Installation Guide For T5555-Aau Presure Proccess Control Learning System

INSTALLATION GUIDE FOR , [ T5555-AAU | PRESSURE PROCESS CONTROL LEARNING SYSTEM AMATROL ; D33308-AAQ0UEN! INTRODUCTION The purpose of this installation manual is to provide you with the steps necessary to set up and test the T5555-AAU Pressure Process Control Learning System. This setup process is outlined in the following sections of this manual: 1. Parts Inventory/Identification 2. Hardware Setup 3. Operation and Testing Procedures FIRST EDITION, REV.A. ‘Amatrol, AMNNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Teshnovate are trademarks or registered trademarks of ‘Anatol, fn. All ther brand and product names are trademarks or registered trademarks oftheir respective companies. Copyright © 2014 by AMATROL, INC. ‘All rights Reserved, No part ofthis publication may bs reproduced, translate, or transite i ey form or by any means, ele tronic, optical, mechanical, or magnetic, including but not limited to photographing photocopying, recording or any information storage and reroval system, without writen permission ofthe copyright vet, Amatrol, Ino, 2400 Centennial Blvd, Jeffersonville, IN 47130 USA, Ph 812-288-8285, PAX 812-283-1584 www amatroLcon, '033908-AAOQUEN TS85S-AAU Pressure Process Contol Leasning System Instllaton Gulde: Copyrigne © 2014 Amati nc. 2f TABLE OF CONTENTS SECTION 1 PARTS INVENTORY/IDENTIFICATION.. SECTION2 HARDWARE SETUP... SECTION3 OPERATION AND TESTING PROCEDURES... APPENDIX A INSTALLER CHECKLISTS APPENDIXB ADDITIONAL PROCEDURE DETAILS 1Dé6906-AACOUEN TESS6-AAL Pressure Procoss Conte Learing Sytem statin Gute Cepyigit © 2014 Anat.ECTION 1 Parts Inventory / Identification The first step to set up your system is to inventory each component and make sure everything is present. PART1 INVENTORY PROCEDURE OVERVIEW This section has two parts, Part 1 is the inventory procedure to use to check out your equipment. Part 2 includes the pictures and descriptions of each component. 1. Use the purchase order to determine the product(s) that your organization has purchased. 2. Locate, in the appendix of this manual, the Installer Checklists) for the T5555-AAU Pres- sure Process Control Learning System. er NOTE Please report any missing items or damaged components within 10 days. ‘Save damaged cartons if components are damaged. Amatrol will not be esponsible after this period. a 3. Your local Amatrol representative should sign each checklist and send it to Amatrol for verification. (0008 AACOUEN, TESS-AAY Presa Proees Canto! Leaning Sytem nataten Gude Copyright © 2014 Amat, nc. aT RaRRianbinaaneR ANA...SECTION 1. Parts Inventory /Idertieation 4. Inaddition to the package provided by Amatrol, the TS585-AAU Pressure Process Control Learning System requires these user-supplied items: Sie PRL) 115/220 VAC, 50/60 Hz, power outlet Tools Flat-head Screwdriver Philips-head Screwdriver Set of Hex Wrenches Adjustable Wrench Digital Multimeter Ar (Compressed Air Supply Water Municipal Water Supply * ‘Additional Supplies Paper Towels ‘Computer Suggested Minimum Hardware Requirements: «Processor: 2.2 GHz Core 2 Duo (T7800) or comparable lain memory: 2 GB RAM + Hard disk: 250 GB SATA HDD * SVGA Monitor min. 1280x1040 resolution Suggested Minimum Software Requirements: * MS Windows XP Professional SP3, or + MS Windows 7 Professional, Enterprise and Ultimate Printer [Laser Jet, ink Jet, or Dot Matrix 'Da3808-AAOOUEN TSSSS-AAL!Piessure Process Contol Learing Systom Inetaation Guido {Copyight © 2014 Amat, ne 5SECTION.1_Parts inventory /dentication PART 2 DESCRIPTION OF LEARNING SYSTEM COMPONENTS ‘The T5855-AAU Pressure Process Control Leaming System provides an induistrial controller and learning curriculum. The following charts show the major components of this learning system. ‘picture of each component and a more detalled description are provided later In this guide. T5555-AAU PRESSURE PROCESS CONTROL LEARNING SYSTEM resstire Process Control Uni 180214 Drain Caps (2) 25102 ‘AC Power Cord, 18A, Typé SIT. 19538 Safety Lockout Hasps (2) t 19539 Safety Lockout Tags (2) 19540 Padlocks (2) 39922 Lead Set (four 12” red, six 24" red, seven 24” black, two 96" black) (€33308-AAQQUEN Instructors Guide 1D33308-AAQOUEN installation Guide M33908-AAQOUEN Multimedia, T5566 1133808 Student Reference Guide {instrument Manual Set (Centrifugal Pump Operating Instructions, Differential Prossure Gauge Instructions) 33320-XX Paid 33319-XX instrument index 1093208-AAOOUEN TSS55-AAL Prassure Process Control Leeming System installation Guide 6 Copyright © 2014 Amaia, Ine. a i al aaa i ai eens ce C ¢SECTION 1 Parts Inventory /Identitcalion A110504-1 PRESSURE PROCESS CONTROL SYSTEM CHASSIS Thie T8555 Pressure Process Control System is shown in figure 1. ~The T5555 includes the components and controls necessary to control the level and pressure in a process tank. The T5555 uses a programmable logic coniroller (PLC) and human machine interface (HM!) to provide manual and automatic control options. ‘D3q08-AADOUEN TSSSS-AAL Pressure Process Control Learring System Instaaton Guide Copyright © 2014 Amatrol, inc. 7SECTION 1 Parts invntory /identication 180211 DRAIN CAPS : ‘The drain caps are placed on the ends of the drain piping, as shown in figuire 2. The drain caps should already be installed on the trainer. DRAIN CAP Figure 2." Drain Caps installed Dane AADOUEN TSSEE-AAU Prose Process Cntr Leaing Systm ntalaton Gude Copyright ©2014 Amato, In.SECTION 1 Parts Inventory /Ioenttiction 25102 AC POWER CORD, 15A, TYPE SUT The AC power cord, shown in figure 3, allows you to connect the T5555 to an AC outlet. *Figure’3. AC Power Cord LOCKOUT/TAGOUT EQUIPMENT Safety equipment is provided to prevent unsafe electrical or pneumatic power up of the trainer. This includes equipment to lockout the circuit breaker and the pressure regulator. This equipment meets OSHA standards. ‘The lockouvtagout equipment is listed below and is shown in figure 4: Safety Lockout Hasp B, 19539 Safety Lockout Tag 2 c. 19540, Padlocks 2 Figure 4, Lookout/Tagout Equipment 'D98308-AAOOUIEN TSS6S-AAU Pressure Process Control Learring Systom instalation Guid Copyright © 2014 Amato, ne. 9—SEGHION-4—Pars inventory /dontteaton 93322 LEAD SET : ‘The 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 figure 5. B22 12" Red Dual Banana Leads Boda 24” Red Dual Banana Leads 24-0 24” Black Dual Banana Leads B-36-0 36” Black Dual Banana Leads wlwlola s}o|m]> Figure 5. Leads Set for the T5555 INSTRUMENT MANUAL SET Included with the T5556 is a set of manufacturer's instruction manuals for some of the devices on the T5555. ‘The manuals that are included are listed below. A 97-5045-01-588 Centrifugal Pump Operating Instructions 1 1&MO11-10164-GC- 8. 52GC52, Vers, 6.03 | Differential Pressure Gauge Instructions 1 OBtoLeANOOUEN TOSS AAL Prt Process Cnt Leaning Stam irstaaton Ge Copyright © 2014 Amat, ine. 10 Se eee[SECTION 1 Parts Inventory /dentieation M33308-AAOOUEN PRESSURE PROCESS CONTROL LEARNING SYSTEM MODULE PACKAGE. ‘The M33308-AAQQUEN Pressure Process Control Learning System consists of 9 modules as listed below. These modules are contained on the M33308-AAOOUEN multimedia disk. The multimedia disk is shown in figure 6. The Student Reference Guide (SRG) H33308 contains all of the courses’ technical content in printed form. Introduction to Process Control instrument Tags Piping and Instrumentation Diagrams Final Control Elements Pressure Measurement Loop Control Devices Pressure Control Systems Methods of Automatic Control ‘Control Loop Performance elolslolalae|m|+ Figure 6. _M33308-AAOQUEN Multimedia Disk basen AADOUEN T5555 AAU Pressure Proce Conc Leaning Sytem hilton Guo © 2014 Amato, Ino+. SECTION-1~Parts inventory ¢dentiication (33308-AAQQUEN PRESSURE PROCESS CONTROL LEARNING SYSTEM INSTRUCTOR’S GUIDE The Instructor’s Guide is shown in figure 7. This book contains all of the information neces- ‘sary to perform the assessment of the students. It also contains all forms the students will need to ‘complete as they work through the modules. INSTRUCTOR'S GUIDE FOR “TSBS5-AAU PRESSURE PROCESS CONTROL LEARNING SYSTEM Figure 7.. Pressure Process Control Systems Instructor's Guide D33308-AAQOUEN PRESSURE PROCESS CONTROL LEARNING SYSTEM INSTALLATION GUIDE This isthe manual you are now reading. Drsoe AAGOUEN TSSS-AAL Pres roses Cnt Learn Syste Itataton Gide Copyright © 2014 Amato, ne. lec dese inHardware Setup OVERVIEW. 1. In this section, you will set up the T5555-AAU Pressure Process Control Learning Systm. t Identify the components listed in the following table on the P&ID and on the T5556, using figures 8 and 9 as references. Lele) eee) te) ee AUER med) Prossurized Process Tank 1 NA 2 [Human Machine Interface (HMI) NA 3 | Pressure Controller (Programmable Logic Controller, PLC) - Same PC 100 ‘component as LC 200 4 __ [Pressure Regulator PC 100A = 5 _ | Pressure Gauge on Pressure Regulator PL 100A 6 __| Proportional Solenoid Inlet Valve (PV1) PCV.100A 7__| Pressure Gauge P1108 8 __ | Flow indicator, inlet FL100A 9 | Flow indicator, Outlet 11008 10 _| Proportional Solenoid Outlet Valve (PV2) PCV 1008 11__ | Pressure Outlet Bypass Hand Valve HV 100 12_ | Pressure Transmitter PT 100 13 _ | Pressure Reliet Valve, 40 psi PSV 100 14 | Lavel Controller (Programmable Logic Controller, PLC) - Same com- Lc 200 ponent as PC 100 Pump Speed Control, Variable Frequency Drive (VFD) ‘80200 Centritugal Pump NA. Reservoir Tank NA Reservoir Tank Outlet Hand Vaive HV 2008 Reservoir Tank Return Hand Valve HV 200D Rotameter FI200A Flow Control Valve, Manual FV 200 Differential Pressure Transmitter Level Sensor U7 200 [3-Way Hand Valve HV 200E 'D53908-AAOOUEN TSSSS-AAU Pressure Process Control Leaming System Installation Guide Capyright © 2014 Amaia, Inc. 13 seesLevel Switch Low LSL 200 Level Switch High LSH 200) Rotameter F1200B == 27° | External Source Inlet Hand Valve. HV 200A. 28. | External Source Outlet Hand Valve HV 2000 29 [Drain Hand Valve HV 200F 30 | Drain Hand Valve Hv200a | “Ne Ae Figure @. T5566 Piping and instrumentation Diagram (PSD) '033308-AACOUEN TSS55-AAL) Pressure Process Contol Learing System instalation Guide Copyright © 2014 Amato}, Inc. 14 / a ena|. AND 14-PLC (INSIDE CABINET) 2 SECTION2 Hardware Seti UG Figure 9, Major Components of the T5555 Only the major components affecting the process are shown on a flow diagram. For that reason, the connection panels are not shown on the P&ID. List URN HAS i HENGE ES NS STERN PIE ee me nae “wie iS a a (Dosa08-AAOIUEN, TEES5-AAJ Pressure Process Con Leaming System rstaaton Guise \ Copytght © 2014 Amato nc 15 iSECTION 2 Hardware Sewp 2. Identify the panels listed in the following table, using figure 10 as a reference. 1 ‘Alarm Horn/DC Power Supply (24 VDC) Connection Panel 2. | Level Switches (LSL 200, LSH 200), Pressure Sensor (PT1), Level Sensor (LT1), and Proportional Valves (PV1, PV2) Connection Panel 3 __| Variable Frequency Drive (VFD) with Operator Interface ‘4 | VFD-PLC Interface Connection Panel (VED discrete inputs, PLC discrete and analog inputs, VED Start Pushbutton, VFD Stop Pushbutton) '5___ [Human Machine Interface (HM. 1 2 3 ay 5 Figure 10. T5555 Panels 3. Position the T5855 so that itis near the following sources: Water supply Compressed air supply 120/220 VAC, 60/50 Hz, single-phase outlet DOE AACQUEN, TSSS-AAL Presue Process Conte Leaning Sytem station Guide Copyright® 2014 Amatel, nc.4 SECTION? Hardware Soup 4.” Perform the following substeps to fill the reservoir tank, ‘A. Make sure the reservoir drain valve is closed and the drain cap is in place, as shown in figure 11. The valve is closed when the handle is perpendicular to the piping. The handle has labels on top to indicate the open (O) and shut (S) positions. This prevents water from escaping from the reservoir. % ‘issa06-AAOOUEN TSSE5-AAU Pressure Process Control Learning Sytem Instalaion Guide Gepytight © 2014 Amat, Inc. 7--+ SECTION 2 Hardware Setup B. Fill the reservoir tank with water until it is about 3/4 full (approximately 30 liters or 7 gallons) as shown in figure 12. 14 FILL LINE RESERVOIR TANK Figure 12, Reservoir Tank Filed {f available, use a faucet and hose to fill the tank. If you do not have a hose, you will need a bucket to get the water from the faucet to the tank. 5. Perform the following substeps to connect the T5555 to the compressed air supply line. A. Locaté the female connector of the main pneumatic line, as shown in figure 13. Figure 13, Female Connector of Main Pneumatic Line 1033008-AAOOUEN TESSS-AAU Pressure Process Control Learning System Instalaton Guide Copyright © 2014 Amatrl, no 18 AAR ARR DR RR RA AAAIG aca ieee ie ee ee er en i i SECTION? Hardware Setup B, Push the female connector onto the male connector on the pressure regulator, as shown in figure 14, to connect the T5555 to the air supply. Listen for a “click” that indicates the main line is locked in place. The T55S6 is now connected to the compressed air supply. NOTE. It is not necessary to pull back the collar on the female connector when attaching it to the male connector. Figure 14, Female Connector Attached to Male Connector 1Dd308-AAGOLIEN “TSSE5-AAU Pressure Process Control Leaning System instalation Guide Clin ©2014 Amato, ie. 19SECTION 2 Hardware Setup 6. Perform the following substeps to connect the power cord to the T5555 system. ‘A. Locate the power supply connection on the right side panel of the, T5555, similar to figure 15. POWER SUPPLY CONNECTION Figure 15. AC Power Supply Connection NOTE The appearance of the pane! will differ based on the electrical power supplied at your location. 1099208-AAQOUEN TSSES-AAU Pressure Process Contre Learning System instalation Guide Copyright © 2014 Amaral, inc. 20SECTION? Hardware Sep B, Attach the female end of the pover cardi the male connector on the T5555, as shown “in figure 16. ELECTRICAL. ‘ounter: ‘CORD Figure 16, T5885 Connected to Electcal Outlet . Plug the opposite end of the power cord into an electrical outlet, similar to figure 16. NOTE ‘The appearance of the electrical outlet will differ based on the electrical power supplied at your location. | 1D33508-AAOOUEN TSS5S-AAU Pressure Process Contol Learning System Installation Guide Copyright © 2014 Amat, ine. 21er eR] Operation and Testing Procedures OVERVIEW In this seetion, you perform the folowing stop to test ihe Compohents of the TS555-AAU Pressure Process Control Learning Systm to make sure they are working properly. PART 3.1 POWER SUPPLY, SELECTOR SWITCH, AND INDICATOR LIGHT TEST i In this section, you will connect a circuit to test the operation of trie 24 VDC VFD Start and VFD Stop pushbuttons and indicator lights (PL1 and PL2). 1. Make suré the main circuit breaker is in the OFF (down) position, as shown in figure 17. Figure 17. Main Circuit Breaker in OFF Position (093308-AAQQUEN TSESS:AAU Prosaure Process Control Learning System Installation Guide Copyright © 2014 Amatrl, no. 22SECTION 3 Operation and Tasting Procedures 2. Locate the connection leads and connect the circuit shown in figure 18. Figure 18. Test Circuit for the DC Power Supply, Pushbutton Switches, and Indicator Lights. 158908-AAGOUEN TSSES-AALPrassure Process Conta Learning Sytem talon Gude (Copyright © 2014 Amatrl, Inc. 23SECTION 8. Operation and Testing Procedures, 3, Locate the VED Start and VFD Stop pushbuttons on the VFD-PLC INTERFACE panel, as shown in figure 19. INDICATOR INDICATOR LIGHT PL LIGHT PL2 FD STOP VED START PUSHBUTTON PUSHBUTTON Figure 19. VFD-PLC INTERFACE Panel 4. Locate the indicator lights, PL1 and PL2, also shown on figure 19. Done AAOOUEN TESA Pres Process Cnt Lering Stam Italo ie Copyright © 2014 Amato, nc.SECTION 3 Operation and Testing Procedures 5. Tum on the main circuit breaker. 6. Verify that the indicator light PL1 is on. ‘The VFD Stop pushbutton is a normally closed pushbutton, so PL1 should be on when that pushbutton is not depressed. 7... Press the red VFD Stop pushbutton on the VFD-PLC INTERFACE panel. Indicator light PL1 should turn off while the pushbutton is depressed, 8. Release the red VFD'Stop pushbutton. Indicator ight PL1 Should turn on and stay on after the pushbutton is reledised. 9. Verify that the indicator light PL2 is off. The VFD Start pushbutton is a normally open pushbutton, so PL2 should be off when that pushbutton is not depressed. 10. Press the green VED Start pushbutton on the VFD-PLE INTERFACE panel. Indicator light PL2 should turn on while the pushbutton is depressed. ‘There will be a high-pitched sound from the pump's motor. At this point, the command from the variable frequency drive (VFD) to the pump motor is 0%, so the pump does not run. However, the command signal is noisy enough to cause the whining sound. “11. Release the green VD Start pushbutton. Indicator light PL2 should turn off and stay off after the pushbutton is released, 12. Press and release the red VFD Stop pushbutton on the VFD-PLC INTERFACE panel. ‘The pump motor’s whine should stop. i 13, Turn off the main circuit breaker. 44, Disconnect all leads, ifthe circuit does not operate as described, contact Amatrol for assistance, [D9a302-AAOOUEN T5555-AAU Pressure Process Contol Learing Systom Instalaion Guide Copyright © 2014 Amato, Inc. 25SECTION 3 Operation and Testing Procedures PART 3.2 CENTRIFUGAL PUMP AND VARIABLE FREQUENCY DRIVE (VFD) TEST In this section, you will connect a circuit to test the operation of the centrifugal pump and the Variable Frequency Drive (VFD). 1, Make sure the main circuit breaker is in the OFF (down) position. 2. Locate the connection leads and connect the circuit shown in figure 20. This circuit connects the VED and the centrifugal pump. Figure 20. Test Citcut forthe Centrifugal Pump and the Variable Frequency Drive (VFD) 3. Locate the reservoir tank outlet hand valve HV 200B, as shown in figure 21. Figure 21. Reservoir Tank Outlet Valve HV 2008 4. Open (fully counterclockwise) HV 2008. DatiogAAGQUEN TSSS-AAL Freer Prous Coto Letting yom naan Gide Copyright © 2014 Amat, Inc. CG ¢ ¢ ¢ cSECTIONS Operation and Testing Procedures 5... Locate the flow control valve FV 200, as shown in figure 22. FLOW ‘CONTROL, VALVE FV200 : Figure 22, Flow Control Valve FV 200, “6: Open (counterclockwise) FV 200, © FV200 should be open a significant amount, but there is no “stop” if the knob is turned too © far counterclockwise. About two full counterclockwise rotations from the fully closed (fully. clockwise) position is a good starting point. ‘D9S808-AAGOUEN TS5S5-AAU Pressure Process Control Leaming System instalation Guido Copjtight © 2014 Artz, ne. ailies SECTIONS. Operation and Testing Procedures 7. Locate the reservoir tank return hand valve HV 200D, as shown in figure 23. RESERVOIR TANK RETURN g HAND VALVE ‘HV 2000 ‘CLOSED Figure 23. Reservoir Tank Return Hand Valve HV 2000 8. Close (fully clockwise) HV 200D. ¢ Oh 1D99908-AAQOUEN TSSS5-AAU Pressure Process Contal Learning System installation Guide Copyright © 2014 Amaia, Inc. 28SECTION’3 Operation and Testing Procedures 9. Locate the pressure outlet bypass harid valve HV 100, as shown in figure 24. PRESSURE OUTLET BYPASS HAND VALVE HV 100 (OPEN) Figure 24, Pressure Outlet Bypass Hand Valve HV 100 * 10. Open HV 100 by turning the black handle right. t ‘The black handle should be perpendicular to the back of the trainer. a 11. Turn on the main circuit breaker. [Dacode-AADOUEN TESES-AAU Preseure Process Coto Laring System nstaiafon Guige i Copyright® 2014 Arai, nc 29 tlSECTIONS Operation and Testing Procedures 12, Locate the Variable Frequency Drive (VFD), as shown in figure 25. Also locate the following information on the VFD's interface panel, as shown in figure 25. * Frequency display * Program indicator + Fault Indicator + Esc button * Sel button + Up and down arrow buttons * Enter button FREQUENCY DISPLAY FAULT INDICATOR e PROGRAM DOWN ARROW ¢ MODE BUTTON. INDICATOR. . ¢ ¢ esc ENTER ~ BUTTON BUTTON rs ¢ SEL ‘up ARROW c BUTTON BUTTON Figure 25. VED Power-up Display 'D3306-AADOUEN TSS5E-AAL Pressure Process Control Learning System Installation Guide Copyright © 2014 Amato nc. 30SECTIONS Operation and Testing Procedtres ‘The VED automatically powers up with the trainer. The initial display should indicate the ccuttent output frequency, which is 0 Hz, as shown in figure 26. Ifthe fault indicator is flashing and a fault code appears (i.e. a value that starts with an “F’) ‘on the display, download the Powerllex 4 User Manual from htip://ab.rockwellautomation. com. the problem cannot be resolved using that manual as guidance, contact Amatol or assistance. “48 On the VFD, press Ese twice to display the Group Parameter. ‘The Group Parameter letter (‘A’, “d’, or “P” on far left of display window) should be flashing. 14, Press the Up Arrow or Down Arrow untl the Group Parameter letter is changed to a “P”, similar to figure 26. GROUP ("P”) ‘AVAILABLE FOR EDITING ceo. BUTTON DOWN ARROW BUTTON ENTER BUTTON UP ARROW BUTTON Figure 28. VFD with Basic Program Group (‘P") Availabe for Editing 408-AADOUEN TBEE. AAU Pressure Pieces Cont Learing Systm nin Ge cap 10.2014 Amara, ro : 4 iSECTION 3. Operation and Testing Procedures ‘The P represents the Basic Program Group. 15. Press the Enter button (+!) to enter the Basic Program Group. The right digit on the display should be flashing. 16. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until POS is displayed. 17. Press the Enter button () to view the parameter value. 18. Check to see if the parameter value is set to 220. 19. If necessary, perform the following substeps to edit the parameter value. A. Press the Enter button (~) to enter the program mode. The right digit should be flashing and the Program LED should be illuminated if it is a programmable parameter. B, ross the Up Arrow or Down Arrow to change the parameter value, C. Press the Enter button (~!) to save the new value. 20. Press the Ese button to retum to the parameter number. 21. Repeat steps 16 through 20 to set or verify the following VFD paraineter settings: P031 = 220 (motor rated voltage [VAC] P033 = 4.5 (motor overload current [Amps] 036 = 1 (3-wite control scheme to start the drive) P038 = 0 (Speed source is potentiometer on VFD control panel) P039 = 10.0 (Acceleration time is 10 seconds) P040 = 5.0 (Deceleration time is 5 seconds) 22. Press Esc to display the Group Parameter. The parameter group menu letter should be flashing. 'D33908-AAGOUEN TSSSS-AAU Pressure Process Control Learing System Installation Guido Copyright© 2014 Arata, no. 32SECTION Operation and Tesing Procedures 23. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to an “A”, similar to figure 27. * Ste satac ego) tena Figure 27. VFD with Advanced Program Group (‘A") Available for Esiting The A represents the Advanced Program Group. 24. Press the Enter button (#) to enter the Advanced Program Group. The right digit on the display should be flashing. 25. Repeat steps 16 through 20 to set or verify the following VFD parameter settings: ‘A088 = 230 (maximum voltage [VAC)) ‘A089 = 3.5 (maximum output current [Amps)) ‘A091 = 2.0 (PWM frequency [kHz]) 'D33308-AAQGUEN TSS55-AAU Pressure Process Control Learning Systam Instaation Guido ‘Copyright © 2014 Amato, In. 8SECTIONS Operation and Testing Procedures 26. Press Esc twice to exit parameter viewing and editing. NOTE To reset all of the VFD's parameter values to their factory defaults, follow the procedure in Appendix B2. If this factory reset is done, repeat steps 12-25. 27. Locate the VFD Start and VED Stop pushbuttons on the VED-PLC INTERFACE Panel as shown in figure 28, ‘ VED STOP. PUSHBUTTON VFO SPEED. i ADJUSTMENT ° PUSHBUTTON KNOB Figure 28. VFD-PLC INTERFACE Panel 28. Press the green VFD Start pushbutton on the VFD-PLC INTERFACE panel to start the centrifugal pump. 29. Monitor the water level in the process tank by observing the level indicated on the level sight gauge on the side of the tank. Do not allow the level to exceed 25 cm (10 inches). 1D33808-AADOUEN TSSSS-AAU Pressure Process Control Leaming System Insallfon Guide Copyright © 2014 Amato, nc 34SECTION 3° Operation and Tasting Procedures 30. Turn the VFD speed control adjustment knob, shown in figure 28, fully clockwise to adjust the pump’s speed to its maximum rpm. The VFD's display should show 50.0 (for 50 Hz operation) or 60.0 (for 60 Hz operation) as shown in figure 29, FREQUENCY Figure 29. VFD Commanding Rated (Maximum) RPM Verity that there is flow through the system by observing the flow through the vertical rota meter Fl 200A, similar to figure 30. If there is not any flow, use the red VFD Stop pushbut- tonto stop the pump from trying to run. Verify that the reservoir tank outlet hand valve HV 200B is open (fully counterclockwise). Verity that the flow control valve EV 200 is open (not fully clockwise). If those valves are open and there still is no flow, the pump may need to be primed, 1089308-AAOOLIEN TSS55-AAU Pressure Process Contol Learning System Installation Gute ‘Copyright © 2014 Amatro, no. 35SECTIONS Operation and Testing Procedures a NOTE The pump should not be operated without quid The pump seals and pack- ing depend on the liquid being pumped for lubrication. The discharge of a centrifugal pump may be completely closed ‘without harming the pump. However, continuous operation with a closed discharge Is. not recommended because the pump may overheat. FLOW RATE INDICATION : G ie c C Figure 30. Flow Rate Indicated on Rotameter ¢ 1D63908-AAQOLIEN.TSS55-AAU Pressure Process Contel Leaving System installation Guide oO Copy 2014 Arak, =SECTION 3_Operation and Testing Procedures 31. Ifthe centrifugal pump does not need to be primed, skip to step 34. Otherwise, to prime the centrifugal pump, locate the priming nut on the left end of the pump, as shown in figure St. ‘Pring NUT Figure 81. Centrifugal Purp Priming Nut 32. Use an adjustable wrench to loosen the priming nut until water is released in a steady stream (i.e. does not contain air). 33, Tighten the priming nut and repeat steps 28-30. If the pump has been primed, and there still is no flow in step 30, double check the VFD. parameters specified in steps 13-26. If those parameters are correct and there still is no flow, contact Amatrol for assistance. ‘34, Monitor the water level in the process tank by observing the level indicated on the level sight gauge on the side of the tank. Allow the level in the tank to reach approximately 20 cm (8 inches). Do not allow the level to exceed 25 cm (10 inches). 35. Press the red VD Stop pushbutton on the VFD-PLC INTERFACE panel to stop the centrifugal pump. 36. Open (fully clockwise) the reservoir tank return hand valve HV 200D to allow the water to drain from the process tank. 37. Turn off the main circuit breaker. NOTE You may see a flashing “F004” fault indication on the VFD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VFD, eee ~, 38, Disconnect all leads. I any of the circuits do not operate as described, contact Amatrol for assistance, (D§5900-AAGOUEN TS6S5-AAL Proesure Process Control Leaning Sysam instataton Gude Cepyright © 2014 Amato, In.SECTION 3 Operation and Testing Procedures PART 3.3 LEVEL SWITCHES TEST In this section, you will connect a circuit to test the low level and high level switches LSL 200 and LSH 200, respectively. This circuit will use the VFD and the centrifugal pump. 1. Make sure the main circuit breaker is in the OFF (down) position, 2. Locate the connection leads and connect the circuit shown in figure 32. This circuit connects the connects the low level and high level switches LSL200 and LSH 200, respectively, to the programmable logic controller (PLC). It also. connects the VED and the centrifugal pump. PiPIPIPIPAEL Figure $2. Test Circuit for the Level Switches, Centritugal Pump, and VFD 1D33908-AADQUEN TS5S5-AAL Pressure Process Control Learning System Installation Guide (Copyright @ 204 Amatro, nc. 38 eeSECTIONS. Operation and Testing Procedures 8._ Locate the reservoir tank outlet hand valve HV 200B, as shown in figure 33. Figure 33. Reservoir Tank Outlet Hand Valve HV 2008, 4. Open (fully counterclockwise) HV 200B. 'D39308-AAOOUEN TSEES-AAL Pressure Process Control Learning System instalation Guide Copyright© 2014 Amara, nc. 39SECTIONS Operation and Testing Procedures 5. Locate the flow control valve FV 200, as shown in figure 34. FV 200 Figure 24. Flow Control Valve FV 200 6. Open (counterclockwise) FV 200. FV 200 should be open a significant amount, but there is no “stop” i the knob is turned too far counterclockwise. About two full counterclockwise rotations from the fully closed (fully clockwise) position is a good starting point. 1093308-AAOQUEN TSSSS-AAU Pressure Process Contol Learning System Insalation Guide Copyright © 2014 Amatal, Inc. 40SECTION 3 Operation and Testing Procedures 7. Locate the reservoir tank return hand valve HV 200D, as shown in figure 35. RESERVOIR ‘TANK RETURN HAND VALVE HV 2000 ‘CLOSED Figure 35. Reservoir Tank Return Hand Valve HV 200D_ 8 Close (fully clockwise) HV 200D. \ ‘D33308-AADOLIEN TSSSS-AAL Pressure Process Conto! Learning System Instaletion Guide Copyright © 2014 Amato, Inc. 4SECTION 3 _Operaion and Testing Procedures eiesitscaicl 9. Locate the pressure outlet bypass hand valve HV 100, as shown in figure 36. laine C C ‘ ¢ ¢ ( ¢ PRESSURE ¢ OUTLET BYPASS HAND VALVE. HV 100 (OPEN) Figure 36. Pressure Outlet Bypass Hand Valve HV 100 10. Open HV 100 by turning the black handle right. ‘The black handle should be perpendicular to the back of the trainer. ; 11. Tum on the main circuit breaker. ‘ ¢ C a ¢ 'D98308-AAOOUEN TSESS:AAU Pressure Process Contol Learning System Installation Guide Copyright © 2014 Amat, nc. 42SECTION 3 Operation and Testing Proceliras 12. Locate the Variable Frequency Drive (VFD), as shown in figure 38. ‘The VED automatically powers up with the trainer. The initial display should indicate the current output frequency, which is 0 Hz, as shown in figure 37. FREQUENCY DISPLAY FAULT INDICATOR DOWN ARROW PROGRAM BUTTON INDICATOR ESC ENTER BUTTON BUTTON SEL, UP ARROW BUTTON BUTTON Figure 37... VFD Power-up Display If the fault indicator is flashing and a fault code appears (i.e. a value that starts with an “F") ‘on the display, download the Powerflex 4 User Manual from http://ab.rockwellautomation. ‘com. If the problem cannot be resolved using that manual as guidance, contact Amatrol for 4 4 assictance. | ‘DaGo08-AADOUEN. TSS5S-AAU Pressure Process Conta Learning System Insalaion Gude Copyright© 2014 Amat nc. 48SECTIONS Operation and Testing Procedures 43. On the VFD, press Sel to display the Group Parameter. ‘The Group Parameter letter (A, d, P) should be flashing. 14. Press the Up Arrow or Down Arrow until the Grouip Parameter letter is changed to a “P”. The P represents the Basic Program Group, 16. Press the Enter button (+) to enter the Basic Program Group. ‘The right digit on the display should be flashing. 16. Press the Up Arrow or Down Atrow to scroll through the parameter numbers until P031 is displayed. 17. Press the Enter button (+) to view the parameter value. 18. Check to see if the parameter value is set to 220. i 19. If necessary, perform the following substeps to edit the parameter value: ‘A. Press the Enter button (!) to enter the program mode. 7 The right digit should be flashing and the Program LED should be lluminated if its programmable parameter. B. Press the Up Arrow or Down Arrow to change the parameter value, C. Press the Enter button (+) to save the new value. 20. Press the Ese button to return to the parameter number. 21. Repeat steps 16 through 19 to set or verify the following VFD parameter settings: PO31 = 220 (motor rated voltage [VAC}) P033 = 4.5 (motor overload current {Amps]) P036 = 1 (wire control scheme to start the drive) 038 = 0 (Speed source is potentiometer on VFD control panel) P39 = 10.0 (Acceleration time is 10 seconds) P040 = 5.0 (Deceleration time is 5 seconds) 22, Press Ese to display the Group Parameter. The parameter group menu letter should be fiashing, 23. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to an “A”. The A represents the Advanced Program Group. 24. Press the Enter button (+) to enter the Advanced Program Group. The right digit on the display should be flashing. 25. Repeat steps 16 through 19 to set or verify the following VFD parameter settings: ‘A088 = 230 (maximum voltage [VAC]) ‘A089 = 3.5 (maximum output current [Amps}) ‘A081 = 2.0 (PWM frequency [kHz]) 26. Press Esc twice to leave parameter viewing and editing. NOTE To reset all of the VFD’s parameter values to their factory defaults, follow the procedure in Appendix B2. If this factory reset is done, repeat steps 12-25. 1033908-AAQOUEN TSSS5-AAL Pressure Process Contol Learning System Installation Guide ‘Copyright® 2044 Amatrol, Inc. 44SECTION 3_Operation and Testing Procedures ‘27: Locate the low level and high level switches LSL 200 and LSH 200, respectively ‘on the process tank, as shown in figure 38. LsH 200 i" st 200 Figure 88. Low Level (LSL 200) and High Level (LSH 200) Snitches 1 28. Verify that the low level switch LSL 200 is positioned as far down in the mounting bracket q as possible. If not, move it. 4 29. Verify that the high level switch isH 200 is positioned as far up in the mounting bracket as possible. If not, move it. '093508-AAOOUEN TSSS5-AAU Pressure Process Control Leaming System Installation Guide Copyright © 2014 Amaia, inc. 45SECTION 9_ Operation and Testing Procedures 30. Locate the LEDs on the ends of low level and high level switches LSL 200 and LSH 200, respectively, as shown in figure 39. LsH 200 uD Ls 200 LeD Figure 39. LEDs on Low Level (LSL 200) and High Level (LSH 200) Switches '038808-AAQQUEN TSSSS-AAU Pressure Process Control Leaning System Installation Guide Copyright © 2014 Amatrl, nc. 48SECTION 8 Operation and Tasting Procedures ‘The LED on the LSL 200 switch will light when that sensor detects the water in the process tank (approximately 0.25 om (0.6 inch)), as shown in figure 40. LsL 200 LeDON Figure 40, LSL200 LED On 'D38008-AAOOUEN TSESS-AAL) Pressure Process Conitol Learning System Instalatlon Guide Copyright © 2014 Amata, Inc. 47SECTIONS Operation and Testing Procedures ‘The LED on the LSH 200 switch will ight when that sensor detects the water in the process tank (approximately 25 om (10 inches)), as shown in figure 41. en NOTE ‘When the high level switch LSH 200 is connected to the PLC, the PLC will automatically stop the pump if the water level in the process tank triggers that switch. That will prevent the water level in the tank from running over. sH 200 LEDON st 200 LEDON Figure 41. LSH 200 LED On 1D93008-AAOOUEN TSS65-AAU Pressure Process Control Leaming Systern Insalatien Guide Copyright © 2014 Amatral, nc. 48 cil caciesaiacassineti ¢SECTION 9 Operation and Testing Procedures 31. Press the green VFD Start pushbutton on the VFD-PLC INTERFACE panel to start the centrifugal pump. 32, Turn the VFD speed control knob fully clockwise to adjust the pump’s speed to its maximum rpm. ‘The VFD's display should show 50.0 (for 50 Hz operation) or 60.0 (for 60 Hz operation). Verify that there is flow through the system by observing the flow through the vertical rotameter Fl 200A, as shown in figure 42. If there is not any flow, use the red VFD Stop pushbutton to stop the pump from trying to run. Verify that the reservoir tank outlet hand valve HV 200B is open (fully counterclockwise). Verity that the flow control valve FV 200 is open (not fully clockwise). if those valves are open and there stil is no flow, the pump may need to be primed. FLOW RATE INDICATION Figure 42. Flow Rate Indicsted on Rotameter ‘Dgas08-AAOOUEN TSSES-AAU Pressure Procass Control Learning System Installation Guide Copyright © 2014 Amaral, inc. 49SECTION 3 Operation and Testing Procedures NOTE The pump should not be operated without liquid. The pump seals and pack- 4 ing depend on the liquid being pumped for lubrication. ‘ The discharge of a centrifugal pump may be completely closed without harming the pump. However, continuous operation with a closed discharge is not recommended because the pump may overheat. 83. If the centrifugal pump does not need to be primed, skip to step 96. Otherwise, to prime the centrifugal pump, locate the priming nut on the left end of the pump, as shown in figure 43. - ‘ PRIMING NUT. Figure 43. Centrifugal Pump Priming Nut 34. Use an adjustable wrench to loosen the priming nut until water is released in a steady stream ([.¢, does not contain ait). 36. Tighten the priming nut and repeat steps 30-31, If the pump has been primed, and there still is no flow in step 31, contact Amatrol for assistance. 36. Monitor the water level in the process tank by observing the level indicated on the level sight gauge on the side of the tank. 37. Monitor the LED on the low level switch LSL 200. Done AAOQUEN TSES-AAY Pretue Process Conte! Learing Sytem Inlabn Ge Copyright © 2014 Amat, inc.SECTIONS Operation and Testing Procedures 38. Verify that the LSL 200 LED lights when the water level rises above about 1/4 of the diam- eter of that sensor, as shown in figure 44. The LED should light when the water level is at approximately 0.25 cm (0.6 inch), st 200 | upon Figure 44, LSL 200 LED On 39, When the water level reaches approximately 15 cm (6 inches), press the red VFD Stop i pushbutton on the VFD-PLC INTERFACE panel to stop the centrifugal pump. 1 40; Open ully clockwise) the reservoir tank return hand valve HV 200D to allow the water to start draining from the process tank. f ) 41. When the water level in the process tank reaches approximaiely 8 cm (3 inches), close (fully clockwise) the reservoir tank return hand valve HV 20D. 42, Press the green VFD Start pushbutton on the VFD-PLC INTERFACE panel to start the centrifugal pump. 43, Monitor the water level in the process tank by observing the level indicated on the level sight gauge on the side of the tank. 44, Monitor the LED on the high level switch LSH 200. 1D98308-AAOOUEN TS5S5-AAU Pressure Process Contol Leaming System Installation Guide Copyright © 2014 Amato, ine 51‘SECTION 3..Operation and Testing Procedures 48. Verify that the LSH 200 LED lights when the water level rises above about 1/4 of the diam- eter of that sensor, as shown in figure 45, ‘The LED should light when the water level is at approximately 25 om (10 inches). sh 200 LED ON Lst 200 LED ON Figure 45. LSH 200 LED On 46. Verify that the centrifugal pump automatically turns off when the water level reaches the high level switch LSH 200 (LED lights). 47. If the pump does not automatically stop when the water reaches the LSH 200 switch, press the red VFD Stop pushbutton on the VFD-PLC INTERFACE panel to stop the cen: triftugal pump. Re-check the wiring in figure 32. If that wiring is correct, contact Amatrol for assistance. Resse: ARGIUEN, TOS AL Prt Pronees Conta Leaning Stem nstalaton Gude Copyright © 2014 Amara, nc.SECTION Operation and Tasting Procedures 48, Open (fully clockwise) the reservoir tank retum hand valve HV 200D to allow the water to start draining from the process tank. 49. If you are continuing on the Part 3.4, skip to step 56. 50. On the VED, press Sel to display the Group Parameter. ‘The Group Parameter letter (A, d, P) should be flashing. _ 51, Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to a “P”. ‘The P represents the Basic Program Group. 82. Press the Enter button (~) to enter the Basic Program Group. ‘The right digit on the display should be flashing. 83. Press the Up Arrow or Down Arrow to scroll through the parameter,numbers until PO38 is displayed. i 54, Press the Enter button (+) to view the parameter valug, : 55. Perform the following substeps to edit the PO38 parameter value. i A. Press the Enter button (++) to enter the program mode. ‘The right digit should be flashing and the Program LED should be illuminated if itis a programmable parameter. B. Press the Up Arrow or Down Arrow to change the parameter value to 3 (Speed source is 4-20 mA analog signal), ©. Press the Enter button (+!) to save the new value. D. Press Esc twice to exit parameter viewing and editing. NOTE ‘To reset all of the VFD's parameter values to their factory defaults, follow ) the procedure in Appendix B2. If this is factory reset is done, repeat steps 12-25 and then steps 48-55. '56. Open (fully clockwise) the reservoir tank return hand valve HV 200D to allow the water to drain from the process tank. 57. Turn off the main circuit breaker. NOTE | You may see a flashing "F004" fault indication on the VFD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VFD. 58. Disconnect all leads. If any of the circuits do not operate as described, contact Amatrol for assistance. 1D53308-AAOOUEN “TSSS5-AAU Pressure Process Contol Learning System Insalation Guide Copyright © 2014 Amatro, nc. 63SECTIONS Operation and Tasting Procedures PART 3.4 DIFFERENTIAL PRESSURE TRANSMITTER (DPT) LEVEL SENSOR TEST In this section, you will connect a circuit to test the operation of the differential pressure transmitter (DPT) level sensor. 1, Make sure the main circuit breaker is in the OFF (down) position. 2._ Locate the connection leads and connect the circuit shown in figure 46. This circuit connects the VFD and the centrifugal pump. That connection is required to run the pump to put some water in the process tank so that the differential pressure transmitter can be tested. This circuit also applies power to the level sensor (LT1) so that the level indication on the HMI can be verified during this test, i In addition, this circuit applies power to the low and high level switches (LSL 200 and LSH 200). This is done in particular so that the high-level ewitch will automatically cause the centrifugal pump to shut off if the water level in the process tank reaches about 25 cm (10 inches). = ap = \ | 2! ATR & ONE ra oo cI CANA d % oe Ke 25809] —> q ° @ren) a = q Pog 6 4 OO 4 g eeee ° q Figure 46. Test Circuit for the Differential Pressure Transmitter (DPT) Level Sensor, Centrifugal Pump, and VFD 8. Tum on the main circuit breaker. 4, On the VED, press Sel to display the Group Parameter. ‘The Group Parameter letter (A, d, P) should be flashing. 5. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed toa “P”. The P represents the Basic Program Group. 6. Press the Enter button (+) to enter the Basic Program Group. The right digit on the display should be flashing, 7. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until PO38 is displayed, ’ 8. Press the Enter button (~!) to view the parameter value. '09a308-AAGQUEN TSSES-AAU Pressure Process Contol Learning System instalation Guide Copyright © 2014 Amati, nc. ‘4 SARA N AN SE eeeSECTIONS Operation and Testing Procedures 9. Perform the following substeps to edit the PO38 parameter value. A. . Press the Enter button (~!) to enter the program mode. ‘The right digit should be flashing and the Program LED should be illuminated if itis a programmable parameter. B, Press the Up Arrow or Down Arrow to change the parameter value to 0 (Spood source is potentiometer on VFD control panel). C. Press the Enter button () to save the new value. D. Press Ese twice to exit parameter viewing and editing. 10. Locate the differential pressure transmitter (DPT) levol sensor shown in figure 47. DIFFERENTIAL PRESSURE. ‘TRANSMITTER ET eye) LEVEL SENSOR Figure 47. Differential Pressure Transmitter (DPT) Level Sensor DstobeAAGIUEN TSSE-AAPrestre Proees Cool Leung Syste inal Gilde Copyright © 2014 Amato, Inc.SECTIONS Operation and Testing Procedures 11. Locate the high and low pressure fines that connect to the differential pressure transmitter, as well as the return line, as shown in figure 48. RETURN LINE, LeveL SIGHT GAUGE Low. PRESSURE UNE: HIGH PRESSURE LINE DIFFERENTIAL B PRESSURE TRANSMITTER Figure 48, High and Low Pressure Lines and Retum Line on the Differential Pres- sure Transmitter (D33008-AAOOUEN TS5S5-AAL Pressure Process Contol Learning System Installation Guide Copyright© 2014 Arata, ne. 58 €L SECTIONS Operation and Testing Procedures 12. If there is arin either the high or low préssure lines to the differential pressure transmitter, i shown in figure 48, those lines need to be bled. Also, ifthe level indicated on the differential | pressure transmitter's display differs from the level value on the process tank’s sight gauge by more than approximately 1 centimeter (0.4 inch), those lines need to be bled. Ifno air Oo is visible in those lines, and the DPT's level display is correct, skip to step 15, There can be air bubbles in the retum line between the top of the tank and the water pipe to the right of the tank That air does not affect the differential pressure trariemitter's read- | ings. The return line only provides a return path for the water and air being bled from the low-pressure line. 13. Perform the following substeps to put some water in the process tank so that the differential pressure transmitter’s high-pressure line can be bled. Open (fully counterclockwise) reservoir tank outlet hand valve HV 200B. Close (fully clockwise) the reservoir tank return hand valve HV 200D. Adjust the speed control knob on the VFD to the full/clockwise position, Press the green VFD Start pushbutton to start the VFD's control of the centrifugal pump. ‘The VFD's display should show 50.0 (for 50 Hz operation) or 60.0 (for 60 Hz operation). E, Onee the water level in the process tank reaches about 8 centimeters (3 inches), use the red VED Stop pushbutton to stop the centrifugal pump. F._ Close the reservoir tank outlet hand valve HV 200B. 14. Perform the following substeps to bleed the air from the lines between the process tank and the differential pressure transmitter. ‘A. Place paper towels or a small container under the differential pressure transmitter. ‘Water will leak from the lines as the air is bled from them. 9OD> Doe AOIUEN TES-AAL! Pere Proce Cotl Lenning St nition Ge CCopyrignt © 2014 Amato, nc. ReesSECTION 3. Operation and Testing Procedures B. Locate the equalizer valve and the high pressure inlet valve of the right side of the differential pressure transmitter as shown in figure 49. ‘The high-pressure side of the differential pressure transmitter is marked with an “H" on the yellow sticker that circles the device, WATER WILL LEAK HERE, HIGH PRESSURE INLET VALVE, INDICATES. HIGH PRESSURE SIDE Figure 49. ight Side of Differential Pressure Transmitter C. Close the pressure outlet bypass hand valve HV 100 by turing it eft. ‘The valve handle should be parallel to the back of the system. D. On the right side of the differential pressure transmitter, as shown in figure 49, use a flathead screwdriver to open (counterclockwise) the equalizer valve a very small ‘amount (about 1/8 of a revolution). NOTE ‘The equalizer valve must be open only a small amount (1/8 of a revolution). If itis opened too far, it allows bubbles to return to the pressure lines at the end of the bleeding procedure. E. On the tight side of the differential pressure transmitter, as shown in figure 49, use the 9/64 inch hex wrench to partially open (counterclockwise) the high-pressure inlet valve to bleed all air from the high-pressure line. ‘The high-pressure side of the differential pressure transmitter is marked with an “H” on the yellow sticker that circles the device. i ‘Some water will leak from the valve as the air is released. Dec05-AADQUENTESSS-AAL Pressure Proctes Conta! Leting Sytem Isalaton Guo ‘Copyright© 2014 Amatro, Inc.SECTION Operation and Testing Proceaires ‘When all of the air is removed from the high-pressure line, fully close (clockwise) the high-pressure inlet valve, Leave the equalizer valve open a small amount (as previously adjusted). i. Open (fully counterclockwise) the reservoir tank outlet hand valve HV 200B. Open (counterclockwise) the reservoir tank return hand valve HV 200D about half way ‘as shown in figure 50. Figure 50. Reservoir Tank Return Hand Valve HV 2000, Open About Half Way This results in the handle at about 45 degrees with respect to vertical, |. Verify that flow control valve FV 200 is open (not fully clockwise). 1D98808-AACOUEN TSSSS-AALJ Pressure Pracess Contol Learning System instalation Guide Copyright © 2014 Amato, Inc. 59SECTIONS Cperation and Tasting Procedures J. Locate the low pressure inlet valve on the left side of the differential pressure transmitter as shown in figure 51. The low-pressure side of the differential pressure transmitter is marked with an *L’ on the yellow sticker that circles the device. WATER WILL. LEAK HERE LOW PRESSURE INLET VALVE INDICATES Low PRESSURE SIDE Figure 51. Left Side of Differential Pressure Transmitter (033008-AADOUEN TSS55-AAU Pressure Process Contol Leeming System Installation Guide Copyright © 2014 Amaia, Inc. 60 ti nA <SECTION Operation and Testing Procedures K, - Locate the 3-way hand valve HV 200E at the top of the process tank as shown in figure 52. SAWAY HAND ps VALE Figure 52. Three-Way Hand Valve for Charging Low Pressure Line L. Fully open the 3-way hand valve HV 200E at the top of the process tank by turning it 4 Up until the handle is vertical. i M. Adjust the speed control knob on the VFD to the full clockwise position. NN. Press the green VD Start pushbutton on the VFD-PLC Interface panel to start the centrifugal pump. ‘The VED's display should show 50.0 (for 50 Hz operation) or 60.0 (for 60 Hz operation). 'D33308:AADOUEN TS555-AAU Pressure Process Control Learning System Intalation Guide (Copyrignt © 2014 Amatrl, no. 1SECTION Operation and Testing Procedures ©. On the left side of the differential pressure transmitter, as shown in figure 53, use the ‘3/64 inch hex wrench to partially open the low-pressure inlet valve to bleed all air from the low-pressure line. (Open this valve quite a bit. You want the air bubbles to clear ftom the line before the water level reaches 25 centimoters (10 inches) and the bump automaticaly shuts oft) WATER WILL, LEAK HERE LOW PRESSURE, INLET VALVE INDICATES LOW PRESSURE SIDE Figure 53. Left Side of Differential Pressure Transmitter The low-pressure side of the differential pressure transmitter is marked with an “L’ on the yellow sticker that circles the device. ‘The air bubbles must be bled from the low-pressure line connected to the left side of the differential pressure senor. The air bubbles do not have to be bled from the return line that connects the pipe and the top flow valve with the yellow handle, Ifthe water level reaches 25 centimeters (10 inches) and the pump automatically shuts off, allow the water level to drain to 0 centimeters (0 inches), and then re-start this procedure from substep L. ‘Some water will eak from the valve as the air is released. P. Whenall of the air is removed from the low-pressure line, full close (clockwise) the low- pressure inlet valve. Use the red VFD Stop pushbutton to stop the centrifugal pump. Fully close the three-way hand valve HV 200E at the top of the process tank by turning it down until the handle is horizontal. pO '093208-AAOOUEN TS555-AAU Preseure Process Control Learning System Installation Guide Copyright © 2014 Amato, in.SECTIONS Operation and Testing Procedures S. -On the right side of the differential pressure transmitter, as shown in figure 54, use a flathead screwdriver to close (clockwise) the equalizer valve. - HES NOTE y Rt Do not over-tighten the equalizer valve but do make sure it is closed. The ‘a operating manual lists a maximum opening and closing torque of 0.75 filbs. EQUALIZER VALVE Figure 54. Equalizer Valve on Right Side of Differential Pressure Transmitter T. Verify that the differential pressure transmitter displays a level value that is close to the water level in the tank as indicated by the sight gauge. If not, the lines may stil have air bubbles and you will need to repeat the bleeding process (steps 6-7). U. Wipe off any water that leaked onto the back part of the differential pressure transmitter. ) 'D58508-AADOUEN TSSS5-AAL) Pressure Pracess Control Learing System Installation Guide ‘Copyright© 2014 Amaltol, nc. 63SECTION 3 Operation and Testing Procedures 15. Perform the following substeps to put some water in the process tank. The process tank must contain some water to prevent air from being forced through the water lines when the tank is pressurized. A. Close (tily clockwise) reservoir tank return hand valve HV 200D. B. Open (fully counterclockwise) reservoir tank outlet hand valve HV 200B. C. Verify that flow control valve FV 200 is open (not fully clockwisé). . Adjust the speed control knob on the VED to the full clockwise position. E, Press the green VFD Start pushbutton on the VFD-PLC Interface panel to start the centrifugal pump. - : ‘The VFD's display should show 50.0 (tor 50 Hz opetation) or 60.0 (for 60 Hz operation). F. Observe the water level on the process tank sight gauge and press the VFD Stop pushbutton when the level reaches approximately 8 centimeters (3.0 inches). G. Close (fully clockwise) the reservoir tank outlet hand valve HV 2008. H. Verify that there is stil moro at least 3 centimeters (1.0 inch) of water in the process tank before proceeding to the next step. 1038308-AAGOUEN TSSSS-AAU Pressure Process Contol Learning System installation Guide Copyright © 2014 Amato), Inc. 64SECTIONS Operation and Tostng Prosedes* 16. Perform the following substeps to scale the differential pressuire transmitters display. ‘A. Wipe off any water on the back part of the differential pressure transmitter. B. Remove the cover from the differential pressure level sensor display by turning the front cap counterclockwise shown in figure 55, 7 FRONT cap Figure 5. Front of Differential Pressure Level Transmitter (099908-AAOOLIEN TSSES-AAJ Pressure Process Control Loaming System Insalatlon Guide Copyright © 2014 Amero, in. 5SECTION 3._Cperation and Testing Procedures C. Enter the setting mode by pressing the M button, shown in figure 56, for more than 3 seconds. The display should appear similar to figure 55. DISPLAY ‘SOFTWARE ‘VERSION INDICATOR i up ” : ARROW BUTTON ( : * BUTTON Figure 56. Differential Pressure Level Transmitter Display Functions Pressing the up and down arrow buttons will change the parameter values. Briefly pressing the M button will display the next parameter, Press the M button so that the F parameter appears on the display. E: Hfnot already sett 0 press the up or down arow bution to change the F parameter to 9 This sets a fiter inside the differential pressure level transmitter to smooth the analog output signal due to pressure fluctuations, F._ Press the M button to display the next parameter. 3208 AACOUEN,TSSS-AAL Presi Process Cont Learing Sytem alton Gude Copyright © 2014 Amat, nc. eae te ¢SECTIONS Operation end Testing Procedures, G.. Continue changing parameter values as they are shown in figure 57. F 0 ‘Moving Average Time of Diferential Pressure (seconds) Fy Lin Linear Display Mode P “133 | Minimum Ditfeental Pressure (n¥0) B 0 Maximum Diferential Pressure (inH,0) d 1 Decimal Point Postion of Displayed Value d 00 Veli Disaye iho Min Pros Serb d '88.80F 13.3 _ | Value Displayed When Maximum Pressure le Sensed (83.8 om, 19.5 im) A 00 Percent of Pressure Span Where 4 mA is Reported (24) i 100.0 | Percent of Pressure Span Where 20 mA ls Reported (%) Figure 57. Display Scaling Parameters H, After all of the parameters are set, press and hold the M button to return to the mea- ‘surement mode. ‘The display should show a value that closely matches the water level on the process tank’s sight gauge. If this display does not match the level on the sight gauge within 1.0m (£0.4 inch), the high and low pressure lines may still contain air and may need to be bled again. If they contain air, repeat steps 6-8. |. Place the front cap onto the differential pressure level sensor and turn it clockwise until it seals. 1D39306-AAUOUEN TSSSE-AAU Pressure Process Cantal Learning System Installation Guide e7 Copyright © 2014 Amato, Ine.SECTION 3. Operation and Testing Procedures 17. Compare the water level indicated on the HMI, next to the LT 200 label, similar to figure 58. The values indicated on the HMl, DPT display, and on the sight gauge should all match within & 1 om (£ 0.4 inch), WATER LEVEL IN [PROCESS TANK Figure $8, HMi's Level Indication, LT 200 tan Alarms pop-up is displayed over the HMI screen, select the X in the upper right ‘corner of that pop-up to remove it from the display. More aspects of the HMI will be addressed in later tests. 18. On the VFD, press Sel to display the Group Parameter. ‘The Group Parameter letter (A, d, P) should be flashing. 19. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to a “P”, The P represents the Basic Program Group. 20. Press the Enter button (+!) to enter the Basic Program Group. ‘The right digit on the display should be flashing. DSB AADQUEN TSSS-AAL Presi Procees Cont Leaning Stem natn Gude ‘Copytight © 2014 Amatro, Inc. Diese eevee ee eee eee eee eet eS eee reSECTION 3 Operation and Testing Procedures 21. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until PO38 is displayed. 22, Press the Enter button (4) to view the parameter value, 23, Perform the following substeps to edit the P038 parameter value. ‘A. Press the Enter button (+) to enter the program mode, ‘The right digit should be flashing and the Program LED should be illuminated if it is a programmable parameter. B, Press the Up Arrow or Down Arrow to change the parameter value to 3 (Speed source is 4-20 mA analog signal). C. Press the Enter button (+4) to save the new value. D. Press Esc twice to’exit parameter viewing and editing. 24. Open (fully clockwise) the reservoir tank return hand valve HV 200D to allow the water to drain from the process tank. ; 25. Turn off the main circuit breaker. NOTE You may see a flashing “F004” fault indication on the VED as the trainer is powered down, That fault indicates an undervoltage condition, and is normal as power is removed from the VED. 26. Disconnect all leads. Ifany of the circuits do not operate as described, contact Amatrol for assistance. 1D98008-AAOOUEN TS5S6-AAU Pressure Process Control Loanning System instalation Guide Copyright © 2014 Amato}, nc. 6SECTIONS Operation and Testing Procoduras PART 3.5 PROPORTIONAL SOLENOID VALVES AND PRESSURE SENSOR TEST In this section, you will connect a circuit to test the operation of the proportional solenoid inlet valve and proportional solenoid outlet valve PCV 100A anc PCV 1008, respectively. 1. Make sure the main circuit breaker is in the OFF (down) position. 2, Locate the proportional solenoid inlet valve PCV 100A (PV1) shown in figure 59. PROPORTIONAL, ‘SOLENOID INLETVALVE PCV 1008 ev) Figure 9. Proportional Solenoid Inlet Valve PCV 100A (PV1) 1099308-AAOQUEN TSSSS-AAU Pressure Process Contol Learning System instalation Guide Copyright © 2014 Amat, ne 70SECTION’ Oporation and Testing Procedures 3. Remove the screw in the center of the top of the proportional solenoid inlet valve's electronic control unit’s (ECU) case, similar to figure 60. cea pave TEL 3700: MA SERIAL No Figure 60, Proportional Solenoid Valve's Electronic Control Unit (ECU) (093508-AAOOUEN. TSS55-AAU Pressure Process Contr Leaming System instalation Guida a Copyright © 2014 Amaral, inc.SECTION 3. Operation and Testing Procedures 4. Verify that the four white DIP switchés in the ECU’s case are set as shown in figure 61. They should be set as follows: $1 = ON, S2 = ON, $3 = ON, $4 = OFF. C € Figure 61. Proportional Solencid Vaio Electronic Contol Unit DIP Switch Set ings 5. Replace the cover on the PCV 100A’s ECU. eas08. AOD TSSS-AA Prost Prosees Cnt Lean Sytem satan Gls Copyright® 2014 Amato, nc.Se SECTION 3 Operation and Testing Procedures 6.. Locate the proportional solenoid outlet valve PCV 100B (PV2) shown in figure 62. iL PROPORTIONAL, SOLENOID OUTLET VALVE, PCV 1008 (v2) Figure 62. Proportional Solenoid Inlet Valve PCV 1008 (PV2) bones AoE THA Penn Poses Core aang Spt rn i i Soto oii nea ne ca iSECTION 3 Operation and Testing Procedures Remove the screw in the center of the top of the proportional solenoid inlet valve's elec tronic control unit's (ECU) case, similar to figure 63. zane ARE 7100 Ma, ROTTS Figure 63. Proportional Solenoid Valve's Electronic Control Unit (ECU) 1033008-AAOOUEN TSSBS-AAU Precsure Prozess Control Leaming Syetam installation Guide Copyright © 2014 Amato, nc. 74 hielo ay 2 : ARAN NSSECTION _Oparation and Testing Procedures 8. Verify that the four white DIP switches in the ECU's case are set as shown in figure 64. ‘They should be set as follows: S1.= ON, S2 = ON, $3 = ON, S4 = OFF. 1 Figure 64. Proportional Solenoid Vato Eloctonie Conta! Unt DIP Switch Set- ings 9. Replace the cover on the PCV 100B's ECU. Qos MOM EN TESS AA Prem se Cv Lair Stns Gale i Copyright 2014 Ara ne. |SECTION 3 _Qvearation and Tasting Procedures 10. Locate the connection leads and connect the circuit shown in figure 65. This circuit connects the PLC and HMI to the proportional solenoid inlet valve and proportional solenoid outlet valve PCV 100A and PCV 100B, respectively. This circuit also applies power to the pressure sensor (PT1) so that the pressure display (PT 100) on the HMI can be verified. This circuit also connects the VFD and the centrifugal pump. That connection is required to run the pump to put some water in the process tank so that the proportional solenoid valves can be tested. The process tank must contain some water to prevent air from being forced through the water lines when the tank is pressurized. Figure 65. Test Circuit for the Proportional Solencid Valves and Pressure Sensor 11. Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle down against the valve case if itis not already open. When you open the shutoff valve, you will hear a brief rush of vented air. This is the sel- bleed feature of this pressure regulator. 12, Pull up the pressure regulator's adjustment knob to unlock it, turn the adjustment knob counterclockwise until the gauge shows 140 kPa (20 psi), and then push down the pressure regulator's adjustment knob to fock it. 18. Close the pressure regulator's shutoff vaive by pushing the top part of the orange handle against the valve case. ‘When you close the shutoff vaive, you will hear a brief rush of vented air. This is the self- bleed feature of this pressure regulator. (033308-AADUUEN TS555-AAL Pressure Procass Control Learing System Instalation Guide Copyright © 2014 Amat Inc. 78SECTION 3 Operation and Testing Procedures 14. Perform the following substeps to set the hand valves so that you can put some water in the process tank. ‘The tank must contain some water to prevent air from being forced through the water lines when the tank Is pressurized. The process tank must contain at least 2.5 cm (1 inch) of water so that it is above the level of the LSL 200 sensor, or the manual control of the electric proportional valves will not operate, ; A. Make sure the system's hand valves, shown in figure 66, are set as indicated in the table. HV 200A, External Source Inlet Hand Valve | Fully closed (CW) HY 2006, External Source Outlet Hand Vawve | Fully closed (OW) HIV 200F, Drain Hand Vaive Fly closed (CW) HV 200G, Drain Hand Valve Fully closed (CW) EXTERNAL. ‘SOURCE, ‘OUTLET HAND VALVE HV 2000 FLOW tap CONTROL hue VALVE HV 200 Hv 2006 DRAIN HAND VALVE DRAIN HAND’ z i nae VALVE HV RESERVOIR TANK OUTLET HAND VALVE HV 2006, Figure 68. T5555 Hand Valves B. Verify that the flow control valve FV 200 is open (not fully clockwise). C. Close (tully clockwise) the reservoir tank return hand valve HV 200D. D. Open (fully counterclockwise) the reservoir tank outlet hand valve HV 2008. E. Open the pressure outlet bypass hand valve HV 100 by turning it right. The black handle should be perpendicular to the back of the trainer. 1D33908-AAGOUEN TSSS5-AAU Pressure Process Control Leaning Syetom instalation Guida Copyright @ 2014 Amat, Inc. 77 —SECTION Operation and Testing Procedures 15. Turn on the main circuit breaker. The HMI automatically powers up with the trainer. The sequence of screens that will be displayed are shown in figure 67. NOTE : Do not make any selections from the HMI’s Loader screen. HMI LOADER SCREEN Figure 67. HMI Boot-up Screen Sequence NAS '093908-AAOOUEN TSE55-AAU Pressure Process Contot Leaming Syetem Installation Guide Copyright © 2014 Amat, Ine 78SECTION 3 Operation and Testing Procedures After the HMI completes its boot up, it may display a low-level alarm pop-up, similar to figure 68. Hu ROOT. ‘SCREEN close OPTION 3} ALARM | WINDOW | POP-UP | Figure 68. Alarm Pop-up ea ‘A. If the low-level alarm is indicated, press the Close option (X) on the alarm pop-up to : remove it from the display. The low-level alarm is triggered when the water level in the process tank is below the | low level switch (LSL 200). U 1D58908-AAQQUIEN TSS5S-AALI Pressure Process Cantal Learning System Installation Guida Copyright © 2014 Amato, inc. 73SECTIONS Operation and Testing Procedures B. After the alarm pop-up is closed, the HMI root screen should appear, similar to figure 69. Ht ROOT: ‘SCREEN UNITS Figure 69. HIM Root Screen The root screen includes a representation of the plant system. Most adjustments will be initiated from this screen. C. Select SI or US units via the option in the lower right corner of the HMI's root screen. . Verify that the Manual Control mode is selected on the HMI screen. If you need to select the Manual Control mode, touch the Control Mode field (white area next to the Control Mode label), select the Manual Control mode on the Mode Entry screen, and then select the Enter (~) option to save that selection and return to the HM's root screen. 1D38308-AADOUEN TSSS5-AALJ Pressure Process Contol Learning System Intataton Guide ‘Copyright © 2014 Amato, Inc. 80 AR RARRARARARARRAAR ARRAS ASECTION 3_ Operation and Testing Procedures 16. The VFD also automatically powers up with the trainer. After the VFD finishes its boot up, its display should indicate the current output frequency, which is 0 Hz. | the fault indicator is flashing and a fault code appears (i.e. a value that starts with an “F") on the display, download the Powerflex 4 User Manual from http://ab.rookwellautomation. com. If the problem cannot be resolved using that manual as guidance, contact Amatrol for assistance. 17. Perform the following substeps to verify that the VFD is set up to accept a speed command from the HMVPLC. ‘A. On the VED, press Sel to display the Group Parameter. ‘The Group Parameter letter (A, d, P) should be flashing. 8. Press the Up Arrow or Down Arrow until the Group Parameter letter fs changed fo a ‘The P represents the Basic Program Group. C. Press the Enter button (+) to enter the Basic Program Group. ‘The right digit on the display should be flashing. D. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until P038 is displayed. E. Press the Enter button (~!) to view the parameter value, F._ Press the Enter button (+) to enter the program mode. ‘The right digit should be flashing and the Program LED should be illuminated if it is a programmable parameter. G. Press the Up Arrow or Down Arrow to verify (or change) the parameter value of 3 (Speed source is 4-20 mA analog signal). H. Press the Enter button (~!) to save the new value. Press Esc twice to exit parameter viewing and editing. 'D33908-AAOQUEN TS5SS-AAU Preesure Process Control Learning System Instaaton Guide Copyright © 2014 Amat, inc. 81SECTION 3_ Operation and Testing Procsdures 18. Perform the following substeps to set the VFD’s percentage command to the motor to be 100% of its rated rpm. ‘A. From the HMI's root screen, as shown in figure 70, select the VFD percentage command field (white box next to the VFD legend), Figure 70. HMi Root Seren (090906-AAGQUEN TS5SS-AAU Pressure Process Contol Learning System Instalation Guide Copyright © 2014 Amat nc. a2 vFD% ‘COMMAND AAR ANN RRR ADR ARR ARR NRAN ANNASECTION Operation and Testing Procedures In response to that selection, the HMI's data entry screen is automatically displayed, as shown in figure 71, ENTER OPTION Figure 71. HMI Data Entry Screen B. Use the on-screen keypad to enter a value of 100. This number represents a motor speed of 100% of its rated speed. | C. Select the Enter () option to save the entered value. The HMI display will return to the root screen, with 100% displayed for the VFD parameter. 19. Press the green VED Start pushbutton on the VFD-PLC INTERFACE panel to start the centrifugal pump. 1D88008-AADOUEN TSES5-AAU Pressure Process Control! Leazning System Insalaion Guide {Copyright © 2014 Amat) nc. 8SECTION Operation and Testing Procedures 20. Verify that there is flow through the system by observing the flow through the vertical rotameter Fl 200A, similar to shown in figure 72. If there is not any flow, use the red VFD Stop pushbutton to stop the pump from trying to run. Verify that the flow control valve FV 200 is open (not fully clockwise). if these valves are open and there still is no flow, the pump may need to be primed. Prime the pump as described in Appendix B3. ‘The pump seals and pack- ing depend on the liquid being pumped for lubrication. The discharge of a centrifugal pump may be completely closed without harming the pump. However, continuous operation with a closed discharge is not recommended because the pump may overheat. f If the pump has been primed and there still is no flow, verify that the VFD parameters are correct as described in Appendix B2. FLOW RATE INDICATOR Figure 72. Flow Rate Indicated on Rotameter 1D38908-AAQOUEN TS555-AAU Proseure Procoes Control Learring System Instalation Guide Copyright® 2014 Amatrl nc. Cy aASECTION S_Operation and esting Procedures 21. Observe the water level on the process tank's level sight gauge, and press the VFD Stop pushbutton when the level reaches approximately 8 cm (3 inches). 22. Close (fully clockwise) the reservoir tank outlet hand valve HV 200B. 23, Double check the level in the process tank to make sure it is above the low level switch (LSL 200). If not, open the reservoir tank outlet hand valve HV 200B and repeat steps 11- 14. 24, Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle back against the valve case. When you open the shutoff valve, you will hear a brief rush of vented air. This is the self- bleed feature of this pressure regulator. 25. Perform the following substeps to make the control selections for the electric proportional valves. A. Verify the Manual Control mode is selected on the HMI screen. | If you need to select the Manual Control mode, touch the Control Mode field (white : area next to the Control Mode label), select the Manual Control mode on the Mode Eniry screen, and then select the Enter (~4) option to save that selection and retum to the HMIs root screen. | | | '098208-AAOOUEN TSS5S-AAU Pressure Process Control Leaming System Installation Guide Copyright © 2014 Amato, in. 85SECTIONS Operation and Testing Procodures B. mo Verify the percentage command for the proportional solenoid outlet valve PCV 100B, is 0% on the root screen, and verify that the pressure in the process tank as indicated below the PT 100 label on the HM is approximately 0 kPa (0 psi), as shown in figure 73. Pov 4008 ‘% COMMAND ev 1008 % COMMAND Figure 73, HMI Root Screen From the HM|'s root screen, select the proportional solenoid inlet valve PCV 100A percentage command value field (white box next to the 100A label). {n response to that selection, the HMI's data entry screen is automatically displayed Use the on-screen keypad to enter a value of 40. Select the Enter button (~) to save the change. ‘The HII display will return to the root screen with 40% displayed for PCV 100A. ‘Observe the flow rate of the air into the process tank indicated on the sight inlet flow indicator Fl 100A. (033908-AADOUEN. TSSS5-AAL Pressure Process Control Learning System installetion Guide Copyright © 2014 Amaro, nc 86 § € { ¢ c NAAG. Verify the process tank pressure indicated below the PT 100 label on the HMI root screen is approximately 11 kPa (1,6 psi). ‘You will hear air being exhausted from the proportional solenoid outlet valve PCV 1008. because the pressure outlet bypass hand valve HV 100 is open. H. Change the PCV 100A percentage command value to 75%. The HMI display will return to the root screen with 75% displayed for PCV 100A. |. Observe the flow rate of the air into the tank on the sight flow indicator Fl 100A, The inlet flow indicator Fl 100A should spin faster here than in substep 25F, J. Verify the process tank pressure indicated below the PT 100 label on the HMI root soreen is approximately 63 kPa (9.2 psi). For a command of 75%, the valve is open more than it was in step 25G, so you should observe a faster flow rate into the tank, and the tank’s pressure should be higher here. ‘You will also hear air being exhausted from the proportional solenoid outlet valve PCV | 100B faster than in substep 25G because there is more air coming into the tank and the pressure outlet bypass hand valve HV 100 is stil open. K. Change the PCV 100B percentage command value to 75%. The HM| display will return to the root screen with 75% displayed for PCV 1008. L. Close the pressure outlet bypass hand valve HV 100 by turning it left. The black handle should be parallel to the back of the trainer. This selection causes the proportional solenoid outlet valve PCV 1008 to only be partially open, based on the selection from the HMI. This will allow less air flow out of the process tank than when HV 100 was open, The outlet flow indicator Fl 100B should indicate outfiow of air (6. should spin). M. Verify the process tank pressure indicated below the PT 100 label on the HMI root screen is approximately 94 kPa (13.7 psi). This pressure should be more than that observed in substep 25J because the proportional solenoid outlet valve is now only partially open. You will also hear less air being exhausted from the proportional solenoid outlet valve PCV 100B than in substep 25J because it is only partially open. N, Change the PCV 100B percentage command value to 40%, The HMI display will return to the root screen with 40% displayed for PCV 100B. This selection causes the proportional solenoid outlet valve PCV 100B to open more, allowing more air flow out of the process tank, The outlet flow indicator should spin slower here than in substep 25L, . Verify the process tank pressure indicated below the PT 100 label on the HMI root screen is approximately 147 kPa (21.3 psi). This pressure should be more than that observed in substep 25M because the propor- , tional solenoid outlet valve is open less than it was in that substep. You will also hear i less air being exhausted from the proportional solenoid outlet valve PCV 100B than in substep 25M because itis open less. 26. Open the pressure outlet bypass hand valve HV 100 by turing it right. The black handle should be perpendicular to the back of the trainer. | 27. Reset the percentage commands for the proportional solenoid inlet and outlet valves PCV | 100A and PCV 1008 to 0% on the HMI. | | | | | | 'D39908-AADOUEN TSSSE,AAU Pressure Proosss Contol Learning System instalation Guide Copyright © 2014 Amato, Inc. 87SECTIONS Operation and Testing Procedures 28. Pull up the pressure regulator's adjustment knob to unlock it, turn the adjustment knob counterclockwise until the gauge shows 0 kPa (0 psi), and then push down the pressure regulator's adjustment knob to lock it. 29. Close the pressure regulator's shutoff valve by pushing the top part of the orange handle down against the valve case to turn off the air flow to the pressure regulator. ‘When you close the shutoff valve, you will hear a brief rush of vented air. This is the self- bleed feature of this pressure regulator. 30. Open (fully clockwise) the reservoir tank return hand valve HV 2000 to allow the water to drain from the process tank. 81. Turn off the main circuit breaker. NOTE You may see a flashing “F004” fault indication on the VFD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VED. 82. Disconnect all leads. If any of the circuits do not operate as described, contact Amatrol for assistance. PART 3.6 PRESSURE RELIEF VALVE TEST In this section, you will test the operation of the pressure relief valve. 1. Make sure the main circuit breaker is in the OFF (down) position, 2, Connect the circuit shown in figure 74, Figure 74. Control Circuit Connections (033308-AAOOUEN TSEE5-AAU Pressure Process Contol Learning Systom instalation Guide Copyright© 2014 Amat), ne 88SECTION 3 Operation and Testing Procedures This circuit will allow you to control the electric proportional solenoid inlet and outlet valves PCV 100A (PV1) and PCV 1008 (PV2), respectively, so that the process tank can be pressurized, This circuit will also allow you to use the VFD to control fluid flow in the system using the centrifugal pump. You will use the pump to put some water in the process tank. The tank ‘must contain some water to prevent air from being forced through the water ines when the tank is pressurized 3. Connect the air supply to the pressure regulator. 4, Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle back against the valve case. When you open the shutoff valve, you will hear a brief rush of vented ait. This is the setf- bleed feature of this pressure regulator. 5. Pull up the pressure regulator's adjustment knob to unlock it, turn the adjustment knob ‘counterclockwise until the gauge shows 140 kPa (20 psi), and then push down the pressure regulator's adjustment knob to lock it. 8. Close the pressure regulator's shutoff valve by pushing the top part of the orange handle down against the valve case. ‘When you close the shutoff valve, you will hear a brief rush of vented air. This is the self » bleed feature of this pressure regulator. ) 7. Tum on the main circuit breaker. ‘The HMI automatically powers up with the trainer. | NOTE Do not make any selections from the HMI's Loader screen. A. After the HMI completes its boot up, it may display a low-level alarm pop-up. If the low- level pop-up is indicated, press the Close option (X) on the alarm pop-up to remove it from the display. The low-level alarm is triggered when the water level in the process tank is below the low level switch (SL 200). B. After the alarm pop-up is closed, the Hill root screen should appear. ©. Select $1 or US units via the option in the lower right corner of the HMI’s root screen. | The VFD also automatically powers up with the trainer. After the VFD finishes its boot i up, its display should indicate the current output frequency, which is 0 Hz. If the fault indicator is flashing and a fault code appears (i.e. a value that starts with an’) on the display, download the Powerflex 4 User Manual 22A-UMOO1 from http:// } ab.rockwellautomation.com/Drives/PowerFlex-4. If the problem cannot be resolved us- | ing that manual as guidance, contact Amatrol for assistance. 1D38308-AACOUEN TS5SS-AAL) Pressure Process Control Learning System Installation Guide Copyright © 204 Amato, Ine 88SECTION Operation and Testing Procedures 8. Perform the following substeps to put some water in the process tank. The tank must contain some water to prevent air from being forced through the water lines when the tank is pressurized. The process tank must contain at least 2.5 om ( inch) of water so that itis above the level of the LSL 200 sensor, or the manual control of the electric proportional vaives will not operate. ‘A. Make sure the system's hand valves, shown in figure 75, are set as indicated in the table. HV 200A, External Source Inlet Hand Valve | Fully closed (CW) HV 2006, External Source Outlet Hand Valve | Fully closed (CW) HV 200F, Drain Hand Valve Fall closed (OW) Fully closed (CW) EXTERNAL ‘SOURCE OUTLET HAND VALVE. HV 2006 WN flow Fano contTOL waive vAvE Hva00 HV 2006 DRAIN HAND S VALVE DRAIN HAND’ ‘ : Hv 200F ‘VALVE HV : 2008, EXTERNAL ‘SOURCE INLET RESERVOIR TANK OUTLET HAND VALVE HAND VALVE HV 2008 HV 2008 Figure 75. T5555 Hand Valves B. Make sure the flow control valve FV 200 is open (not fully clockwise). C. Close (fully clockwise) the reservoir tank return hand valve HV 200D. D. Open (fully counterclockwise) the reservoir tank outlet hand valve HV 200B. E. Close pressure outlet bypass hand valve HV 100 by turning it left. The black handle should be parallel to the back of the trainer. F. Verify the Manual Control mode is selected on the HM screen. {f you need the Manual Control mode, touch the Control Mode field on the HMI and select Manual Control from the menu. ‘D32208-AADOUEN TSSSS-AAL Pressure Process Contol Leeming System inctallaion Guide Copyright © 2014 Amatal, inc. ‘90 eee ¢SECTIONS _Operaion and Testing Procacues G. From the HMI’s root screen, as shown in figure 76, select the VFD percentage command field (white box next to the VFD legend). vFD% ‘coMMAND a FIELD Figure 76. HMI Root Screen In response to that selection, the HMI's data entry screen is automatically displayed. Dios AAGOUEN TSEE6-AAL Pressure Process Cnt Learn System Istalaton Guide Copyright © 2014 Amato, Inc.SECTIONS Operation and Testing Procedures H. Use the on-screen keypad to enter a value of 100. This number represents a motor speed of 100% of its rated speed. 1. Select the Enter (+) option to save the entered value. The HMI display will return to the root screen, with 100% displayed for the VFD parameter. J. Press the green VED Start pushbutton on the VFD-PLC INTERFACE panelto start the centrifugal pump. Verify that there is flow through the system by observing the flow through the vertical rotameter Fl 200A. If there is not any flow, use the red VFD Stop pushbutton to stop the pump from trying to run. Verify that the flow valve FI 200A is open (counterclockwise). Ifitis open and there stil is no flow, the pump may need to be primed, Prime the pump as described in Part 3.2 steps 31-32. es NOTE ‘The pump should not be operated without liquid. The pump seals and pack- ing depend on the liquid being pumped for lubrication. The discharge of a centrifugal pump may be completely closed without harming the pump. However, continuous operation with a closed discharge is. not recommended because the pump may overheat, If the pump has been primed and there stil is no flow, double check that the VFD parameters are correct as described in Appendix B2. K. Observe the water level on the process tank's level sight gauge, and press the red VED Stop pushbutton when the level reaches approximately 8 cm (3 inches). L. Close (fully clockwise) the reservoir tank outlet hand vaive HV 200B. M. Double check the level in the process tank to make sure it is above the low level switch (LSL 200). If not, open the reservoir tank outlet hand valve HV 200B and repeat sub- C steps IK. 9. Verify the Manual Control mode is selected on the HMI screen. C Ifyou need the Manual Control mode, touch the Control Mode field on the HMI and select ¢ Manual Control from the mode entry screen. 10. Ifthe tank's proportional solenoid outlet valve PCV 100B valve is not being commanded to is fully closed (0%), perform the following substeps to command that valve to be fully closed (0%). If itis already commanded to 0%, skip to step 11. ¢ A. From the HMl’s root screen, select the proportional solenoid outlet valve PCV 1008 ( percentage command value field (white box next to the 100B label). In response to that selection, the HMI's data entry screen is automatically displayed ¢ B. Use the on-soreen keypad to enter a value of 0. C C. Select the Enter button (+) to save the change. The HMI display will return to the root screen with 0% displayed for PCV 100B. ¢ (083308-AAGOLIEN TS5E5:AAL Prossure Procass Contol Learning System installation Guide ¢ Copyright © 2014 Amato, nc. 2SECTIONS Operation and Testing Procedures 11, Perform the following substeps to command the tank's proportional solenoid inlet valve PCV 100A to be approximately 75% open, ‘A. From the HMI’ root screen, select the proportional solenoid inlet valve PCV 100A Percentage command value field (white box next to the 100A label). In response to that selection, the HMI's data entry screen is automatically displayed B. Use the on-screen Keypad to enter a value of 75. €. Select the Enter button (+) to save the change. ‘The HMI display will return to the root soreen with 75% displayed for PCV 100A. 12, Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle back against the valve case. When you open the shutoff valve, you will hear a brief rush of vented air. This is the self bleed feature of this pressure regulator. 18. Locate the ring on the safely relief valve, as shown in figure 77. PRESSURE RELIEF VALVE Figure 77. Pressure Reliet Valvo '953306-AAGOUEN TSS5S-AAU Pressure Process Contrat Leaining System Instalafon Guide Copyright© 20%4 Amat, Inc. 93SECTIONS Operation and Testing Procedures 14. Monitor the process tank’s pressure (value below the PT 100 label) on the HMI's root screen, as shown in figure 78. Process PRESSURE Figure 78. Hil Root Screen 'D38908-AAOOUEN TSSS5-AAU Proseue Procoss Contrl Leaning System Installation Guide Copyright © 2014 Amat Inc. of PEE ic ae te a a a aeSECTIONS Operation and Testing Procedures 18. When the tank's pressure reaches 140 kPa (20 psi), pull upward on the ring attached to the safety relief valve to manually release the pressure in the system, as shown in figure 79. MANUAL, RELEASE OF PROCESS TANKS PRESSURE Figure 79. Manual Release of Pressure Reliot Valve ‘The pressure relief valve is designed to relieve the pressure at 280 kPa (40 psi) (set pressure). The BPVC says that the manual lever must work after 75% of the set pressure. For this particular pressure relief valve, the manual release works at all pressures. Continue to pull upward on the pressure relief valve's ring until the process tank's pressure on the HMI reduces to less than 15 kPa (2 psi). In this case, the pressure in the tank begins to increase again after the manual lever is released. This would typically be the case. If the pressure relief valve releases pressure automatically because of an over-pressure in the system, some systems have additional interlocks to prevent the pressure from increasing again unti the source of the problem is fixed. 16. Open the pressure outlet bypass hand valve HV 100 by turning it right The black handle should be perpendicular to the back of the trainer, 17. Reset the percentage command for the proportional solenoid inlet valve PCV 100A to 0% on the HMI. 18. Pull up the pressure regulator's adjustment knob to unlock it, tum the adjustment knob counterclockwise until the gauge shows 0 kPa (0 psi), and then push down the pressure regulator's adjustment knob to lock it, 19, Close the pressure regulator's shutoff valve by pushing the top part of the orange handle down against the valve case to tum off the air flow to the pressure regulator. ‘When you close the shutoff valve, you will hear a brief rush of vented air. This is the self- bleed feature of this pressure regulator. 20. Open (fully clockwise) the reservoir tank return hand valve HV 20D to allow the water to drain from the process tank. 21. Tum off the main circuit breaker. Da308-AAQOUEN TSSS6-AAL Prescure Procass Control Learning System Installation Guide Copyright © 2014 Amato, ne. coSECTION 3_Qvaraton and Testing Procedures NOTE You may see a flashing *F004" fault indication on the VFD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VFD. 22. Disconnect all leads. If any of the circuits do.not operate as described, contact Amatrol for assistance. PART 3.7 PROGRAMMABLE LOGIC CONTROLLER (PLC) AND HUMAN MACHINE INTERFACE (HMI) TEST In this section, you will connect a circuit to test the basic operation of the programmable logic controller (PLC) and the human machine interface (HMI). 1. Make sure the main citcuit breaker is in the OFF (down) position. 2. Locate the connection leads and connect the circuit showm in figure 80. This circuit connects the PLC and HMI to the level and pressure components of the pro- ‘cess control system. This circuit allows you to control the proportional solenoid inlet valve PCV 100A (PV1) and proportional solenoid outlet valve PCV 100B (PV2) as well as the VED and centrifugal pump. This circuit also allows you to read the process tank pressure (PT 100) and the process tank water level (LT 200) on the HMl screen, Figure 80, Test Circuit for the PLC and HMI '038908-AAOOUEN TSSS5-AAU Pressure Process Contrl Leaning System instalation Guide Copyright® 2014 Amat, Ine. 96SECTION Operation and Tasting Procedures 3. Open (fully counterclockwise) pressure outlet bypass hand valve HV 100. oe No 2 The valve handle should be perpendicular to the back of the trainer. Connect the air supply line to the pressure regulator, if itis not already connected. . Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle back against the valve case, if itis not already open. Set the pressure regulator to 140 kPa (20 psi). . Close the pressure regulator's shutoff valve by pushing the top part of the orange handle down against the vaive case. Close (fully clockwise) the external source inlet hand valve HV 200A. Close (fully clockwise) the external source outlet hand valve HV 2006. 10. Turn on the main circult breaker. The HMI automatically powers up with the trainer, NOTE Do not make any selections from the HMI's Loader screen. ‘A. Afterthe HMI completes its boot up, it may display a low-level alarm pop-up. If the low- level alarm is indicated, press the Close option (X) on the alarm pop-up to remove it from the display. The low-level alarm is triggered when the water level in the process tank is below the low level switch (LSL 200), B. After the alarm pop-up is closed, the HMI root screen should appear. . Select SI or US units via the option in the lower right comer of the HMI's root screen. The VED also automatically powers up with the trainer. After the VFD finishes its boot Up, its display should indicate the current output frequency, which is 0 Hz. If the fault indicator is flashing and a fault code appears (i.e. a value that starts with an “F’) on the display, download the Powerflex 4 User Manual from hitp:// ab.rockwellautomation.com. If the problem cannot be resolved using that manual as guidance, contact Amatrol for assistance. (098908-AAOOUEN TSE55-AAU Pressure Process Contre Learning System Instalation Guide Copyright © 2014 Amato), in. 7SECTIONS Operation and Tasting Procedures 11. Itthere is air in either the high or low pressure lines to the differential pressure transmitter, shown in figure 81, those lines need to be bled. Also, if the level indicated on the differential pressure transmitters display differs from the level value on the process tank's sight gauge by more than approximately 1 centimeter (0.4 inch), those lines need to be bled. if no air is visible in those lines, and the DPT's level display is correct, skip to step 13. There can be air bubbles in the return line between the top of the tank and the water pipe to the right of the tank. That air does not affect the differential pressure transmitter's read- ings. The return line only provides a return path for the water and air being bled from the low-pressure line. ¢ 12. Ifthere is air in the DPT's high and/or low pressure lines, perform the bleed procedure from ( Appendix B1. a cesses Ic ROL SYSTEM | ( : C ¢ RETURN i INE « l¢ Leven ( signt t GAUGE ( ¢ i \¢ Low ! PRESSURE iC LINE | € 1¢ I High ¢ PRESSURE ‘LINE DIFFERENTIAL ¢ PRESSURE TRANSMITTER ( Figure 81. High and Low Pressure Lines on the Differential Pressure Transmitter 1033908-AAQOUEN TSS55-AAU Pressure Process Contol Learning Systom intallation Guide ( ‘Copyright © 2014 Amato, ne. 98| SECTION 3 Operation and Testing Procedures 18, Perform the following substeps to put some water in the process tank. The tank must contain some water to prevent air from being forced through the water lines when the tank is pressurized. A. Close (fully clockwise) reservoir tank return hand valve HV 200D. B. Open (fully counterclockwise) reservoir tank outlet hand valve HV 200B. C. Verify that Manual Control mode is selected on the HMI as shown in figure 82. MANUAL CONTROL MODE Figure 82. Manual Control Mode Display D. From the HMl display, select the VED percentage command option (white box next to the VFD label). 'D93808-AAOOUEN TSEES-AAU Pressure Process Contal Leaming System Installation Guide Copyright © 2014 Amato), Inc. 99SECTION 3 Operation and Testing Procedures E, In response to that selection, the HMI's data entry screen is automatically displayed, as shown in figure 83. ENTER ‘oPTION Figure 83. HMI Data Entry Seren H. Use the on-screen keypad to enter a value of 100. This number represents a motor speed of 100% of its rated speed. |. Select the Enter (+) option to save the entered value. ‘The HMI display will retum to the root screen, with 100% displayed for the VED parameter. J. Press the green VFD Start pushbutton on the VFD-PLC-INTERFACE panel to start the centrifugal pump. Verity that there is flow through the system by observing the flow through the vertical rotameter Fl 200A. If there is not any flow, use the red VFD Stop pushbutton to stop the pump from trying to run. Verify that the flow valve Fl 200A is open (counterclockwise). Ifitis open and there stil is no flow, the pump may need to be primed. Prime the pump as described in Appendix B3. 'D3908-AADQUEN TS555-AAU Preceure Procoes Control Learning System Installation Guide Copyright © 2014 Amat ine. 100)SECTION 3_ Operation and Testing Procedures seen eeERREreeeneeenee NOTE ‘The pump should not be operated without quid. The pump seals and pack. ing depend on the liquid being pumped for lubrication. The discharge of a centrifugal pump may be completely closed without harming the pump. However, continuous operation. with a closed discharge is not recommended because the pump may overheat. anIIEEEIREIRTnecemeemnme ee If the pump has been primed and there still is no flow, double check that the VFD parameters are correct as described in Appendix B2. K. Observe the water level on the process tank’s level sight gauge, and press the VFD Stop pushbutton when the level reaches approximately 8 cm (3 inches). L. Close (fully clockwise) the reservoir tank outlet hand valve HV 200B. M. Double check the level in the process tank to make sure itis above the low level switch {LSL 200). If not, open the reservoir tank outlet valve HV 200B and repeat substops 1K. ‘D3S08-AADOUEN TS565-AAU Pressure Process Control Learning System Installation Guide Copyright © 2014 Amato, ine. 101SECTIONS Operation and Testing Procedures 14, Perform the following substeps to select the PID Pressure Controi mode and sat the process tank pressure setpoint value. ‘A. Select either US or SI units located at the bottom right of the Hil display B. Press inside the field on the right side of Control Mode located on the top of the HMI display. The HMI display will change to that shown in figure 84. ‘MODE ‘SELECTIONS. ‘OPTION Figure 84, HMI Control Mode Menu ©. Select the PID Pressure Control from the control mode menu. The up & and down W arrow keys move the selection highlighting up or down one mode, respectively. The key with two up arrows moves the selection highlight to the top of the list (Le. Manual Control). The key with two down arrows moves the selection highlight to the bottom of the list (.¢, Gas Blanket Control). Desa AACCUEN TSS6-AA Pressure Process Crt Learn System iiaton Guide ‘Copytight © 2014 Amaro, Inc.SECTIONS Operation and Testing Procedures D. Select the Enter (~) option to save the contro! mode. ‘The PID Pressure Control display will appear as shown in figure 85. Figure 85. PID Pressure Control Mode Display E. If the low-pressure alarm is indicated, press the Close option (X) on the alarm pop-up to remove it from the display. F. From the HM's PID Pressure Control display, select the Pressure Setpoint (SP) box. The HMI display will change to the keypad display. G. Use the keypad to enter 105 kPa (15 psi). H. Select the Enter (+) option to save the change. ‘The HM! dispiay will automatically return to the PID Pressure Control display. 1 Select the 100A box on the PID Pressure Control display to adjust the proportional 4 solenoid inlet valve PCV 100A. ‘The HMI will change to the keypad display. 'D33906-AADOUEN TSSS5-AAL) Pressure Process Control Leaming System Installation Guide -Copytight © 2014 Amatal, Inc. 103SECTION 3_Operation and Testing Procedures J. Use the keypad to enter 60. i This sets the proportional solenoid inlet valve's position to 60% of fully open. \ K. Select the Enter (4) option to save the change. 15. Perform the following substeps to set up the PID control tuning parameters, A, Select the Tuning button on the PID Pressure Control display. The display will automatically change to that shown in figure 86. Figure 86, PID Pressure Control Tuning Display B. Select the Proportional Gain box and use the keypad to enter a gain of 25. ©. Select the Enter (+) option to save the change. The HMI display will automatically return to the Tuning display. ‘ D. Select the Integration Time box and use the keypad to enter a time of 9 seconds. E. Select the Enter (+) option to save the change. ‘ F. Select the Derivative Time box and use the keypad to enter a time of 0 seconds. ¢ {D30908-AAQQUEN TSS6S-AAU Pressure Process Contl Learning System intllation Guide € Copyright © 2014 Arata, Inc. 104anigiegoauideygnuoo yooqaoey mwa wid eUuB@gqnpjobossuideyp ‘Wews - LOLQCOCELE/ ¥ZLB SL¥ LZE JEINIED awaieg Z3NQ9 OWALNIND OGYYNOI av stoz ap aiquiandas ap seu [ap Sep ZO So} e opesaaiut jap prypifos e UP!edY!YWa9 ayUAseld e| apidxe ag 10 19P okew ap €z e35e4 ZTOZ [ep asquiandss ap To [9p onnesrsiutuupe selene owo> eyeduios ensanu ua ofeqen ‘eio8og ap {909"89"'8TO'T “ON eJUePEpN'D ap eINpe9 UOD opeayRLAP! NIMVIN OWBININD 3SOF OWAId 4002S 13 130 VOIdILY3ID STOZ 30 BUBWILA3S 3G 20 N19 109 OWINIdVHDSECTION 3 _Operation and Testing Procedures G. Select the Enter (~) option to save the change, H. Select the Back button after entering the tuning parameters, The HMI display will return to the PID Pressure Control display. 16. Close (fully clockwise) pressure outlet bypass hand valve HV 100. The valve handle should be parallel to the back of the trainer, 17. Open the pressure regulator's shutoff valve by pushing the bottom part of the orange handle against the valve case, 18, Select the Chart button at the bottom of the PID Pressure Control display and observe the minimum and maximum tank pressure, 19. Observe the maximum and minimum pressures. After the initial overshoot, you should notice the pressure settling to the setpoint value. If there is any deviation from the setpoint, you should observe that the minimum and maximum tank pressure values are very close to the setpoinf. 20. Open pressure outlet bypass hand valve HV 100 to allow pressure to vent from the tank. 21. Read the tank pressure displayed on the lower right of the chart display and close pressure outlet bypass hand valve HV 100 after the pressure drops to approximately 36 kPa (5 psi). : 22. Observe the maximum and minimum pressures. You should observe that the control system responds the same way it did in step 19. 23, Pull up the pressure regulator's adjustment knob to unlock it, turn the adjustment knob counterclockwise until the gauge shows 0 kPa (0 psi), and then push down the pressure regulator's adjustment knob to lock it. 24. Close the pressure regulator's shutoff valve by pushing the top part of the orange handle down against the valve case to turn off the air flow to the pressure regulator, ‘When you close the shutoft valve, you will hear a brief rush of vented air. This is the self bleed feature of this pressure regulator, 25. Open (fully clockwise) the reservoir tank return hand valve HV 200D to allow the water to drain from the process tank, 26. Tum off the main circuit breaker. NOTE You may see a flashing “F004” fault indication on the VD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VFD. 27. Disconnect all leads. Hf any of the circuits do not operate as described, contact Amatrol for assistance, 'D3G908-AACOUEN TSSSS-AAL Pressure Process Contol Learring Systom Instaatlon Guida Copyright @ 2014 Amato) ne. 105Viena j Installer Checklist(s) ——————— This appendix includes the following Installer Checklist: Learning System Checkist T5555-AAA Pressure Process Control Learning System Desco0s-AADQUEN, TESSS-AAU rea Prosees Cont Lenring Sytem aaton Gua ‘Copyright © 2014 Amato}, ncAPPENDIXA Installer Checklists) ‘SHIPPING CHECKLIST 42/13/2013 CUSTOMER PLEASE REPORT at” MISSING ITEMSIDAWAGED ‘COMPONENTS WITHIN 10 DAYS. CusTOMER P. [SAVE DAMAGED CARTONS IF COMPONENTS ARE 480 : ‘DAMAGED, ‘SERIAL NUMBER, ASUATROL WL NOT BERESPONSIBLE AFTER i i ) ‘TS555-AAA PRESSURE PROCESS CONTROL Office tem Check Part Use_Number_Off Qty. Number __Description 1. 1 A110504-4 PROCESS CONTROL UNIT z 2 19538 ‘SAFETY LOCKOUT HASP ) 3. 2 19539 ‘SAFETY LOCKOUT TAG 4 2 19540 PADLOCK 5 5 1 ©33308-AAQQUEN Instructor's Guide 6 1 D33308-AAQOUEN installation Guide , 7 1 M33308-AADOUEN Multimedia, T5555 } 8 1 33320XX aD Diagram | a. 4 33319.XX Instrument index ) 10. 1 33322 Lead Set Including: 4 ‘Lead, Dual Banana Stack 12 In, Red ) 6 Lead, Dual Banana Stack 24 In. Red 7 Lead, Dual Banana Stack 24 In, Black 2 Lead, Dual Banana Stack 36 In. Black 11 1 Instrument Manual Set including: ) 1 97-5046-01-588 Purp Operating Instructions 1 1@Mo11-10164-6c52 __ifferential Pressure Gauge Instructions 12, 133308 ‘Student Reference Guide i PREPARED BY. DATE (000908-AAGOUEN TSSS5-AAL Pressure Process Control Learring System Instaatlon Guide Copyright © 2014 Amato, In. 107Additional Procedure Details Appendix B1 - Differential Pressure Transmitter (DPT) Bleed Procedure for Differential Pressure Transmitter Level Sensor Differential Pressure Transmitter Display Scaling } Zero Adjustment of Differential Pressure Transmitter Appendix B2 - Variable Frequency Drive (VFD) Entry of Variable Frequency Drive Parameters Factory Rest of All Variable Frequeney Drive Parameters Fault Indications on Variable Frequency Drive Appendix B3 - Centrifugal Pump Priming the Centrifugal Pump Pump Cycling Causing Ground Fault Appendix B4 - Human Machine Interface (HMI) ‘Human Machine Interface Power Up (059306-AADCUEN TSS55-AAL Pressure Process Conia Leaming Systom Insalaton Guide Copyright © 2014 Amato, nc 108 ROR RTA RASAPPENDIX _Adaltional Procedure Detals APPENDIX B1- DIFFERENTIAL PRESSURE TRANSMITTER (DPT) | | Bleed Procedure for Differential Pressure Transmitter Level Sensor | | 1 i 1. If there is air in elther the high or low pressure lines to the differential pressure trans- miter, shown in figure Bt-1, those lines need to be bled. Also, if the level value indicated on the differential pressure transmitter’s (DPT) display differs from the level value on the process tank's sight gauge by more than about 1 om (0.4 in), those lines need to be bled. Ino air is visible in those lines and the DPT's level display is correct, the lines do not need tobe bled. There can be alr bubbles in the return line between the top of the tank and the water pipe to the right of the tank. That air does not affect the differential pressure transmitter's read- ings. The return line only provides a return path for the water and air being bled from the low-pressure line. RETURN LINE Levet, ) SIGHT me GAUGE | i Low DIFFERENTIAL PRESSURE ‘TRANSHITTER Figure B1-1. High and Low Pressure Lines and Return Line on the Differ- ential Pressure Transmitter 'D9G308-AAOOUEN TSS5S-AAU Pressure Process Control Learning System instalation Guide Copyright © 2014 Amato, in. 109APPENDIX Adeitional Procodure Dotalis 2. Ifthere is at least 8 centimeters (3 inches) of water in the tank, skip to step 4. 3. Otherwise, perform the following substeps to get water in the tank so that the differential pressure transmitters high-pressure line can be bled. Fully open (counterclockwise) reservoir tank outlet hand valve HV 2008. Fully close (clockwise) the reservoir tank return hand valve HV 200. Make sure that Manual Control mode is selected on the HML Set the VFD percentage command to 100% from the HMI. Use the green VED Start pushbutton to start the VFD's control of the centrifugal pump. ‘Onee the water level in the tank reaches about 8 centimeters (3 inches), use the red VED Stop pushbutton to stop the centrifugal pump. Close the reservoir tank outlet hand valve HV 2008, m™moOR> 2 1098008-AAOUEN TSESS-AAU Pressure Process Control Learning System Installation Guide Copyright© 2014 Amat, nc 110 aAPPENDIXB Additonal Procedure Details 4. Perform the following substeps to bleed the air from the lines between the tank and the differential pressure transmitter. # ‘A. Place paper towels or a small container under the differential pressure transmitter. Water will leak from the lines as the air is bled from them. B. If itis not already closed, close the pressure regulator's shutoff vaive by pushing the top part of the orange handle down against the valve case, C. Fully close the pressure outlet bypass hand valve HV 100. The valve handle should be parallel to the back of the system. D. On the right side of the differential pressure transmitter as shown in figure B1-2, use a flathead screwdriver to open (counterclockwise) the equalizer valve a very small amount (about 1/8 of a revolution). NOTE ; The equalizer valve must be open only a small amount (1/8 of a revolution). If itis opened too far, it allows bubbles to return to the pressure lines at the end of the bleeding procedure, WATER WILL LEAK HERE, HIGH, PRESSURE, INLET VALVE INDICATES: HIGH PRESSURE ‘SIDE Figure B1-2. Right Side of Differential Pressure Tansmitter 1032908-AAOQUEN TS556-AAL Pressure Process Conta! Leaining System Inetilaton Guide Copyright © 2014 Amatal, ine. 1MAPPENDIX B_Adeltional Procedure Details E. =o zraze ‘On the right side of the differential pressure transmitter as shown in figure B1-2, use the 33/64 inch hex wrench to partially open (counterclockwise) the high-pressure inlet valve to bleed all air from the high-pressure line, The high-pressure side of the differential pressure transmitter is marked with an “H” ‘on the yellow sticker that circles the device, ‘Some water will leak from the valve as the air is released. ‘When all of the air is removed from the high-pressure line, fully close (clockwise) the high-pressure inlet valve Fully open (counterclockwise) reservoir tank outlet hand valve HV 2008. ‘Open (counterclockwise) reservoir tank return hand valve HV 200D about halt way. This results in the handle at about 45 degrees with respect to vertical Fully open the Sway hand valve HV 200E at the top of ‘ tank by turning it up until the handle is vertical. Make sure that Manual Control mode is selected on ho HM, Adjust the VFD percentage to 100% on the HMI. Verity that flow control valve FV 200 is open (not fully clockwise). Press the green VFD Start pushbutton on the VFD-PLC Interface panel to start the centrifugal pump. (059908-AAOGUEN TSS5S-AAU Pressure Process Control Learning System instalation Guide Copyright © 2014 Amat nc 112APPENDIX B Additonal Procedure Details N. On the left sido of the differential pressure transmitter as shown in figure B1-3, use the 3/64 inch hex wrench to partially open the low-pressure inlet valve to bleed all air from the low-pressure line, (Open this valve quite a bit. ou want the air bubbles to clear from the line before the water level reaches 25 centimeters (10 inches) and the pump automatically shuts off.) WATER WILL, LEAK HERE i Low PRESSURE IWLET VALVE, i inoicares Low PRESSURE SIDE Figure B1-3. Left Side of Differential Pressure ansmitter The low-pressure side of the differential pressure transmitter is marked with an“L’ on the yellow sticker that circles the device. The air bubbles must be bled from the low-pressure line connected to the left side of the differential pressure senor. The air bubbles do not have to be bled from the return line that connects the pipe and the 3-way hand valve HV 200E with the yellow handle. if the water level reaches 25 centimeters (10 inches) and the pump automatically shuts cff, allow the water level to drain to 0 centimeters (0 inches), and then re-start this procedure from substep M. Some water will leak from the valve as the air is released. 'D33306-AAOOUEN TS55S-AAL Pressure Process Control Learning System Instaation Guide ‘Copyright © 2014 Amat, nc 113APPENDIX 8 Additional Procedure Dota °. When all of the air is removed from the low-pressure line, full close (clockwise) the low- pressure inlet valve. Use the red VFD Stop pushbuttoi to stop the centrifugal pump. Fully close the 3-way hand valve HV 200E at the top of the tank by turning it down until the handle is horizontal. On the right side of the differential pressure transmitter as shown in figure 5-7, use a flathead screwdriver to close (clockwise) the equalizer valve, \erity that the differential pressure transmitter displays a level value that is close to the water level in the tank as indicated by the sight gauge. If not, the lines may still have air bubbles and you will need to repeat the bleeding process (steps 23-25). Wipe off any water that leaked onto the back part of the differential pressure transmitter. '038308-AAQOUEN TSSSS-AAL Pressure Process Control Learning System instalation Guide Copyright © 2014 Amato, inc. 114 iCAPPENDIX 8 _Adkitional Procedure Details Differential Pressure Transmitter Display Scaling 1. Perform the following substeps to fill the tank with water. The tank must contain some water to prevent air from being forced through the water lines When the tank is pressurized. | A. Close (fully clockwise) reservoir tank return hand valve HV 200D. Open (fully counterclockwise) reservoir tank outlet hand valve HV 200B, Verify that Manual Control mode is selected on the HMI, From the HMI display, select the VED field and use the keypad to enter a VFD value of 70. Select the Enter option (+) to save the VFD % command. ‘The HM! display will return to the Manual Control display. Verify that flow control valve FV 200 is open (not fully clockwise). G. Press the green VFD Start pushbutton on the VFD-PLC Interface panel to start the centrifugal pump. H. Observe the water level on the tank level indicator and press the VFD Stop bution when the level reaches approximately & centimeters (3.0 inches). |. Close (fully clockwise) reservoir tank outlet hand valve HV 2008, : J. Verify that there is more than 3 centimeters (1.0 inch) of water in the tank before proceeding to the next step, The low level alarm is activated when the water level is below approximately 3 centimeters (1.0 inch). poof m m } 'D3a308-AAGOUEN TSSSS-AAL) Pressure Process Contr! Learning System Inetalaton Guide | Copyright © 2014 Amato, inc. 115APPENDIX Additional Procedure Dota 2. Perform the following substeps to scale the differential pressure transmitter display. A. Wipe off any water on the back part of the differential pressure transmitter. B. Remove the cover from the differential pressure transmitter cap shown in figure B1-4 counterclockwise. FRONT cap Figure B1-4. Front of Differential Pressure Transmitter 'D38508-AAOOUEN TS555-AAU Pressure Process Contra! Learning System Installation Guide ¢ ‘Copyright© 2014 Amaro, Ine. 116APPENDIX B Additonal Procedure Details | a C. Enter the setting mode by pressing the M button for more than 3 seconds. The display } should appear similar to figure B1-5. u BUTTON > ARROW BUTTON Figure B1-6. Differential Pressure Transmitter Display Functions Pressing the up and down arrow buttons will change the setting parameter values, Briefly pressing the M button will display the next parameter. D. Press the M button so that the F parameter appears on the display. E. Ifnot already set to 0, press the up or down arrow button to change the F parameler to 0. This sets a filter inside the differential pressure transmitter to smooth the analog output signal due to pressure fluctuations. F. Press the M button to display the next parameter. 'D98308-AAOCUEN TSE56-AAU Procure Process Contol Leaming System Installation Guide Copyright® 2014 Amatrl, Inc. 17APPENDIX Additional Procedure Details G. Continue setting values as they are shown in figure B1-6. F 0 Moving Average Time of Differential Pressure (seconds) A in Linear Display Mode P =183 | Minimum Diferental Pressure (nH,0) i ° Maximum Differential Pressure (nH,0) d 1 ‘Decimal Polat Postion of Diplayed Value d 00 ‘Value Displayed When Minimum Pressure js Sensod a ‘8.80R 19. | Value Displayed When Maximum Pressure is Sensed (83.8 om, 19.3 n) Al 00 Percent of Pressure Span Where 4 mA Is Fleported (95) i 100.0 - | Percent of Pressure Span Where 20 mA is Reported (2) Figure B1-6. Display Scale Parameters H. After all parameters are set, press and hold the M button to return to the measurement mode. |. Place the front cap onto the differential pressure sensor and tum clockwise. 8. Close (fully clockwise) the reservoir tank return hand valve HV 200D. 4, Run the pump and verity that the levels indicated on the process tank's sight gauge, on the differential pressure transmitter, and on the HMI next to the LT 200 label all match within approximately 1 cm (0.4 inch). ‘D&8308-AAGOUEN TSE65-AAU Pressure Process Control Learning Systom Installation Guide Copyright © 2014 Amaral, In: 118 € W| | | | | | t i APPENDIX _Addivonal Procedure Details Zero Adjustment of Differential Pressure Transmitter In the Measurement mode, if the up arrow key is pressed for longer than 3 seconds, the DPT enters the Zero Adjustment mode and shifts the zero point of the DPT to the sensed atmospheric pressure. However, the differential pressure transmitter's Zero Adjustment mode should not be selected unless both the high and low pressure ports on the DPT are open to the atmosphere. ‘These ports are not open to the atmosphere on the T8855, so this mode should not be selected on the T5555. Ifthe Zero Adjustment mode is selected when both ports are not open to the atmosphere, the accuracy of the device may be affected. Ifthe Zero Adjustment mode is selected when there is a differential pressure between the high and low pressure ports, the zero point is established based on that differential pressure, If the Zero Adjustment mode has been selected while there was a differential pressure between the high and low pressure ports, the resulting bias will cquse errors in all of the level mea- surements. The following steps should be used to remove this Bias. 1. Remove the high and low pressure lines from the differential pressure transmitter. 2. Select the Zero Adjustment mode (press the up arrow key for longer than 8 seconds). After the Zero Adjustment has been completed, the display should show “Adj? for 2 seo- ‘onds’and then should return to the regular measurement display. 3. Connect the high and low pressure lines to the differential prossure transmitter. 4. Bleed the air from the high and low pressure lines, as described in the first section of Ap- pendix B1. 'D38a08-AAOQUEN TSSBS-AAU Preseure Process Control Leaming System installation Guid Copyright © 2014 Arete, ne 119APPENDIX 8 Additional Procedure Details APPENDIX B2- VARIABLE FREQUENCY DRIVE (VFD) Entry of Variable Frequency Drive Parameters The VFD automatically powers up with the trainer. The initial display should indicate the current output frequency, which is 0 Hz, as shown in figure B2-1. FREQUENCY DISPLAY Fault OICATOR PROGRAM own aRRow mode BUTTON tnpIcaToR _ ENTER suTTON BUTTON set up ARROW suTron BUTTON Figure B2-1. VFD Power-up Display If the fault indicator is flashing and a fault code appears ([.e. a value that starts with an “F*) on the display, download the Powerflex 4 User Manual from htfp://ab.rockwellautomation.com. If the problem cannot be resolved using that manual as guidance, contact Amatrol for assistance. 1DSG006-AAGOUEN TSSEE-AAU Pressure Proness Control Learning System inetllaton Guide ‘Copyright © 2014 Amati nc. 120 RAR RRARARADDA AAA eee NAATAPPENDIX B Additonal Procedure Details A summary of the required VFD parameters are shown in the following table. Post Motor Nameplate Valls (VAC) 220 O33 ‘Motor Overload Current (A) 45 POS6 ‘Start Source 1 (B-wire control scheme) O88: ‘Speed Reference 8 (Speed source is 4-20 mA analog signal) PO3d ‘Acceleration Time (sec) 10.0 O40 Decsleration Time (sec) 50 ‘A088 ‘Maximum Voltage (VAC) 230 A089) ‘Current Limit (A) a5) ‘AOS Carrier Frequency for PWM Output (kHzy [2.0 * This is the carrier frequency for the PWM pulses. This is not the frequency command to the motor. The frequency command to the motor will be determined by the VFD based on the speed control knob’s position or the PLC's percentage command. The frequency command to the motor will be 0 Hz up to the motors rated frequency (50 or 60 Hz). ‘The following steps should be used to view or change VFD parameters. 1. On the VFD, press Sel to display the Group Parameter. The Group Parameter letter (“A", “d’, or “P* on far left of display window) should be flashing, 'D32a0e-AAGOUEN TSS5S-AAL Pressure Process Control Learning System installation Guide Copyright © 2014 amatry, nc. 124APPENDIX Addlional Procedure Details 2. _ Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to a“P", similar to figure B2-2. The P represents the Basic Program Group. BASIC 7 PARAMETER GROUP. PROGRAM MODE. INDICATOR. PARAMETER ‘NUMBER Figure B2-2. VFD with Basic Program Group ("P”) Available for Exiting 3. Press the Enter button (1) to enter the Basic Program Group. ‘The right digit on the display should be flashing. 4. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until POS1 is displayed. 5. Press the Enter button (1) to view the parameter value. 6. Check to see if the parameter value is set to 220. 1D38308-AACQUEN TSSSE-AAU Pressure Process Control Learning System Installation Guide Copyright © 2014 Amati, nc. 12210. APPENDIX 8 Additional Procedure Details If necessary, perform the following substeps to edit the parameter value. A. Press the Enter button (4) to enter the program mode. The right digit should be flashing and the Program LED should be illuminated if it is a programmable parameter. B. Press the Up Arrow or Down Arrow to change the parameter value. C. Press the Enter button (~!) to save the new value, Press the Esc button to retur to the parameter number. Repeat steps 4 through 8 to set or verity the following VFD parameter settings: 031 = 220 (motor rated voltage [VAC] P33 = 4.5 (motor overload current [Amps)) O36 = 1 (3-wire control scheme to start the drive) P0838 = 3 (Speed source is 4-20 mA analog signal) P039 = 10.0 (Acceleration time is 10 seconds) P040 = 5.0 (Deceleration time is 5 seconds) Press Esc to display the Group Parameter. ‘The parameter group menu letter should be flashing. 1033306-AAGOUEN TSSSS-AAU Pressure Process Control Learning Systam Installation Guide ‘Copytight © 2014 Amaro, no. 123,APPENDIX Additional Procodure Details 11. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to an “Be, similar to figure B2-3. ‘The A represents the Advanced Program Group. ADVANCED PARAMETER GROUP PROGRAM MODE INDICATOR PARAMETER ‘NUMBER Figure B2-3. VFD with Advanced Program Group (“A”) Available for Editing 12. Press the Enter button (1) to enter the Advanced Program Group. The right digit on the display should be flashing. 13. Repeat steps 16 through 20 to set or verity the following VFD parameter settings: ‘A088 = 230 (maximum voltage [VAC)) ‘A080 = 3.5 (maximum output current (Amps) ‘A091 = 2.0 (PWM frequency [kHz]) 14, Press Esc twice to exit parameter viewing and editing. (D93208-AADQUEN TSESS-AAL Preseure Process Control Laeming System Installation Guide Copyright © 2014 Amatral, nc. 124 Play teat AAAAPPENDIX _Adstional Procedure Detaiis Factory Reset of All Variable Frequency Drive Parameters Before attempting to reset all of the VFD’s parameter values to their factory defaults, depress the red VFD Stop pushbutton on the VFD-PLC Interface panel to make sure the VFD is not trying to command the centrifugal pump to run. Then perform the following steps to reset all of the VFD’s parameter values to their factory defaults. 1. On the VFD, press Sel to display the Group Parameter. The Group Parameter letter ("A’, “d", or P” on far left of display window) should be flashing. : 2. Press the Up Arrow or Down Arrow until the Group Parameter letter is changed to a“P”, similar to figure B2-4, The P represents the Basic Program Group. BASIC PARAMETER ‘GROUP PROGRAM: ‘MODE INDICATOR PARAMETER NUMBER Figure B2-4. VFD with Basic Program Group (‘P") Available for Editing 1D33008-AAQOUEN TSSSS-AAU Pressure Process Control Leaming System installation Guida Copyright © 2014 Amato) ne. 125APPENDIX _Addlional Procedure Deis 3. Press the Enter button (1) to enter the Basic Program Group. The right digit on the display should be flashing. 4. Press the Up Arrow or Down Arrow to scroll through the parameter numbers until PO41 is displayed. 5. Press the Enter button (1) to view the parameter value. 6. Press the Enter button (1) to enter the program mode, The right digit should be flashing and the Program LED should be illuminated if it is a programmable parameter. 7. Press the Up Arrow or Down Arrow to change the P041 value to “1”. 8. Press the Enter button (1) to save the new value. 9. _ Press the Enter button (1) to enter the program mode. 40. Press the Up Arrow or Down Arrow to change the P041 Value to “0”. 411... Press the Enter button (1) to save the new value. 12, Press Esc twice to exit parameter viewing and editing. If this factory reset is done, you must set a subset of the parameters to specific values for correct operation of the T5555, See the previous section of Appendix B for a description of how to set those specific parameters. Fault Indications on Variable Frequency Drive If.a fault indicator is flashing and a fault code appears (i.e. a value that starts with an “F’) on the VFD's display, download the Powerflex 4 User Manual from http://ab.rockwellautomation.com. If the problem cannot be resolved using that manual as guidance, contact Amatrol for assistance. NOTE You may see a flashing “F004” fault indication on the VFD as the trainer is powered down. That fault indicates an undervoltage condition, and is normal as power is removed from the VFD. (032908-AADQUEN TE555-AAU Pressure Process Contol Learning System Inetalation Guide ‘Copyrignt © 2014 Amat, nc 126 ¢ € € CAPPENDIX Additonal Procedure Details i APPENDIX B3- CENTRIFUGAL PUMP Priming the Centrifugal Pump 1. Depress the green VED Start pushbutton on the VFD-PLC Interface panel, and monitor whether there is fiow through the system by observing the flow through the vertical rota, meter F1 200A, similar to figure B3-1. (The observed flow rate will vary) If there Is flow through the system, the centrifugal pump does not need to be primed, Ifthere is not any flow, depress the red VED Stop pushbutton to stop the pump from try. ing to run. Double check the following valve settings. A. Verify that the reservoir tank outlet hand valve HV 2008 is open (fully counterclockwise). } B. Verify that the flow control valve FV 200 is open (not fully clockwise). Ifitis not very far from fully clockwise, tum it farther counterclockwise. ©. If both HV 200B and FV 200 are open and there still is no flow, the pump may need to be primed, aaunTEESSpEREEEnnn NOTE ‘The pump should not be operated without liquid. The pump seals and pack- ing depend on the liquid being pumped for lubrication. The discharge of a centrifugal pump may be completely closed without harming the pump. However, continuous operation with a closed discharge Is not recommended because the pump may overheat. Ss nnNERINNIreemeneeeeeeee ‘293206-AAOOUEN TSESS-AAL Pressure Process Control Learning System Inealation Guide Copyright © 2014 Amato, rc. 127APPENDIX Additional Procedure Dati FLOW RATE INDICATION Figure 89-1. Flow Rate Indicated on Rotameter (009908-AAOOUEN TES5S-AAU Pressure Process Control Learning System Insitation Guide Copyright © 2014 Amato), nc 128 ¢APPENDIX Additional Procedure Details 3. _ Perform the following substeps to prime the pump. A. Locate the priming nut on the left end of the pump, as shown in figure B3-2, PRIMING NUT Figure B3-2. Centrifugal Pump Priming Nut B. Use an adjustable wrench to loosen the priming nut until water is released in a steady stream (i.e, does not contain air). , Tighten the priming nut and verify that there Is flow through the system, similar to figure B3-1, Ifthe pump has been primed, and there still is no flow, contact Amatrol for assistance. Centrifugal Pump Cycling Causing Ground Faults If the centrifugal pump cycles on and off fairly fast, it may cause a ground fault on the trainer. This will result in the loss of all power on the trainer. If this occurs, reset the GFCI on the end of the trainer. Then check the values of the P39 and A091 parameters in the VFD. (See Appendix B {for a description of how to check the value of a parameter.) ‘The P039 parameter should be set to 10.0. Ifitis set to some other value, change it to 10.0, as described in Appendix B2. The A091 parameter should be set to 2.0. If itis set to some other value, change it to 2.0, as described in Appendix B2. 1D33006-AAQOUEN TRESS.AAL Pressure Process Contol Learning System Instaaton Guide Copyright © 2014 Amato}, In: 129APPENDIX Adeftonsl Procedure Dota APPENDIX B4- HUMAN MACHINE INTERFACE (HMI) Human Machine Interface Power Up The Human Machine Interface (HMl) automatically powers up with the trainer. A sequence of displays similar to figure 84-1 should be observed during the HMI’s power-up sequence. Hu LOADER Hea ROOT ‘SCREEN ‘SCREEN iam ‘ALARM POP-UP (MAY BE DISPLAYED) Figure B4-1. HMI Power-up Display Sequence ————— NOTE No adjustments should be made from the HMI's Loader screen. ee If the HMI does not progress to the root screen, contact Amatrol for assistance. If changes are attempted on the Loader screen and then the HMI does not operate correctly, ‘tum off the trainer and turn it back on. Check the HM|’s operation again. If i stil does not operate correctly, contact Amatrol for assistance. 1093908-AA0QLIEN TS5SS-AAU Presaure Process Contol Learning System instalation Guide Copyright © 2014 Amat inc. 190

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