I

I CORPORATION I 1 470 PARK AVE. SOUTH N.Y., N.Y. 10016 1

- . . . .... L- 15 BURLIER, HlNGE SMtTCH OPEr\l 55'4 5 k S AUic) :)cC)NDENS. BADGER -.

.. PURCIIASE ORDER NO.: BH-283 1-H01-10 > rn - 6 FLAME FAILURE A \ \~f i ; \ 'Ep, F,Tb,Clv. TEf4F E

HEkTF P \ ! . \LET -\ 3001-F-O~A/HS-~O~A Rr 2001-F03B/HS-101B ICHANOM ONSHORE FACILITIES B

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E- 10064 - 1 * A H awL I S * mllS IL 1 (..la - w

PLAN V1E.N

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BADGER PURffUSE ORDER NO.: DH-2831-H01-I0

2lOl-*%/tl:-i:t~. Z C O ~ - ~ - O ~ B / H S - ~ O I B KIiANOM ONSIiORE FACILnTES THE PETROLEUM AUTHORITY OF THAILAND KHANOM. THAUAM)

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125 PSI

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BADGER PURCHASE ORDER NO.: BH-2831-HOI-10

I

NO.

2001-F-03A/HS-lOlA KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KHANOM, THAILAND

THIS DRAWING IS THE PROPERTY OF AMERICAN HYDROTHERM CORPORATION AND IS TO BE RETURNED UPON REQUEST. I T CONTAINS CONFIDENTIAL INFORMATION WHICH MUST NOT BE DISCLOSED TO ANYONE WITHOUT PRIOR WRITTEN CONSENT. IT IS LOANED W I M THE EXPRESS AGREEMENT THAT THE DRAWING AND INFQRMATION THEREON WILL NOT, DIRECTLY OR INDIRECTLY, BE REPRODUCED. COPIED OR OTHERWISE DISPOSED OF. OR BE USED IN WHOLE OR PART TO ASSIST I N MAKING OR TO FURNISH ANY INFORMATION FOR THE MAKING 01: DRAWINGS. PRINTS OR OTHER REPRODUCTIONS THEREOF. OR OF APPARATUS OR PARTS THEREOF. OR FOR ANY OTHER PURPOSE. WITHOUT PRIOR WRITTEN CONSENT. THE ACCEPTANCE OF THIS DRAWING CONSTITUTES ACCEPTANCE OF THE FOREGOING AGREEMENT.

REVISIONS

?hoh3 DATE



B U R N E R S C H E F v l A T I C f - !5l0lA

FINAL WHEN STAMPED AS FIZL AND SIGNED BY PROJECT ENGINEER

& BY

PROJECT NO.: DATE: I SCALE%

A M - 2579' 1 1 - 1 1 - 93 , -. ...J

R E V I F E R PER CUSTOMER COMMENTS

D E S C R I P T I O N

DRAWN BY:

APPROVED By: C- (772-3

HEATED G A S (~TREAM * 5)

I O O P S I

CONDEN SATE (STREAM* a)

125 PSI

STA 61 LIZ ER OVERHEAD

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I REVISIONS

&

AMERICAN HYDROTHERM

R E V I 5 E D PER CU5T;TOMER COMMEEITS

D E S C R I P T I O N

I CORPORATION 1 470 PARK AVE. SOUTH, N.Y., N.Y. 10016

BADGER I BAOGER DESIGN 4 CO~ISTRUCTORS , INC.

PURCHASE ORDER NO. : BH-283 1 -HO 1 - 10 E U D I - F - ~ ~ B / H5-1018

KHANOM ONSHORE FACILITIES THE PETROLEUM AUTHORITY OF THAILAND KIiMNOM, THAILAND

THIS DRAWING IS THE PROPERTY OF AMERICAN HYDROTHERM CORPORATION AND IS TO BE RETURNED UPON REQUEST. IT CONTAINS CONFIDE~TIAL INFOAMATION WHICH MUST NOT BE DISCLOSED TO ANYONE WITHOUT PRIOR WRITTEN CONSENT. I T I S LOANED WITH THE EXPRESS AGREEMENT THAT THE DRAWING AND INFORMATION THEREON WILL NOT, DIRECTLY OR INDIRECTLY, BE REPRODUCED. COPIED OR OTHERWISE DISPOSED Of, OR USED I N WHOLE OR PART TO ASSIST IN MAKING OR TO FURNISH ANY

INFORMATION FOR THE HAKING OF DRAWINGS, PRINTS OR OTHER REPRODUCTIONS THEREOF. OR OF APPARATUS OR PARTS THEREOF. OR FOR ANY OTHER PURPOSE, WIT~OUT PRIOR WRITTEN COI(SEHT, THE ACCEPTANCE OF THIS DRAWING CONSTITUTES ACCEPTANCE OF THE FOREGOlNa AGREEMENT.

IiSlol B FINAL WHEN STAMPED A S FINAL AND SIGNED BY PRC lECT ENGINEER

PROJECl NO.: D A T E : SCALES

AF.1- P 5 7 9 1 1-11-45 ,-" ..

A P P R O V E D BY:

C- 1776-3

220 VAC , SOHz, i PNASE FROM G U S T ' S FUSED POWER SOURCE A LLEN-BRADEY PROGRAMMABLE LOGIC COh!TROLLER

T Y ? E "SLC 500" MODULAR 'GARDWARE S T Y L E

G E N E R A L NOTES

?

N O T E : I THESE DW G T A 5 S ARE SUFFIXED w 1 - i ~ TME (

I L E T T E R "A' F O R HEATER, H 5 - IOIA

] FOR HEATER H S - \ O I B T g ( S 5 U F i i X i E T E R * K 1

1. ALL 2 2 0 V AC CONTROL WIRES qRE 1 /C # 1 G "THHN" .90' C, 600V

STRANDED UNLESS OTHERWISE SPECIFIED.

2. ALL EXTERNAL 2 2 0 ~ AC CONTROL WIRES TO BE I/C # I 4 "AWG"

"THHN" 90' C, 600V STRANDED UNLESS OTHERWISE SPECIFIED.

3. ALL POWER WIRES TO BE STRANDED, TYPE "THHN" OR EQUAL 600V.

4. ALL CONTROL' WIRES TO AND FROM ANALOG DEVICES LOCATED

IN THE FIELD TO BE #l8 "AWG" SHIELDED AND TWISTED. 5 . USE OF # I 8 "AWG" TYPE "THHN" BETWEEN "SLC" AND

TERMINAL BLOCI<S "TB" IS PERMITTED.

6. EACH END OF EACH WIRE TO BE PERMANENTLY TAGGED FOR

IDENTIFICATION.

7. WIRES TO BE COLOR CODED AS FOLLOWS (UNLESS OTHERWISE

SPECIFIED):

BLACK - LlNE LOAD AND CONTROL CIRCUITS AT LlNE

VOLTAGE AC or DC. BLUE - DC CONTROL CIRCUIT

RED - AC CONTROL CIRCUIT

YELLOW - INTERLOCI< CONTROL CIRCUITS WIRES FROM AN EXTERNAL POWER SOURCE

GREEN - EQUIPMENT GROUNDING CONDUCTORS

WHITE - GROUNDED CIRCUIT CONDUCTORS

8. CABLE SHIELD IS CONNECTED CHASSIS GROUND AT THE

CONTROLLER CHASSIS MOUNTING BRACKET ONLY. DO NOT

GROUND ANY CABLE SHIELD AT BOTH ENDS.

9. ALL CONTACTS SHOWN IN SHELF POSITION (DE-ENERGIZED)

UNLESS OTHERWISE NO;ED.

10. EQUIPMENT GROUNGS TO USE EYE LUGS WITH STAR WASHER,

STAR ON OUTSIDE.

11. ALL CONDUITS TO AVOID CROSSING HOT PIPES.

12. A L L TAG tJUi..ISERS A R E SUFF\XED M \ T H THE LETTER"A" FOR t4EATER HS-\O\A AND "B" FOR HEATER H S - \ 0 \ 8

13." MOV" FOR TH\S DRAW\NG O U L Y \E\\D\CATES M E T A L OX\DE

V4R\STOR TYPE TRANS\ENT SURGE PROTECTC>R.

b 320009 vendor data catalog vol.5

Business

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