DB270-XD00XEN-E1 Guia de Instalacion

INSTALLATION GUIDEFOR

T5552 PROCESS CONTROL LEARNING SYSTEM

DB270-XD00XEN

DB270-XD00XEN T5552 Process Control Learning System Installation GuideCopyright © 2011 Amatrol, Inc. 2

INTRODUCTIONThis installation guide will take you through the process of setting up and testing the T5552

Process Control Learning System.

1. Parts Inventory/Identifi cation

2. Hardware Setup

3. T5552 Trainer Operation/Testing Procedures

FIRST EDITION, REV. AAmatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies.Copyright © 2011 by AMATROL, INC.All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, elec-tronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission of the copyright owner.Amatrol,Inc., 2400 Centennial Blvd, Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com


TABLE OF CONTENTS

SECTION 1 PARTS INVENTORY/IDENTIFICATION ............................................................ 41.1 Inventory Procedure ............................................................................................................ 41.2 Description of Module Components ..................................................................................... 6

SECTION 2 HARDWARE SETUP ....................................................................................... 21

SECTION 3 T5552 SYSTEM OPERATION/TESTING PROCEDURES .............................. 293.1 Power Supply, Selector Switch, and Indicator Light Test ................................................... 293.2 Control Relays CR1, CR2, and CR3 Test .......................................................................... 313.3 Circulation Pump and Solenoid Valve Test......................................................................... 343.4 Level (Float) Switch and Alarm Horn Test .......................................................................... 403.5 Level Test ........................................................................................................................... 44 3.5.1 Honeywell UDI 1700 Process Meter Setup ............................................................ 44 3.5.2 Level Test ............................................................................................................... 513.6 Flow Test ............................................................................................................................ 523.7 PID Controller Test ............................................................................................................. 543.8 Optional Ultrasonic Level Sensor Test ............................................................................... 603.9 Optional Smart Flow Differential Pressure Transmitter Test ............................................... 63

APPENDIX INSTALLER CHECKLISTS ............................................................................. 70


SECTION 1

Parts Inventory / Identifi cation

The fi rst step to setting up your system is to inventory each component. The T5552 Process Control Learning System can include several optional components in addition to the base system. This section covers the base system and the optional components.

PART 1.1 INVENTORY PROCEDURE

OVERVIEWPerform the following steps to take an inventory of the T5552 Process

Control Learning System.

1. Use your school’s purchase order to determine what (if any) optional components you have in addition to the T5552 base system.

These optional components are identifi ed on page 3 and shown throughout Section 1.2.

2. Locate in the appendix of this manual the Installer Checklist for the base system and any optional packages you have in the appendix of this manual.

The Installer Checklist identifi es the details of the components of the system and support materials in your package.

3. Check off each item on the Installer Checklist as you identify it. The pages in Section 1.2 give you a picture of each item to assist you.

Each of the optional components has a separate detailed checklist in the appendix. Use the detailed checklists to identify and inventory all of the components included.

NOTEPlease report any missing items or damaged components within 10 days.

Save damaged cartons if components are damaged. Amatrol will not be responsible after this period.


SECTION 1 Parts Inventory / Identifi cation

4. Your local Amatrol representative should sign each checklist and send a copy to Amatrol for verifi cation.

5. In addition to the package provided by Amatrol, the T5552 Process Control Learning Sys-tem requires these school-supplied items:

ITEM DESCRIPTION

Single-Phase Power Supply 220 VAC 60 Hz

Safety Safety Glasses

Tools Phillips ScrewdriverSmall Slotted ScrewdriverSet of Allen WrenchesAdjustable WrenchDigital MultimeterLoop Calibrator (Optional)

Air Compressed Air Supply

Water Municipal Water Supply



PART 1.2 DESCRIPTION OF UNIT COMPONENTSThe T5552 is designed to teach basic process control concepts, safety, and applications. The

T5552 base system includes several panels and components attached to the system chassis.

The following charts list the components included with the T5552 Process Control Learning System and the optional add-on components. You may have one or more of the optional compo-nents.

MAJOR COMPONENTS LISTING OF T5552Part Number Description

A010618-1 Process Control System Chassis

– Lead Set

– Lockout/Tagout Equipment

86240200 AC Power Cord

33242 Precision Resistor Assembly

180211 Drain Cap

– Instrument Manual Set

– Spare Parts Set

BB270-XD00XEN Student Learning Activity Packets

CB270-XD00XEN Portfolio/Assessment Package

DB270-XD00XEN Installation Guide for T5552

OPTIONAL COMPONENTS OF T5552Part Number Description

T5552-C1-A PID Controller Module w/Lead Set

T5552-L1 Ultrasonic Liquid Level Module

T5552-F1 Smart Flow Transmitter

T5552-F1A Pitot Tube Flow Transducer

T5552-F1B Venturi Flow Transducer

T5552-F1C Orifi ce Plate Flow Transducer



A010618-1 PROCESS CONTROL SYSTEM CHASSISThe T5552 Process Control System is shown in fi gure 1.

The T5552 includes the components and controls necessary to control the level and fl ow of fl uid through the system. The T5552 can be connected to a PLC or an optional PID controller can be added to provide automatic control.

NOTEThe T5552 in fi gure 1 shows the optional T5552-C1-A PID controller unit. If

the T5552-C1-A is not used, there will be a blank panel in that location.

Figure 1. T5552 Process Control System with Optional PID Controller

T5552PROCESS CONTROL SYSTEM AMATROL

4-20mA

OPEN COLLECTOR

DISCRETE

24 VDC

AUX. POWER

FLOW TRANSMITTER

OUTPUTS

ANALOG

PLC ANALOG I/O4-20mA

DC POWER SUPPLY

24VDC

SV3

CR3

SV2SV1SOLENOID VALVES

12

12

43

9 10

9 10

1 2

11

11

GND

24VDC24VDC

15 16

15

7

16

8

1413

14

5 6

13

PROCESS METER

OUTPUT RELAY 2

NO

OUTPUT RELAY 1NO

PLC DISCRETE I/O24VDC

SS1

PL1FV1

4-20mA

FLOWPVALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARMPHORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

ANALOG OUTPUTP4-20mA

ANALOG INPUTP0-10 VDC

431 2

SS4

PL4

SS3

PL3

SS2

PL2

CIRC.PPUMPP1

7 8

COM

COM

5 6

NC

NC

PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp

OPTIONAL T5552-C1-APID CONTROLLER

1 9 9.0SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



LEAD SETThe lead set provides the leads necessary to connect the various circuits. The leads use

banana-type plugs.

The leads are listed below and shown in fi gure 2.

REF. PART NUMBER DESCRIPTION QTY.

A. B-12-2 12” Red Dual Banana Leads 10

B. B-12-0 12” Black Dual Banana Leads 10

C. B-24-2 24” Red Dual Banana Leads 4

D. B-24-0 24” Black Dual Banana Leads 4

Figure 2. Lead Set for the T5552

A.

B.

C.

D.



LOCKOUT/TAGOUT EQUIPMENTSafety equipment is provided to prevent unsafe power up of the T5552 system. This includes

equipment to lockout the circuit breaker. This equipment meets OSHA standards.

The lockout/tagout equipment is listed in the table below and is identifi ed in fi gure 3.


A. 1U177 Safety Lockout 1

B. 5T155 Safety Lockout Tag 1

C. 5T807 Padlocks 2

Figure 3. Lockout/Tagout Equipment

C.

A.

B.



86240200 AC POWER CORD, TYPE GThe AC power cord, shown in fi gure 4, allows you to connect the T5552 to an AC outlet.

Figure 4. AC Power Cord



33242 PRECISION RESISTOR ASSEMBLYThe precision resistor assembly, as shown in fi gure 5, includes a dual-banana plug and a

250Ω resistor. The precision resistor assembly is plugged into the voltage input jacks on the Pro-cess Meter panel to convert a current signal to a voltage signal.

Figure 5. Precision Resistor Assembly

180211 DRAIN CAPThe drain cap is placed on the end of the reservoir tank drain piping, as shown in fi gure 6.

Figure 6. Drain Cap on End of Reservoir Drain Piping

RESERVOIRDRAINPIPING

DRAINCAP



INSTRUMENT MANUAL SETIncluded with the T5552 is a set of manufacturer’s instruction manuals for some of the devices

on the T5552.

The manuals are listed below.

REF. MANUFACTURER’S MANUAL NUMBER DESCRIPTION QTY.

A. 51-52-25-138 Honeywell UDI 1700 Process Meter Instruction Manual 1

B. 3-2000.090-1 GF Signet Flow Sensor Instruction Manual 1

C. 3-3550.090-1 GF Signet 3550-1 Flow Transmitter Instruction Manual 1

D. P-5000 Robert Shaw Proportional Valve Instruction Manual 1

E. 546-622-053 Dwyer IP-42 Current-to-Pressure Transmitter Instruction Manual

1

SPARE PARTS SETThe following spare parts are included with the T5552 and shown in fi gure 7.

PART NUMBER DESCRIPTION QTY.

2-211N O-Ring 2

3121.25 Fuse 1

Figure 7. Spare Parts Set

O-RINGS

FUSE



B270-XD00XEN PROCESS CONTROL SYSTEMS STUDENT LEARNING ACTIVITY PACKETS (LAPs)

Included with the T5552 Process Control Learning System is a set of 10 LAPs, as listed below and shown in fi gure 8.

LAP TITLE

1 Introduction to Process Control

2 Instrument Tags

3 Piping & Instrumentation Diagrams

4 Loop Controllers

5 Final Control Elements

6 Level Measurement

7 Liquid Level Control

8 Methods of Automatic Control

9 Basic Flow Measurement and Control

10 Control Loop Performance

Figure 8. BB270-XD00XEN Process Control LAP Package



CB270-XD00XEN PORTFOLIO/ASSESSMENT PACKAGEThe Portfolio/Assessment Package is shown in fi gure 9. This book provides all of the informa-

tion necessary to perform the assessment of the students. It also contains all forms the students will need to complete as they go through LAPs 1-10 of Process Control Systems, as well as the two optional LAPs (LAP 11 and LAP 12).

Figure 9. Process Control Systems Portfolio/Assessment Package

DB270-XD00XEN INSTALLATION GUIDEThis is the manual you are now reading.

PROCESS CONTROL SYSTEMS

CB270-XD00XEN

Portfolio/ Assessment

Package



T5552-C1-A PID CONTROLLER MODULE (OPTIONAL)WITH LEAD SET

The T5552-C1-A PID Controller Module, as shown in fi gure 10, teaches the concepts and ap-plications of proportional-integral-derivative control using an industrial PID controller.

Figure 10. PID Controller Panel

PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp



The components included with the PID Controller Module are listed below and identifi ed in fi gures 10 and 11.


Figure 10 A010618-12-22 PID Controller Panel 1

Figure 11-A B-24-2 24” Red Dual Banana Leads 2

Figure 11-B B-24-0 24” Black Dual Banana Leads 2

Figure 11-C 51453375-501 Honeywell UDC Controller Manual CD-ROM 1

Figure 11. Lead Set and Controller Manual CD-ROM

A.

B.

C.



T5552-L1 ULTRASONIC LIQUID LEVEL MODULE (OPTIONAL)The T5552-L1 Ultrasonic Liquid Level Module teaches concepts and applications of liquid

level measurement using ultrasonic waves. It also teaches fundamentals of calibration and tuning.

The components included with the T5552-L1 are listed below and shown in fi gure 12.

PART NUMBER DESCRIPTION QTY.

T5552-L1 Ultrasonic Liquid Level Module 1

33255-XD LAP 11 Ultrasonic Level Measurement and Control (not shown) 1

Figure 12. Ultrasonic Liquid Level Module

ULTRASONICLEVEL SENSOR

MODULE



T5552-F1 SMART FLOW TRANSMITTER ASSEMBLY (OPTIONAL)The T5552-F1 Smart Flow Transmitter Assembly teaches the concepts of fl ow measurement

and control using differential pressure. The T5552-F1 works with the three optional differential pressure fl ow sensors available for the T5552 (orifi ce plate, venturi tube, pitot tube). Each of the differential pressure fl ow sensors creates a restriction in the process piping. When fl uid fl ows through the restriction, a difference in pressure results across the restriction. This differential pres-sure is read by the T5552-F1, which can be programmed to display the fl ow rate based on the differential pressure and supply an analog signal (4-20mA) to the controller that is proportional to the fl ow rate.

The components included with the T5552-F1 are listed in the table below and identifi ed in fi gure 13.


A. 3051CD1A52A1AM5 Smart Flow Transmitter 1

B. MD808SCT Differential Pressure Transmitter Manifold 1

C. 33256-XD LAP 12 Differential Pressure Flow Measurement and Control (not shown)

1

Figure 13. Smart Flow Transmitter and Differential Pressure Transmitter Manifold

A.

B.



T5552-F1A PITOT TUBE FLOW TRANSDUCER (OPTIONAL)The T5552-F1A Pitot Tube Flow Transducer, as shown in fi gure 14, is used with the T5552-F1

Smart Flow Transmitter to teach concepts and applications of differential pressure fl ow measure-ment using a pitot tube.

Figure 14. Pitot Tube Flow Transducer

T5552-F1B VENTURI FLOW TRANSDUCER (OPTIONAL)The T5552-F1B Venturi Flow Transducer is shown in fi gure 15. The T5552-F1B is used with

the T5552-F1 Smart Flow Transmitter to teach concepts and applications of differential pressure fl ow measurement using a venturi tube.

Figure 15. Venturi Flow Transducer



T5552-F1C ORIFICE PLATE FLOW TRANSDUCER (OPTIONAL)The T5552-F1C Orifi ce Plate Flow Transducer, as shown in fi gure 16, is used with the T5552-

F1 Smart Flow Transmitter to teach concepts and applications of differential pressure fl ow mea-surement using orifi ce plates.

Figure 16. Orifi ce Plate Flow Transducer

ORIFICEPLATE


SECTION 2

Hardware Setup

OVERVIEWIn this section, you will ensure proper location of the T5552 system and any

of the optional packages that you might have. You will also connect the T5552 to the appropriate supplies.

1. Identify the components listed in the following table on the P&ID and also on the T5552, using fi gures 17 and 18 as references.

MAJOR COMPONENTS LISTING OF T5552Item Description Instrument Tag

1 Dual-Compartment Process Tank N/A2 Reservoir Tank N/A3 Water Pump N/A4 Pressure Gauge 1 PI 100-A5 Pressure Gauge 2 PI 100-B6 Manual Valve (HV2) HV 100-A7 Manual Valve (HV1) HV 100-B8 Solenoid Valve (SV1) SV 100-A9 Manual Flow Control Valve (HFV) FV 10010 Rotameter FI 10011 Pressure Regulator with Gauge PC 100

PI 100-C12 Current-to-Pneumatic Converter (I/P) IYT 10013 Diaphragm-Actuated Flow Control Valve FCV 10014 Paddle-Wheel Flow Sensor FE 10015 Float (Level) Switch 1 LSH 200-A16 Float (Level) Switch 2 LSH 200-B17 Head Pressure (Level) Sensor/Transmitter LET 200-A18 Solenoid Valve (SV2) SV 100-B19 Solenoid Valve (SV3) SV 100-C20 Manual Valve (HV3) HV 30021 Manual Valve (HV4) HV 100-C22 Manual Valve (HV5) HV 40023 PID Controller (Optional) FIC 10024 Ultrasonic Level Sensor (Optional) LET 200-B25 Flow Meter/Transmitter FIT 100


SECTION 2 Hardware Setup

Figure 17. T5552 P&ID

RE

SE

RV

OIR

TAN

K

SS

DU

AL-

CO

MPA

RT

ME

NT

PR

OC

ES

STA

NK

S

OV

ER

FLO

W

PI

100-

A

DR

AIN

H 400

HV

100-

A

HV

100-

B

SV

100-

A

FV

100

PI

100-

B

FC

V10

0LS

H20

0-B

LSH

200-

ALE

T20

0-B

LET

200-

A

HV

300

SV

100-

BH

V10

0-C

SV

100-

C

FI

100

FE

100

FIC

100

IYT

100

PLA

NT

AIR

PC

100

PI

100-

C

WAT

ER

PU

MP

FIT

100

2415

1625 14

13

23 12

11

10

59

86

4

7

22

2018

2119

17



Figure 18. Major Components on the T5552

Only the major components affecting the process are shown on a fl ow diagram. For that rea-son, the connection panels are not drawn on the P&ID.


4-20mA

OPEN COLLECTOR

DISCRETE

24 VDC

AUX. POWER

FLOW TRANSMITTER

OUTPUTS

ANALOG


DC POWER SUPPLY

24VDC

SV3

CR3


12

12

43

9 10

9 10

1 2

11

11

GND

24VDC24VDC

15 16

15

7

16

8

1413

14

5 6

13

PROCESS METER

OUTPUT RELAY 2

NO

OUTPUT RELAY 1

NO


SS1

PL1FV1

4-20mA

FLOWPVALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARMPHORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA



431 2

SS4

PL4

SS3

PL3

SS2

PL2

CIRC.PPUMPP1

7 8

COM

COM

5 6

NC

NC

14 9

10

7 8

5

11

251615

24

2

22

1

20

18

24

17

19

4

6

13

12

23 PID(NOT

SHOWN)24 VDC

1 9 9.0SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



2. Identify the connection panels listed in the following table, using fi gure 19 as a refer-ence.

T5552 CONNECTION PANELSItem Description

1 Flow/Level Sensor Connection Panel

2 Control Relays/Solenoid Valve Connection Panel

3 Discrete I/O Connection Panel

4 Power Supply/Alarm Horn/Circulation Pump Connection Panel

5 PLC Analog/Discrete I/O Connection Panel

6 Process Meter Connection Panel

7 Flow Transmitter Connection Panel

8 PID Controller Connection Panel (Optional)

Figure 19. Connection Panels

3. Position the T5552 so that it is near the following sources:

• Water supply

• Compressed air supply

• 220VAC, 60 Hz Single-phase outlet

4-20mA

OPEN COLLECTOR

DISCRETE

24 VDC

AUX. POWER

FLOW TRANSMITTER

OUTPUTS

ANALOG


DC POWER SUPPLY

24VDC

SV3

CR3


12

12

43

9 10

9 10

1 2

11

11

GND

24VDC24VDC

15 16

15

7

16

8

1413

14

5 6

13

PROCESS METER

OUTPUT RELAY 2

NO

OUTPUT RELAY 1

NO


SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA



431 2

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

7 8

COM

COM

5 6

NC

NC

DISCRETE I/O

1 3

2 4

5

6

24 VDC

78 (OPTIONAL)

PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp

1 9 9.0SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



4. Fill the reservoir tank until the water level is 2 inches from the top (approximately 10 gal-lons), as shown in fi gure 20.

CAUTIONIt is important that the reservoir tank contain enough water to keep the

pump completely submerged at all times. The pump can overheat and crack if it does not remain submerged during operation.

Figure 20. Reservoir Tank

5. Perform the following substeps to connect the T5552 to the compressed air supply line.

A. Locate the female connector of the main pneumatic line, as shown in fi gure 21.

Figure 21. Female Connector of Main Pneumatic Line

WATERLEVEL



B. Push the female connector onto the male connector of the T5552, as shown in fi gure 22, to connect the T5552 to the air supply.

Listen for a “click” that indicates the main line is locked in place. The T5552 is now con-nected to the compressed air supply.

NOTEIt is not necessary to pull back the collar on the female connector when

attaching it to the male connector.

Figure 22. Female Connector Attached to Male Connector


4-20mA

OPEN COLLECTOR

DISCRETE

24 VDC

AUX. POWER

FLOW TRANSMITTER

OUTPUTS

ANALOG


DC POWER SUPPLY

24VDC

SV3

CR3


12

12

43

9 10

9 10

1 2

11

11

GND

24VDC24VDC

15 16

15

7

16

8

1413

14

5 6

13

PROCESS METER

OUTPUT RELAY 2

NO

OUTPUT RELAY 1

NO


SS1

PL1FV1

4-20mA

FLOWPVALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARMPHORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA



431 2

SS4

PL4

SS3

PL3

SS2

PL2

CIRC.PPUMPP1

7 8

COM

COM

5 6

NC

NC

CONNECTEDTO MALE

CONNECTOR

MAINAIR SUPPLY

LINE

1 9 9.0SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



6. Perform the following substeps to connect the power cord to the T5552 system.

A. Locate the power supply connection on the right side panel of the T5552, similar to fi gure 23.

Figure 23. Power Supply Connection

NOTEThe appearance of the panel will differ based on the electrical power

supplied at your location.

POWERSUPPLY

CONNECTION



B. Attach the female end of the power cord to the male connector on the T5552, as shown in fi gure 24.

Figure 24. T5552 Connected to Electrical Outlet

C. Plug the opposite end of the power cord into an electrical outlet, similar to fi gure 24.

NOTEThe appearance of the electrical outlet will differ based on the electrical

power supplied at your location.

ANALOG I/O DISCRETE I/O

CONTROLPOWER

ALARM

ON

OFF

RECEPTACLE

GFI

120 VACSUPPLY

OUTLET

POWERCORD

FEMALEEND


SECTION 3

T5552 System Operation/Testing Procedures

OVERVIEWIn this section, you will perform the steps to test the components of the

T5552 to make sure they are working properly.

PART 3.1 POWER SUPPLY, SELECTOR SWITCH, AND INDICATOR LIGHT TEST

In this section, you will connect a circuit to test the operation of the 24 VDC power supply se-lector switches (SS1, SS2, SS3, SS4) and indicator lights (PL1, PL2, PL3, PL4).

1. Make sure the main circuit breaker is in the OFF (down) position, as shown in fi gure 25.

Figure 25. Main Circuit Breaker in OFF Position


SECTION 3 T5552 System Operation/Testing Procedures

2. Locate the connection leads and connect the circuit shown in fi gure 26.

Figure 26. Test Circuit for the Power Supply, Selector Switches, and Indicator Lights

3. Make sure each of the selector switches (SS1, SS2, SS3, and SS4) is in the OFF (up) position.

4. Turn on the main circuit breaker.

5. Turn selector switch SS1 to the ON (right) position.

Indicator light PL1 should turn on.

6. Turn SS1 to the OFF (up) position.

PL1 should now be off.













13. Turn off the main circuit breaker.

14. Disconnect all leads.

If the circuit does not operate as described, contact Amatrol for assistance.

DC POWER SUPPLY

24VDC

GND

24VDC24VDC

SS1

PL1

ALARM HORNAH1

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O

SS1

PL1

SS2

PL2 PL3 PL4

SS3 SS4



PART 3.2 CONTROL RELAYS CR1, CR2, AND CR3 TEST

In this section, you will connect a circuit to test the control relays (CR1, CR2, CR3).

1. Make sure the main circuit breaker is in the OFF (down) position.


This circuit will test the coil of CR1 as well as the normally open and normally closed con-tacts.

Figure 27. Test Circuit for Control Relay CR1

3. Make sure each of the selector switches (SS1, SS2, SS3, and SS4) is in the OFF (up) position


Indicator light PL1 should be on and indicator light PL2 should be off.


Indicator PL1 should turn off and indicator PL2 should turn on.

6. Turn selector switch SS1 to the OFF (up) position.


DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O

CR1CR2

CR3



8. Move the control relay connections from CR1 to CR2, leaving the other connections in place, as shown in fi gure 28.


Figure 28. Test Circuit for Control Relay CR2







DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



13. Move the control relay connections from CR2 to CR3, leaving the other connections in place, as shown in fi gure 29.


Figure 29. Test Circuit for Control Relays CR3








If any of the circuits do not operate as described, contact Amatrol for assistance.

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



PART 3.3 CIRCULATION PUMP AND SOLENOID VALVE TEST

In this section, you will connect a circuit to test the circulation pump and the solenoid valves.



This connects the circulation pump to SS1 and solenoid valve SV1 to SS2.

Figure 30. Pump Test Circuit

3. Make sure each of the selector switches (SS1, SS2, SS3, SS4) is in the OFF (up) position.


SV1SV2

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O

SV3



5. Locate the drain hand valves HV3 and HV4 beneath the process tank, as shown in fi gure 31.

Figure 31. Two Drain Hand Valves for the Process Tank

6. Turn HV3 and HV4 to the fully closed (clockwise) position.

7. Locate the manual fl ow control valve HFV2, as shown in fi gure 32.

Figure 32. Manual Flow Control Valve

HV3 HV4



8. Open HFV2 (fully counterclockwise).

9. Locate hand valves HV1 and HV2, as shown in fi gure 33.

10. Close hand valve HV1 and open hand valve HV2, as shown in fi gure 33.

Figure 33. Hand Valves HV1 and HV2

11. Turn on selector switch SS1 to start the pump.

There should be no water fl ow.

HV2

HV1



12. Turn on selector switch SS2 to energize the solenoid.

The water should now start fl owing at a rate between 1.2 and 1.4 GPM on the rotameter, as fi gure 34 shows.

NOTEIf you hear the pump running but no water is fl owing, reach into the reser-

voir tank and turn the pump onto its side. This allows any trapped air in the pump to escape. When water begins to fl ow, return the pump to its upright position.

Figure 34. Rotameter Indicates Flow Rate of 1.3 GPM

FLOW RATE = 1.3 GPM



13. Turn off selector switch SS2 to de-energize the solenoid.

The fl ow should stop.

14. Close hand valve HV2.

15. Open hand valve HV1.

16. Turn off SS1 to stop the pump


18. Move the connections from solenoid valve SV1 to solenoid valve SV2, leaving the remain-der of the circuit in place, as shown in fi gure 35.

Figure 35. Test Circuit for Solenoid Valve SV2



21. Allow the water level to reach approximately 4 inches.

You can determine the level of water in the process tank by viewing the scale on the front of the tank.

22. Turn off selector switch SS1 to stop the pump.

23. Turn on selector switch SS2 to energize the solenoid of SV2.

The tank should start to drain.

24. Turn off selector switch SS2 to close SV2 once the level reaches 3 inches.

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



25. Move the connections from solenoid valve SV2 to solenoid valve SV3, leaving the remain-der of the circuit in place, as shown in fi gure 36.

Figure 36. Test Circuit for Solenoid Valve SV3


27. Allow the water level to reach approximately 4 inches.


29. Turn on selector switch SS2 to energize the solenoid of SV3.

The tank should start to drain.

30. Turn off selector switch SS2 to close SV3 once the level reaches 3 inches.

31. Open hand valves HV3 and HV4 to drain the process tank.

32. Close hand valves HV3 and HV4 when the process tank is empty.



If any of the circuits do not operate as described, contact Amatrol for assistance.

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



PART 3.4 LEVEL (FLOAT) SWITCH AND ALARM HORN TEST

In this section, you will connect a circuit to test the level switches and the alarm horn.



Figure 37. Level (Float) Switch and Alarm Horn Test Circuit for LS1



5. Open hand valves HV3 and HV4 to drain the process tank if necessary.

6. Close hand valves HV3 and HV4 when the process tank is completely drained.

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/OLS1

LS2



7. Locate the two level (fl oat) switches in the process tank, as shown in fi gure 38.

Figure 38. Level (Float) Switches LS1 and LS2

The level switches are height adjustable by loosening the locking screws, as shown in fi gure 39.

Figure 39. Locking Screw on the Level Switches

LS1 LS2

LS1LS2

LOCKINGSCREW

LOCKINGSCREW



8. Loosen the locking screw and adjust the height of level switch LS1 to approximately the 3-inch mark on the tank.

You can pull up or down on the shaft, as fi gure 40 shows, to adjust the height of LS1.

Figure 40. Height Adjustment of Level Switch

9. Turn on selector switch SS2 to enable the alarm.

The alarm should not sound because the water level is too low. The alarm should not sound until the water actuates LS1.


When the level of the water reaches the trip level of the fl oat switch LS1, the alarm should sound.

11. Turn off selector switch SS2 to silence the alarm.


13. Open hand valves HV3 and HV4 to drain the process tank.

14. Close hand valves HV3 and HV4 when the process tank is completely drained.




16. Move the connection leads from LS1 to LS2, as shown in fi gure 41 to test the second level switch.

Figure 41. Level (Float) Switch and Alarm Horn Test Circuit for LS2

17. Repeat steps 8-15. However, use LS2 instead of LS1.


If either of the circuits does not operate as described, contact Amatrol for assistance.

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



PART 3.5 LEVEL TESTIn this section, you will connect a circuit to test the level in the process tank using the level

transmitter LT1 and the Honeywell UDI 1700 Process Meter. To complete this test, you will need to program the Honeywell Process meter.

3.5.1 Honeywell UDI 1700 Process Meter Setup 1. Make sure the main circuit breaker is in the OFF (down) position.


Figure 42. Level Test Circuit



1 9 9.0

PROCESS METER

OUTPUT RELAY 2

NO

OUTPUT RELAY 1

NOCURRENT INPUT

mA

COM

COM

NC

NC

VOLTAGE INPUTmV/V

SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5


DC POWER SUPPLY

24VDC

SV3

CR3


12

12

43

9 10

9 10

1 2

11

11

GND

24VDC24VDC

15 16

15

7

16

8

1413

14

5 6

13


SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

431 2

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

7 85 6

DISCRETE I/O



5. Press and hold the SETUP key and then press the up arrow key.

This places the meter in the Select Mode. The letters “SLCt” should appear on the display briefl y, indicating that the meter is now in the Select Mode. Then, the last selected menu will appear on the display.

From the Select Mode, you can select from the four available menus, as listed in the table in fi gure 43. Two of the menus, Set Up and Confi guration, require codes to unlock them. The unlock codes are also listed in the table.

SELECTION MODE MENUS

MENU DISPLAY DESCRIPTION UNLOCK CODE

Operator Optr Normal operation - Allows user to view process variable or other data

None

Set Up SetP Allows user to customize settings for specifi c application. Includes adding an offset for the PV, adding a fi lter for the input, and setting scaling breakpoints.

10

Confi guration ConF Allows user to confi gure the meter settings including in-puts, alarms, and outputs.

20

Product Infor-mation

InFo Displays product information for meter including options, fi rmware information, manufacture date, and serial num-ber.

None

Figure 43. Selection Mode Menus

6. Use the up and down arrow keys to scroll through the menus until the Confi guration Menu (ConF) appears on the display.

“ConF” should now appear on the display.

7. Press the SETUP key to open the Confi guration Menu.

Since the Confi guration Menu is locked, “ULoc” appears on the display briefl y, followed by 0. The unlock code must be entered before you can continue.

8. Use the up and down arrow keys to change the displayed value to 20, which is the unlock code for the Confi guration Menu.



9. When 20 is displayed, press the SETUP key to enter the unlock code.

The Confi guration Menu should now be unlocked and the fi rst parameter in the menu should be displayed. The fi rst parameter is the input (inPt) parameter. The display should briefl y show “inPt”, followed by the current setting for the input parameter, similar to fi gure 44.

You should also notice that the SET indicator, shown in fi gure 44, is fl ashing to indicate that the meter is in the Confi guration Menu. It continues to fl ash until the Confi guration Menu is closed. When the Set Up Menu is opened, the SET indicator remains on con-stantly until the menu is closed.

Figure 44. Example of Current Input Parameter Value

The output from the level sensor (LT1) is a current with a 4-20mA range.

10. If 4-20mA is not currently displayed, as shown in fi gure 44, use the up and down ar-row keys to scroll through the input selections until it appears on the display.

NOTEThe longer you hold a key, either up or down, the faster the value scrolls.

SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



11. When the correct input is displayed, press the SETUP key.

This causes the Yes prompt to appear on the display, as shown in fi gure 45. This prompt appears any time you change a value in the Confi guration Menu.

Figure 45. Yes Prompt

12. Press the up arrow key to accept the new value for the input parameter.

NOTEIf you do not press the up arrow key in response to a Yes prompt, the

value of the selected parameter reverts to the previous setting.

With the correct input selected, the next step is to set the scale range limits for the process variable.

NOTEIn order to scroll through the parameters using the SETUP key, the name of

a parameter (i.e. inPt) must appear on the display. If a value is displayed (i.e. 4_20), pressing the SETUP key displays the parameter name. The parameter name will appear for about one second before returning to the value. You can only scroll with the SETUP key when a parameter name is displayed.

The scale range limit parameters are also located in the Confi guration Menu.

SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



13. Using the SETUP key, scroll to the Scale Range Upper Limit (ruL) parameter. When “ruL” appears on the display, stop scrolling.

After a second, the current value of the parameter should appear.

14. Use the up and down arrow keys to change the value to 27.7.

The measurement range for the level sensor is 0 to 27.7 inches.

15. When the correct value is displayed, press the SETUP key.

The Yes prompt again appears on the display.

16. Press the up arrow key to accept the new value for the parameter.

17. Using the SETUP key, scroll to the Scale Range Lower Limit (rLL) parameter. When “rLL” appears on the display, stop scrolling.


18. Use the up and down arrow keys to change the value to 0.0.




21 Using the SETUP key, scroll to the to the Decimal Point Position (dPoS) parameter. When “dPoS” appears on the display, stop scrolling.


22. Use the up and down arrow keys to change the value to 1, if necessary.

A setting of 1 for this parameter indicates that there is one position after the decimal point (XXX.X). Other settings for this parameter are 0 (XXXX), 2 (XX.XX), and 3 (X.XXX).




Next, you need to set the Alarm Parameters.

The alarm parameters are also located in the Confi guration Menu.

25. Using the SETUP key, scroll to the Alarm 1 Type parameter (ALA1).

26. Use the up and down arrow keys to set the parameter to P_Lo.

This sets Alarm 1 as a Process Low Alarm.

27. Press the SETUP key to bring up the Yes prompt.

28. Press the up arrow key to accept the setting.

29. Using the SETUP key, scroll to the next parameter (PLA1).

This is the Process Low Alarm 1 parameter.

30. Use the up and down arrow keys to set the value to 2.0.

This sets the low alarm value as 2.0 inches.

31. Press the SETUP key to bring up the Yes prompt and then press the up arrow key to accept the setting.

32. Using the SETUP key, scroll to the next parameter (AHY1).

This is the Hysteresis setting for alarm 1.


This sets the hysteresis to 0.1 inch.




35. Using the SETUP key, scroll to the Alarm 2 Type parameter (ALA2).

36. Use the up and down arrow keys to set the parameter to P_H1.

This sets Alarm 2 as a Process High Alarm.

37. Press the SETUP key to bring up the Yes prompt.

38. Press the up arrow key to accept the setting.

Using the SETUP key, scroll to the next parameter (PhA2).

This is the Process High Alarm 2 parameter.



41. Using the SETUP key, scroll to the next parameter (AHY2).

This is the Hysteresis setting for Alarm 2.


This set the hysteresis to 0.1 inch.

43. Press the SETUP key to bring up the Yes prompt and then press the arrow key to accept the setting.

The Output Usage parameters must be set for the alarms to turn on the indicator lights (PL3 and PL4).

These parameters are also located in the Confi guration Menu.

44. Using the SETUP key, scroll to the Output 1 Usage parameter (USE 1).

This parameter sets the relay action for alarm 1.

45. Use the up and down arrow keys to set the parameter to A1nd.

This sets Alarm Relay 1 as direct acting, non-latching. That means that when the process variable value is below the low alarm value (2.0), the NO contact of Alarm Relay 1 is closed and the NC contact is open. Since non-latching is also selected, the contacts will return to their normal states when the process variable exceeds 2.0.


47. Repeat steps 44-46 to set the Output Usage 2 parameter (USE 2) to A2nd.

That completes the parameter settings in the Confi guration Menu. You can now exit the Confi guration Menu and Select Mode.

48. Press and hold the SETUP key and then press the up arrow key.

This exits the Confi guration Menu and returns to the Select Mode.

49. Use the up and down arrow keys to scroll until “OPtr” appears on the display.



50. Press the SETUP key to exit the Select Mode and return the meter to the normal operating mode.

“Proc” should appear briefl y on the display followed by the process variable value. You should notice that the value shows a level of approximately 1.6 inches, even though the actual level is zero. This offset is caused by the location of the level sensor (below the process tank). In order to compensate for the offset, the Process Variable Offset (OFFS) parameter in the Setup Menu must be changed.

The offset value is used to make the process variable value read 0.0 when the level is at the zero inch mark on the tank.

51. Press and hold the SETUP key and then press the up arrow key to enter the Select Mode.

52. Use the up and down arrow keys to scroll to the Set Up Menu (SEtP).

The Set Up Menu is locked and requires the unlock code.

53. Use the up and down arrow keys to set the value to 10 and press the SETUP key to enter the unlock code.

The fi rst parameter in the Set Up Menu is the Input Filter Time Constant (FILt) parameter.

54. Using the SETUP key, scroll to the Process Variable Offset (OFFS) parameter.

55. Use the up and down keys to change the value to -1.6.

The sensing element for the level sensor is located approximately 1.6 inches below the zero inch mark in the tank. A setting of -1.6 offsets the zero reading so that the meter dis-plays 0.0 when the water is at the zero inch mark on the tank.

56. Press the Setup key to accept the value.

57. Press and hold the Setup key and press the up arrow key to exit the Set Up Menu.

58. Scroll until “OPtr” appears on the display and press the Setup key to exit the Select Mode and return the meter to normal operation.

The process meter is now programmed and should return to the normal operating mode. When the process meter returns to the operating mode, the display should indicate 0.0, as shown in fi gure 46. If it does not indicate 0.0, you may need to go back and adjust the Process Variable Offset parameter (OFFS) value.

Figure 46. Process Meter Display PV Value of 0.0

59. After you have programmed the meter, proceed with Section 3.5.2 to perform the level test.

SETUPSET

UDI1700

ALM1

ALM2

ALM3

ALM4

MAX

MIN

ALM5



3.5.2 Level Test 1. Open hand valves HV3 and HV4 to drain the process tank if there is water in it.

2. Close HV3 and HV4 when the process tank empties.

Indicator light PL3 should turn on, indicating a low level alarm.


The process meter should display the water level in inches.

4. Observe the level reading on the process meter as the tank fi lls and compare it to the level scale on the tank.

When the level reaches 2.0 inches, indicator light PL3 should go out indicating a suffi -ciently high level in the tank. There should be no alarms between 2 and 8 inches (the low and high-level parameters you set on the process meter). At 8 inches, indicator light PL4 should turn on indicating a high level alarm.

5. At 10 inches, turn off selector switch SS1 to stop the pump.

6. Open hand valves HV3 and HV4 to lower the level in the tank until indicator light PL4 turns off. Then, close the hand valves.

You should notice that PL4 does not turn off until the level reaches 7.9 inches. This is due to the hysteresis value of 0.1.

7. Open hand valves HV3 and HV4 to lower the level in the tank until indicator light PL3 turns on. Then, close the valves.

You should notice that PL3 turns on when the level reaches 2.1 inches. Again, this is due to the hysteresis value of 0.1.

8. Open hand valves HV3 and HV4 and allow the tank to empty.

9. Close the hand valves when the tank is empty.



If either the circuit or the Honeywell Process Meter does not operate as described, contact Amatrol for assistance.



PART 3.6 FLOW TESTIn this section, you will connect a circuit to test the fl ow through the T5552 and verify that fl ow

rate measurements on the fl ow transmitter are approximately equal to the reading on the rotame-ter. You will control the fl ow using the manual fl ow control valve, HFV2.



Figure 47. Flow Test Circuit

3. Make sure each of the selector switches is in the OFF (up) position.

4. Open the tank drain hand valves, HV3 and HV4, by rotating each counterclockwise as far as possible.

HV3 and HV4 will remain open throughout this test so that you can observe the fl ow into the tank and later compare it to the fl ow into the tank when the manual fl ow control valve (HFV2) is in different positions.

4-20mA

OPEN COLLECTOR

DISCRETE

24 VDC

AUX. POWER

FLOW TRANSMITTER

OUTPUTS

ANALOG

DC POWER SUPPLY

24VDC

GND

24VDC24VDC

SS1

PL1

ALARM HORN

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMP

DISCRETE I/O



5. Adjust the pneumatic pressure regulator so that the gauge indicates 0 psi.

To adjust the pressure regulator, turn the knob located under the gauge, as fi gure 48 shows. Turning the knob clockwise increases the pressure, while turning counterclockwise decreases the pressure.

Figure 48. The Pressure Regulator Knob

6. Fully open the manual fl ow control valve (HFV2) by rotating it counterclockwise as far as possible.


Water should not fl ow through the system because the pump is not on.

8. Rotate selector switch SS1 to the ON (right) position to activate the pump.

Water should begin fl owing into the tank. Because there are no restrictions on the fl ow, the fl ow rate should be approximately 1.5 gpm, which is the maximum rate.

9. Verify that the reading on the rotameter is approximately equal to the reading on the fl ow transmitter. Also, observe the fl ow of water into the tank.

10. Rotate the manual fl ow control valve clockwise as far as possible to close the valve.

The fl ow rate on the fl ow transmitter and the rotameter should read 0 gpm. You should also visibly notice that water is no longer fl owing into the tank. This is because the manual fl ow control valve is now fully closed.

11. Rotate the manual fl ow control valve counterclockwise until the hand valve is approximate-ly halfway between the fully open and fully closed positions. The fl ow rate on the rotameter and the fl ow transmitter should read approximately 1.0 gpm. You should also notice that although water is fl owing into the tank, there is less fl owing in than when the valve was fully open.

12. Move selector switch SS1 to the OFF (up) position to turn off the pump.

13. Rotate the manual fl ow control valve (HFV2) counterclockwise as far as possible to fully open the valve.




PRESSUREGAUGE

REGULATORCONTROL

KNOB



PART 3.7 PID CONTROLLER TESTIn this section, you will connect a circuit to test the operation of the PID controller. This circuit

will allow you to automatically control the level of water in the process tank using the PID control-ler.



Figure 49. PID Controller Test Circuit

3. Make sure each of the selector switches is in the OFF (up position).

4. If necessary, open the tank drain hand valves (HV3 and HV4) to drain the process tank. When the tank is empty, close the tank drain hand valves HV3 and HV4.

PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



5. Adjust the pneumatic pressure regulator so that the gauge indicates 20 psi, as fi gure 50 shows.

Figure 50. Pneumatic Pressure Regulator Set to 20 PSI

6. Make sure the manual fl ow control valve (HFV2) is fully open (counterclockwise).

GAUGEINDICATES

20 PSI

PRESSUREREGULATOR

KNOB



7. Turn on the main circuit breaker and observe the display of the PID controller.

The PID controller should go through a boot-up series during which the controller performs a series of self-diagnostic tests. Once the tests are completed, the display should indicate that the controller is in the manual mode, as fi gure 51 shows. The manual mode is indi-cated by “MAN” in the upper left portion of the display.

NOTEThe controller will always default to the manual mode when it is powered

up.

Figure 51. PID Controller in the Manual Mode

8. Make sure that the set point (SP) is displayed in the lower portion of the display, as fi gure 51 also shows.

If the set point value is not displayed, repeatedly press the Lower Display key on the key-pad of the PID controller until SP appears.

9. Use the or key on the keypad of the PID controller to change the SP value to 5.00 inches.

NOTEThe longer you press and hold the or key, the faster the value will

change. After a few seconds, the cursor will move to the next signifi cant digit (next digit to the left) as you continue to hold the or key.

-SP

1234

1234

1234

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

ALM

DI

OUT

MAN FC

PV

SP

CONTROLLER INMANUAL MODE



10. Perform the following substeps to set the control parameters for the PID controller.

A. Press the Setup key repeatedly to scroll through the different parameter groups until TUNING appears.

B. Press the Func Loop1/2 key repeatedly to scroll through the tuning settings until the GAIN value is displayed.

C. Use the or key on the keypad of the PID controller to change the gain to 30.

D. Press the Func Loop1/2 key again to scroll to the next setting, RATE MIN.

E. Use the or buttons on the keypad of the PID controller to change this setting to 0.

F. Press the Func Loop1/2 key again to scroll to the next setting, RSET MIN.

G. Use the or buttons on the keypad of the PID controller to change this setting to 0.25.

The setting of 0.25 represents a time of 15 seconds (1/4 minute).

H. Press the Lower Display key on the keypad of the PID controller until SP again ap-pears.

11. Program the following input parameters in the Honeywell controller. Recall that pressing the Setup key allows you to enter the setup menu and scroll through the function groups. Pressing the Func Loop1/2 key allows you to view the parameters within a group, and pressing the up and down keys adjusts the parameter settings.

PARAMETER GROUP PARAMETER SETTING

INPUT1 IN1 TYPE 1-5 V

XMITTER1 LINEAR

IN1 HI 27.76

IN1 LO 0.0

BIAS -1.6

12. When you fi nish entering the parameters for INPUT1, press the Lower Display key until the setpoint (SP) is displayed in the lower display of the controller.

13. Switch the controller to the automatic mode by pressing the Man/Auto button on the key-pad of the controller.

This will allow the controller to automatically sense and control the level of water in the process tank.



14. Place selector switch SS1 in the ON (right) position to start the pump.

You should notice that water begins to fl ow into the process tank. You should also notice that the current water level (process variable or PV) is displayed above the SP value on the display of the controller, similar to fi gure 52. The PV value should continue to increase as the level in the tank increases.

NOTEThe water level (PV) is provided to the controller by a sensor located in the

bottom of the process tank.

Figure 52. PV and SP Displayed

You should notice that the PV value actually surpasses the SP value. This is referred to as overshoot. It is not a concern at this point.

At some point, the PID controller will cause the fl ow into the tank to stop.

15. Place selector switch SS2 in the ON (right) position.

This opens solenoid valve SV3 and causes the water in the process tank to begin to drain into the reservoir. When the level in the tank falls below the set point (5.00), the PID con-troller will react by allowing water to resume fl owing into the process tank.

The controller will adjust the fl ow of water into the tank until the level in the tank is main-tained at 5.00 inches (the fl ow in equals the fl ow out). You may notice that the PV value oscillates above and below the SP value several times before fi nally settling at the set point. This is normal when the controller is not fully tuned (i.e. programmed) for a process.

16. Place selector switch SS2 in the OFF (up) position.

This will close solenoid valve SV3.

1234

1234

1234

SP VALUE

ALM

DI

OUT

A F

PV

SP

PV VALUE



17. Place selector switch SS1 in the OFF (up) position.

This will shut off the circulation pump, which will stop the fl ow of water into the process tank.

18. Switch the controller to the manual mode by pressing the Man/Auto key on the keypad of the controller.

19. Open the tank drain hand valves (HV3 and HV4) to drain the process tank.

When the process tank is drained, close the tank drain hand valves (HV3 and HV4).






PART 3.8 OPTIONAL ULTRASONIC LEVEL SENSOR TEST

In this section, you will connect a circuit to test the operation of the ultrasonic level sensor. This circuit will allow you to measure the level in the process tank using the ultrasonic level sensor and display the level measurement on the PID controller. If your trainer does not have the optional ultrasonic level sensor, skip this test.



Figure 53. Ultrasonic Level Sensor Test Circuit


4. If necessary, open the tank drain hand valves (HV3 and HV4) to drain the process tank. When the tank is empty, close the tank drain hand valves.

PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O




You should notice that the red LED indicator on the top of the ultrasonic sensor and shown in fi gure 54 turns on. You may also notice a low hum from the ultrasonic level sensor. This is normal.

Figure 54. LED Indicator on the Ultrasonic Level Sensor

6. Program the Honeywell PID controller to the values listed in the following table. Leave any parameters not listed in their default settings.

Recall that pressing the Setup key allows you to enter the setup menu and scroll through the function groups. Pressing the Func Loop1/2 key allows you to view the parameters within a group, and pressing the up and down keys adjusts the parameter settings.



XMITTER1 LINEAR

IN1 HI 27.76

IN1 LO 0.0

BIAS -1.6

7. When the parameters are programmed, press the Lower Display key.

8. If necessary, press the Man/Auto key to place the controller in manual mode. You should notice “MAN” in the upper left portion of the controller display.

SIGNALWIRE

RED LEDINDICATOR

ZERO/SPANADJUSTMENTS




You should notice that water begins to fl ow into the tank. You should also notice that as the tank fi lls, the level indicated on the controller display (PV) begins to increase. The reading on the controller may not exactly match the sight scale on the front of the process tank because the sensor may not be calibrated. However, as the level in the tank rises, the (PV) reading on the controller display increases. This indicates that the sensor output increases as the level increases.


11. Open the right-side process tank drain valve (HV4) approximately halfway. You should no-tice that the level in the tank and the reading on the controller display begin to decrease. This indicates that the ultrasonic sensor output decreases as the level decreases.

12. Fully open (counterclockwise) both process tank drain hand valves to empty the process tank. When the tank is empty, close the valves.


14. Disconnect all the leads.




PART 3.9 OPTIONAL SMART FLOW DIFFERENTIAL PRESSURE TRANSMITTER TEST

In this section, you will connect a circuit to test the smart fl ow differential pressure transmitter. This circuit will allow you to measure the differential pressure across the restriction in a differen-tial pressure fl ow sensor using the smart fl ow differential pressure transmitter. It also allows the Honeywell controller to display the volumetric fl ow rate. If your trainer does not have the optional smart fl ow differential pressure transmitter, skip this test.



Figure 55. Smart Flow Differential Pressure Test Circuit



PID CONTROLLER

INPUTSANALOG

AL1

DISCRETE

DL1

DL2

OUTPUTSANALOG

AO1

AL2

ALARMAL1

AL2

SPSelect

RunHold

ManAuto

Setup

LowerDisplay

Func.Loop 1/2

FC

PV

SP

1234

1234

1234

ALM

DI

OUT

MAN

00.0-sp

DC POWER SUPPLY

24VDC

SV3

CR3


GND

24VDC24VDC

SS1

PL1FV1

4-20mA

FLOW VALVE

FT2

4-20mA

FT1

FLOW SENSORS

TEST4-20mA

ALARM HORNAH1

4-20mA

LS2

LT2

LS1

LT1

LEVEL SENSORS

24VDC

CONTROL RELAYS

CR2

CR1

4-20mA

SS4

PL4

SS3

PL3

SS2

PL2

CIRC. PUMPP1

DISCRETE I/O



5. Perform the following substeps to install one of the differential pressure fl ow sensors (ori-fi ce plate, venturi tube, or pitot tube).

A. Identify the stand-offs and unions on the T5552, as shown in fi gure 56.

Figure 56. Unions and Stand-Offs

B. If the paddlewheel fl ow sensor is installed, loosen the unions on both sides of the sen-sor by rotating the top of the union towards you.

STAND-OFF 1

UNION

STAND-OFF 2

STAND-OFF 3

UNION



C. Disconnect the paddlewheel fl ow sensor from the T5552 by rotating the locking collar on the electrical connector counterclockwise, as fi gure 57 shows.

Figure 57. Paddlewheel Electrical Connector

TURN CCW

LOCKINGCOLLAR



D. Remove the paddlewheel fl ow sensor from the process line.

To remove the sensor, it may be necessary to pull back the process piping, as shown in fi gure 58. If the process piping does not move, loosen the cap assembly screws on the standoff, as fi gure 60 also shows, by turning them counterclockwise. This requires a 5/32 Allen wrench.

Figure 58. Flow Sensor Removal

E. Orient the differential pressure fl ow sensor in the direction of fl ow (right to left).

The orifi ce plate should indicate the fl ow inlet on the tab between the two fl anges. The venturi tube and pitot tube should both have an arrow indicating the direction of fl ow.

F. Tighten the unions to install the differential pressure fl ow sensor. If necessary, tighten the cap screws to secure the process piping.

G. Connect the tube leading from the high-pressure side of the smart fl ow transmitter (indicated by an ‘H’ on the transmitter) to the pressure tap on the high-pressure (inlet) side of the differential pressure fl ow sensor. On the orifi ce plate and pitot tube, the high-pressure tap is on the right side. The venturi tube has an ‘H’ and ‘L’ marked next to the high and low-pressure taps.

H. Connect the tube leading from the low-pressure side of the smart fl ow transmitter (indicated by an ‘L’ on the transmitter) to the pressure tap on the low-pressure (outlet) side of the differential pressure fl ow sensor. On the orifi ce plate and pitot tube, the low-pressure tap is on the left (downstream) side. The venturi tube has an ‘H’ and ‘L’ marked next to the high and low-pressure taps.


PULLBACK

CAPASSEMBLYSCREWS



7. Perform the following substeps to bleed the manifold on the smart fl ow differential pres-sure transmitter.

A. Identify the equalizer valve, the high and low-pressure shut-off valves, and the left and right bleed valves on the differential pressure manifold, as shown in fi gure 59.

Figure 59. Equalizer, Shut-off, and Bleed Valves on the Differential Pressure Mani-fold

B. Fully open (counterclockwise) the equalizer valve.

C. Fully close (clockwise) the high and low-pressure shut-off valves. It does not matter which one is closed fi rst.

D. Turn on selector switch SS1 to start fl ow through the system.

E. Fully open the high and low-pressure shut-off valves. It does not matter which one is opened fi rst.

F. Fully open (counterclockwise) the right bleed valve to release air from the tubing and manifold. When there are no air bubbles in the tubing, close (clockwise) the valve. Wa-ter may drip from the bleed valve during this step. This is normal.

G. Fully open (counterclockwise) the left bleed valve to release air from the tubing and manifold. When there are no air bubbles in the tubing, close (clockwise) the valve. Wa-ter may drip from the bleed valve during this step. This is normal.

H. Fully close (clockwise) the equalizer valve.

I. Turn off selector switch SS1 to stop fl ow through the system.

HIGH PRESSURETAP

LOW PRESSURETAP

BLEEDVALVE

LOWPRESSURESHUTOFF

VALVE

BLEEDVALVE

HIGH PRESSURESHUTOFF VALVE

EQUALIZERVALVE

MANIFOLD

L H



8. Perform the following substeps to calibrate the differential pressure fl ow sensor.

NOTEThe smart fl ow transmitter on the T5552 is set up to accept a maximum

differential pressure of 25 in H2O. Therefore, the fl ow rate must be suffi ciently low to prevent exceeding this pressure when calibrating the transmitter zero and span.

A. Locate the zero and span buttons on top of the smart fl ow differential pressure trans-mitter, as shown in fi gure 60. You may not be able to see them because of the position of the transmitter, but you can feel for them.

B. If the cover plate is covering the buttons use a small screwdriver to loosen one of the cover plate screws and rotate the plate to uncover the buttons.

Figure 60. Zero and Span Buttons

C. Using a small right angle Allen wrench, press and hold the zero button, indicated by a ‘Z’ on the transmitter. After approximately 3 seconds, the display should read “ZERO PASS”. This indicates that the transmitter accepts the low fl ow rate value (0 gm).

D. Turn on selector switch SS1 to start fl ow through the system.

E. Adjust the manual fl ow control valve until the fl ow rate indicated on the rotameter is 1.1 gpm.

F. Using a small right angle Allen wrench, press and hold the span button, indicated by an ‘S’ on the transmitter. After approximately 3 seconds, the display should read “SPAN PASS”. This indicates that the transmitter accepts the high fl ow rate value (1.1 gpm).

G. Turn off selector switch SS1 to stop fl ow through the system.

Z

S

REAR

ZEROADJUSTMENT

BUTTON

SPANADJUSTMENT

BUTTON

COVERPLATE

COVERPLATE

SCREWS



9. Program the Honeywell PID controller to the values listed in the following table. Leave any parameters not listed in their default settings.

Recall that pressing the Setup key allows you to enter the setup menu and scroll through the function groups. Pressing the Func Loop1/2 key allows you to view the parameters within a group, and pressing the and keys adjusts the parameter settings.



XMITTER1 LINEAR

IN1 HI 27.76

IN1 LO 0.0

BIAS -1.6

10. Press the Lower Display key.

11. Press the Man/Auto key to place the controller in manual mode. You should notice “MAN” in the upper left portion of the controller display.

12. Turn on selector switch SS1 to start fl ow through the system.

13. Adjust the manual fl ow control valve to different fl ow rates between 0 and 1.1 gpm (the transmitter display will indicate an over range error outside these limits). You should fi nd that the transmitter display alternates between the differential pressure (in inches of H2O) and the percentage of the full range that is fl owing through the system. You should also notice that the controller display indicates the fl ow rate through the system (PV). It should closely agree with the fl ow rate indicated on the rotameter.

14. Turn off selector switch SS1 to stop fl ow through the system.






APPENDIX

Installer Checklists

This appendix includes the following Installer Checklists:T5552-XDE Process Control Learning SystemT5552-C1-A PID Controller ModuleT5552-F1 Smart Flow TransmitterT5552-F1A Pitot Tube Flow TransducerT5552-F1B Venturi Flow TransducerT5552-F1C Orifi ce Plate Flow TransducerT5552-L1 Ultrasonic Liquid Level Module


APPENDIX Installer Checklists



SHIPPING CHECKLIST

3/16/07AMATROL

PLEASE REPORT ANY MISSING ITEMS/DAMAGED COMPONENTS WITHIN 10 DAYS.

SAVE DAMAGED CARTONS IF COMPONENTS ARE DAMAGED.

AMATROL WILL NOT BE RESPONSIBLE AFTER THIS PERIOD.

CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-C1-A PID CONTROLLER MODULE

Office Item Check Part Use Number Off Qty. Number Description 1. _____ 1 A010618-12-22 PID CONTROLLER PANEL ASSEMBLY

2. _____ 3 PATCH CORDS, 24", RED

3. _____ 3 PATCH CORDS, 24", BLACK

4. _____ 1 HONEYWELL UDC CONT. MANUALS (CD-ROM)

PREPARED BY ___________________________ DATE __________



SHIPPING CHECKLIST

11/12/07AMATROL




CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-F1 SMART FLOW TRANSMITTER

Office Item Check Part Use Number Off Qty. Number Description 1. _____ 1 T5552-F1 DP FLOW TRANSMITTER ASSEMBLY INCLUDING: _____ 2 - 3/8-16 MOUNTING BOLTS, 2-1/4" LG. _____ 2 - 3/8" FLAT WASHERS _____ 2 - 3/8" LOCK WASHERS 2. _____ 1 33256-XD STUDENT LEARNING ACTIVITY PACKET 3. _____ 1 ROSEMOUNT 3051CD PRESSURE TRANSMITTER INSTRUCTION GUIDE NO. 00825-0100-4001

PREPARED BY ___________________________ DATE __________



SHIPPING CHECKLIST

3/12/02AMATROL




CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-F1A PITOT TUBE FLOW TRANSDUCER

Office Item Check Part Use Number Off Qty. Number Description 1 _____ 1 T5552-F1A PITOT TUBE FLOW ASSEMBLY 2 _____ 1 SPARE O-RING, BUNA, 13/16" ID, 1-1/16" OD

PREPARED BY ___________________________ DATE __________



SHIPPING CHECKLIST

3/22/04AMATROL




CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-F1B VENTURI FLOW TRANSDUCER

Office Item Check Part Use Number Off Qty. Number Description 1. _____ 1 T5552-F1B VENTURI FLOW ASSEMBLY 2. _____ 1 SPARE O-RING, BUNA, 13/16" ID, 1-1/16" OD 3. _____ 1 PRESO VENTURI INSTRUCTION MANUAL - FORM #4-20-23 REV. 1 w/ FLOW CHART

PREPARED BY ___________________________ DATE __________



SHIPPING CHECKLIST

11/17/09

CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-F1C ORIFICE PLATE FLOW TRANSDUCER

Office Item Check Part Use Number Off Qty. Number Description 1. _____ 1 T5552-F1C ORIFICE PLATE FLOW ASSEMBLY INCLUDING: _____ 1 - ORIFICE PLATE w/ 0.250" ORIFICE _____ 2 - ORIFICE PLATE GASKETS 2. _____ 1 SPARE O-RING, BUNA, 13/16" ID, 1-1/16" OD

PREPARED BY ___________________________ DATE __________

AMATROL






SHIPPING CHECKLIST

11/27/07AMATROL




CUSTOMER _________________________

CUSTOMER P.O. _____________________

ASO _______________________________

SERIAL NUMBER_____________________

T5552-L1 ULTRASONIC LIQUID LEVEL MODULE

Office Item Check Part Use Number Off Qty. Number Description 1. _____ 1 T5552-L1 ULTRASONIC LEVEL SENSOR ASSEMBLY INCLUDING: _____ 1 - ULTRASONIC SENSOR _____ 1 - SENSOR MOUNT _____ 2 - #10-32 x 1/2" LG SOCKET HEAD CAP SCREW _____ 2 - #10 FLAT WASHER _____ 2 - #10-32 TEE NUT 2. _____ 1 Operating Manual ULTRASONIC SENSOR 3. _____ 1 33255-XD STUDENT LEARNING ACTIVITY PACKET

PREPARED BY ___________________________ DATE __________

DB270-XD00XEN-E1 Guia de Instalacion

Documents

Transcript of DB270-XD00XEN-E1 Guia de Instalacion