INSTRUCTION MANUAL FOR DD-01 DIGITAL DIVERT CONTROL SYSTEM VERSION 4.1. WITH MAIN PROGRAM 8.5 OR HIGHER
WARNING The process medium may be hot or otherwise hazardous. Precautions when removing the sensor from the process line: Make sure that the process line is not under pressure. Open a vent valve to the atmosphere. For a retractor/isolation valve the line pressure should be within specifications. For a prism wash system, close a hand valve for the wash medium and disable the wash valve. Loosen the clamp or flange bolts cautiously, be prepared to tighten again. Be out of the way of any possible splash and ensure the possibility of escape. Use shields and protective clothing adequate for the process medium. Do not rely on avoidance of contact with the process medium. After removal of the sensor, it may be necessary to mount a blind flange for security reasons.
Document/Revision No. IMD 1/5
Effective: June 20, 2005
This product manual is delivered to the end-user with a K-Patents product. Information in this manual is subject to change without notice. The latest manual version is freely available at http//www.kpatents.com/. You can also contact
[email protected]. THE PASSWORD FOR PR-01-S IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.
K-PATENTS OY
K-PATENTS OY
K-PATENTS,INC.
Postal address: P.O. Box 77 FIN-01511 Vantaa, Finland
Street address: Elannontie 5 FIN-01510 Vantaa, Finland
1804 Centre Point Circle, Suite 106, Naperville, IL 60563
Tel. + 358-9-825 6640 Fax +358-9-825 66461 E-mail:
[email protected] http://www.kpatents.com/
Tel. + 358-9-825 6640 Fax +358-9-825 66461
Tel. 630-955 1545 Fax 630-955 1585 E-mail:
[email protected] http://www.kpatents.com/
1
1. TABLE OF CONTENTS
1
TABLE OF CONTENTS........................................................................................................................1
2
GENERAL INFORMATION .................................................................................................................2 2.1 Digital divert control system DD-01 .................................................................................................2 2.2 Operator panel...................................................................................................................................3 2.3 Alarms ...............................................................................................................................................4 2.4 Prism wash ........................................................................................................................................4 2.5 Master divert control unit..................................................................................................................5 2.6 Indicating transmitters.......................................................................................................................6 2.7 K-Patents digital divert control unit specifications............................................................................7
3
MOUNTING...........................................................................................................................................8 3.1 Wiring ...............................................................................................................................................8
4
START-UP ...........................................................................................................................................12 4.1 Divert control unit start-up ..............................................................................................................12 4.2 Divert control system trimming.......................................................................................................12
5
CALIBRATION....................................................................................................................................13 5.1 Refractometer concentration measurement .....................................................................................13 5.2 Refractometer activation for divert control .....................................................................................13 5.3 Signal difference alarm ...................................................................................................................14 5.4 Low alarms......................................................................................................................................14 5.5 Refractometer malfunction alarm ....................................................................................................14 5.6 Prism wash ......................................................................................................................................14 5.7 Divert decision rules........................................................................................................................15
6
MAINTENANCE .................................................................................................................................17 6.1 Information flow..............................................................................................................................17 6.2 Divert control circuit boards ...........................................................................................................18 6.3 Diagnostic messages........................................................................................................................23 6.4 Diagnostic lights..............................................................................................................................23 6.5 Push-button assembly......................................................................................................................24 6.6 Fuses................................................................................................................................................24
7
DIVERT CONTROL LOGIC ...............................................................................................................25 7.1 Block diagram .................................................................................................................................25 7.2 Logical diagrams .............................................................................................................................26 7.3 Safety Decision Logics....................................................................................................................28
8
OPTIONAL CONFIGURATIONS.......................................................................................................30 8.1 Remote divert control unit...............................................................................................................30 8.2 Equipment .......................................................................................................................................30 8.3 Remote divert control unit in the control room ...............................................................................31 8.4 Wiring and mounting.......................................................................................................................32 8.5 Serial output ....................................................................................................................................34 8.6 Current output signal .......................................................................................................................34 8.7 External DC power supply ..............................................................................................................34
9
DIVERT CONTROL UNIT PARTS LISTS.........................................................................................35 9.1 Divert control unit and optional remote divert control unit.............................................................35 9.2 Remote divert control unit...............................................................................................................36
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
2
2. GENERAL INFORMATION The K-Patents Digital Black Liquor Divert Control System DD-01 provides a divert signal preventing black liquor with dangerously low solids to reach the black liquor burners. The system is built strictly according to the principles of Recommended Good Practice "Safe Firing of Black Liquor in Black Liquor Recovery Boilers" (BLRBAC August, 1982 and revisions April, 1991, and March, 2001). 2.1. DIGITAL DIVERT CONTROL SYSTEM DD-01
Figure 2.10
Complete Digital Divert Control System DD-01
The system consists of the following parts (Figure 2.10): Two K-Patents Process Refractometers PR-01-S (A & B) are installed in series in the main black liquor line. Each refractometer is complete with a Sensor, an Indicating transmitter and Interconnecting cables. Each refractometer provides also a 4-20 mA % solids output signal not used by the divert control system. The Divert Control Unit DD-01 is contained in one enclosure with the same dimensions as the refractometer Indicating transmitter enclosure. The control unit includes: an operator panel control logics contact outputs for prism wash, warnings, alarms and black liquor diversion Two isolation valves HIMP-2 (optional) for the refractometers above to allow removal of the refractometers from a pipe with full flow and pressure. The isolation valve includes a prism wash nozzle and two check valves (one for prism wash, one for stuffing box flush). A roofed mounting plate to mount the two Indicating transmitters and the Divert Control Unit together. Two steam valves with steam traps for prism wash (pneumatic + solenoid valves). Two hand valves (one for prism wash, one for stuffing box flush). One alarm horn (supplied by the customer). Note. BLRBAC (The Black Liquor Recovery Boiler Advisory Committee) recommends a spare sensor to be maintained in stock on-site. INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
3 2.2. OPERATOR PANEL
3
7
4 5
Figure 2.20
6
The operator panel.
The operator panel has a clear layout and the operator can see all information at one glance. The divert decision is controlled from the operator panel which provides doubled security, since all information is simultaneously shown both as LED indication in the Divert Control Unit and as a diagnostic messages in the Indicating Transmitters (Figure 2.20). Each refractometer has a green OPERATING light (1), so the operator knows when he can rely on the refractometer measurement. A refractometer will influence the divert decision only when the green OPERATING light is on. A malfunctioning refractometer is automatically taken out of operation. One green indicator light SAFE% SOLIDS (2) is based on the two refractometers and the divert decision rules (Section 5.7). One red DIVERT light (3) that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light indicates divert status of the divert relay. The divert relay has an output switch contact, for use in the Black Liquor Firing Tripping Logic. The relay is OFF in the DIVERT position, because a power failure will give a DIVERT decision. A lockable OVERRIDE/AUTOMATIC switch (5) and a red OVERRIDE warning light (4) is ON always if switch in OVERRIDE position. If the SAFE% SOLIDS goes OFF and this switch is in the OVERRIDE position, then the OVERRIDE light is lit instead of the DIVERT light. One RESET push-button (6) for the DIVERT action. The DIVERT action always has to be manually reset. If the override switch is in Automatic position and SAFE% SOLIDS is off, the DIVERT action cannot be reset. One EMERGENCY DIVERT push-button (7) to manually initiate DIVERT in an OVERRIDE or emergency situation. The DIVERT light is lit also after manual divert action. The EMERGENCY DIVERT button has a protective hinged cover, to prevent inadvertent use. Two indicator lights (8) for the divert valve status TO BY-PASS/TO BURNER from microswitches on the valve. For intermediate valve positions both lights are off. A row of four alarm lights (9) that indicate black liquor SOLIDS WARNING (at 60%), black liquor SOLIDS ALARM (below 58%), refractometer reading more than 2% absolute difference and refractometer malfunction.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
4 A light test button (10) switches all 11 lights on. An alarm reset button (11) resets the alarm lights. For normal operation the operator panel has four green lights on (A OPERATING/B OPERATING/ VALVE TO BURNER/SAFE% SOLIDS). 2.3. ALARMS The divert control system has four alarms, audible and indicating: 1. 2. 3. 4.
Black liquor SOLIDS WARNING, yellow light (60% or below) Black liquor SOLIDS ALARM, red light (58% or below) Refractometers reading more than 2% absolute DIFFERENCE, yellow light Refractometer MALFUNCTION, yellow light
The alarms 1, 2 and 4 are initiated by either refractometer. System contains also optional alarms, see wiring drawing 3.11. The operator panel contains four indicator lights and an ALARM RESET button. The reset button will silence the audible alarm, but the visual indication will remain until the condition has returned to normal. To avoid unnecessary alarms the following interlocks are implemented: -
A refractometer can initiate an alarm only when it is operating. Alarm 4 can be initiated only if both refractometers are operating.
The parameters (2%, 58% and 60%) are default settings, which can be changed from the Indicating transmitter keyboard (Sections 5.3 and 5.4). The parameter for 2% can be decreased and the parameter for 58% and 60% can be increased. 2.4. PRISM WASH For K-Patents Process Refractometer, the need of prism wash is reduced and even in some cases eliminated. The prism keeps clean due to the probe design features: -
The prism is flush mounted in a surface deflecting the black liquor main flow, which causes a strong mechanical cleaning action.
-
The prism has the same temperature as the black liquor.
In any case, however, an automatic regular prism wash provides an efficient check that the refractometer reacts. A steam wash of 3 seconds every half hour should be sufficient. Automatic single (one-of-two) diversion will occur if either of the refractometers is in wash cycle. The Divert Control Unit contains two relays for prism wash, WASH A and WASH B. To follow the BLRBAC recommendation not to wash both prisms at the same time, there is an interlock. If both refractometers try to wash simultaneously, one will display "WAIT" and perform the wash when the other has finished. K-Patents recommends to use a steam trap instead of preconditioning valve to remove condensate from the steam line. The wash times can be seen pressing soft keys "Display"/"System configuration"/"Wash times". To change the wash times, see Section 5.6.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
5 2.5. MASTER DIVERT CONTROL UNIT
Figure 2.50 indications.
Operator’s panel and functions of the master divert control unit in the field with LED
1. Black liquor SOLIDS WARNING (at 60%), Black liquor SOLIDS ALARM (below 58%), Refractometer reading more than 2% absolute difference, and Refractometer malfunction). 2. Each refractometer A and B has an OPERATING green light, A refractometer will influence the divert decision only when the green OPERATING light is on. A malfunctioning refractometer is automatically taken out of operation. 3. One green indicator light SAFE% SOLIDS, based on the two refractometers and the divert decision rules. 4. A red OVERRIDE warning light is on always if the override switch is switched on.
INSTRUCTION MANUAL FOR DD-01
5. One red DIVERT light that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light indicates divert status of the divert relay. 6. Two indicator lights for the divert valve status. TO BY-PASS/TO BURNER from microswitches on the valve. For intermediate valve positions both lights are off. 7. A lockable Override/Automatic divert switch 8. A DIVERT RESET push-button. 9. An EMERGENCY DIVERT push-button. 10. A light test button switches all 11 lights on. 11. An alarm reset button resets the alarm lights.
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
6 2.6. INDICATING TRANSMITTERS An Indicating transmitter in a Divert Control System is identical (both hardware and software) to a standard transmitter described in the PR-01-S Instruction manual.
1
3 2
A
C ONC
°C P R O C E S S T E M P E R A T U R22.1 E T E S T 109.3 In d iv e r t c o n tr o l o p e r a tio n R em oved S ta r t fr o m d iv p r is m C a lib r a te c o n tr o l wash
A
Figure 2.60
B 8
9
4
5
6
1
2
3
0
.
-
4
D
C
7
5 D is p la y
K -PT E N T S P R O C E S S IN S T R U M E N T S
ENTER
RESET
The Indicating transmitter.
The display, Figure 2.60, will give the following additional information pertinent to the Divert system: 1. A or B in the upper right corner indicates that the transmitter is OPERATING in the divert system as refractometer A or B, Figure 2.10. If a or b is displayed instead, the refractometer is removed from divert control operation. (If the upper right corner is empty, see Section 5.2). For A or B the corresponding green OPERATING light, Figure 2.20, is on, for a or b it is off. If you see a ? in this corner, see Section 5.2. 2. A softkey (B) defined by "Remove from divert control" or alternatively "Restore to divert control". The visible effects of pressing "Remove" for refractometer A is that the soft key changes to "Restore", A switches to a, and the green OPERATING light goes off. Further the "Remove" soft key disappears from refractometer B, because B must not be removed if it is the only refractometer in operation. Note. Always press "Remove" for a refractometer before making service or switching the power off.
INSTRUCTION MANUAL FOR DD-01
3. The "Normal operation" message is substituted by "In divert control operation" or "Removed from divert control". Those messages may change to "Solids warning" or "Solids alarm" at low solids. An additional error message may occur: ** Divert control fault ** combined with a ? in the upper right corner, see Section 6.3. 4. The softkey "Display" (D) leads via "System configuration" (C) to "Divert control system" (D) which gives the following information: Refractometer difference alarm limit in % solids Solids warning limit in % solids (default value 60%) solids alarm limit in % solids (default value 58%) Divert rule and SW1/SW2 positions (Section 5.7) 5. The softkey "Calibrate" (C) gives possibilities to set up for divert control and calibration, see Chapter 5.
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
7
2.7. K-PATENTS DIGITAL DIVERT CONTROL UNIT SPECIFICATIONS Model:
DD-01
Enclosure:
IP66 Nema 4X, dimensions 226 x 267 mm (8.91 x 10.5 in)
Supply:
24 V DC, provided by the Indicating transmitters
Ambient temperature:
max 45 °C (113 °F)
Accessory:
Roofed mounting plate for the Divert Control Unit and 2 Indicating transmitters, Figure 2.60.
Material:
AISI 316, dimensions 916 x 488 mm (36 x 19.2 in)
Figure 2.70
Divert Control Unit Mounting Plate: Dimensions (mm/in)
Figure 2.71
Divert Control Unit and Indicating Transmitter Enclosures: Dimensions (mm/in)
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
8
3. MOUNTING For mounting of the process refractometer and the isolation valve, consult the separate Refractometer PR-01-S(-EX/FM) Manual. 3.1. WIRING Wiring for the complete system, see Figure 3.10 and Figure 3.11 which describe also all cables and how each cable is connected. The cables 1 and 2 are included in the delivery. The terminal strip positions of the Divert Control Unit are specified in Figure 3.11 and Figure 3.12.
Figure 3.10
Divert Control System Wiring Cables and Connections
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
9
Figure 3.11
Divert Control System Wiring and Connections
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
10
Figure 3.12
Cable connections
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
11
RN2
SW 12345678
C16
X2
IC8
IC25
IC21 C38
IC27
D13
K2
8 9 10 11 12 13 14
8 9 10 11 12 13 14
15 16
SERIAL BUS A
SERIAL BUS B
EXT24V
D17 D18
D23
D24
D25 R23
D26 R24
C49
R21 R22
D27
1A
RE1
V1
18
LN
SGND
R28
D30 RE2
19
AC-POWER
RE3
RE4
V4 V3
K5
17
D28 C51 R27
C50 R25 R26 D29
TP4
D31 V2
K4
C41 R12 R13 C42
R16
D2
F2
C40
D14 K3
IC30 L1
R11
RN7
D12
D9
TP3
C26
IC22 R9
C36
SWGND
R15
R14
IC19
C25 D16
R10
D8
K1
IC16
F1
D11
D20 D21 D22 C48 D19 R17 R18 R19 R20
C47
IC23
D7
C35 C52
IC29
IC13
C21
RN5
C33 C34
IC26
D6 D10
1A
C46
D5
C22
D15
C43
C31
R8 C30
C37
C23 1
IC11
C29
IC14 C44
C32
IC18
R7
RN6
IC28
C24
IC12
C19 C20
D1 C45
J2
C27 X1IC17 C28
RN4
GND
IC24
IC5 IC15
D4
IC20
IC4
D3
IC9
C14 IC1
TP2
C13
IC7
IC10
J1
C7
C18
C1 R2 C2 R3 C3 R4 C4 R5 C5 R6 C6
R1
C15
IC6
RN1
+5V
C39
C11
C17 SW1
IC3
C10
TP1
CONTROL UNIT
C12
IC2
C9
C8
PR-7310 Rev.C DIVERT
RN3
K-PATENTS
K6
20 21
22 23
WASH A
WASH B
RE5 V6
K8
RE7
RE8
V8
V5 K7
RE6
V7 K9
V9 K10
K11
K12
D32 63mA
63mA
F3
F4 K13
K14
VALVE 35 36 POSITION37 38 39 40 BYPASS BURNER HORN SOLIDS SOLIDS NORM. OVERRIDE REF.DIFF. WARN. ALARM DIVERT 24 25
26 27
28 29 30
31 32
33 34
DANGER HIGH VOLTAGE Figure 3.13
Divert control circuit board, layout.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
12
4. START-UP For refractometer start-up consult the separate Refractometer PR-01-S(-EX/FM) Manual and the Mounting and start-up check list. 4.1. DIVERT CONTROL UNIT START-UP 1.
Check the wiring and supply voltage. Note: Before the power is switched on, the DIVERT output relay is in DIVERT position.
2.
Switch the power on for both Indicating transmitters. The control system is now in the DIVERT mode, and the red DIVERT light is on.
3.
Press the LIGHT TEST button. All eleven lights should switch on.
4.
The upper right corner of the Indicating transmitter displays should now state a or b respectively. If not, see Section 5.2. If the message is "Removed from divert control" the refractometer is ready to "Restore to divert control", softkey B. If the message is "Solids warning" or "Solids alarm" then "Restore" provokes an alarm. Press the ALARM RESET button. For any other message, see Section 6.3.
5.
Observe that the VALVE STATUS lights follow the position of the valve. Now the Divert Control System is set for normal monitoring operation.
6.
Check that the prism wash is working. Press the "Start prism wash", softkey A.
7.
When the SAFE % SOLIDS has turned on and also the other conditions for safe boiler operation are satisfied, the DIVERT can be turned off using the RESET button.
4.2. DIVERT CONTROL SYSTEM TRIMMING During the trimming of a new system, it is recommended to keep the key in the OVERRIDE position. When the key is in the OVERRIDE position, the DIVERT action has to be initiated manually using the EMERGENCY DIVERT button. This should be done when the green SAFE %SOLIDS light turns off. The trim procedures are described in Chapter 5, the measurement calibration in Section 5.1 and the prism wash in Section 5.6. The key should be turned to the AUTOMATIC position only after it has been decided that sufficient experience has been gained.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
13
5. CALIBRATION The K-Patents Divert Control System is calibrated by the manufacturer. This chapter contains instructions how to make the fine adjustment of the system. 5.1. REFRACTOMETER CONCENTRATION MEASUREMENT For refractometer calibration consult also the separate Refractometer PR-01-S(-EX/FM) Manual. The CONC% displays of the two Indicating transmitters have to show the same value. If there is a difference, this can be eliminated by changing the Bias for one of the refractometers. Key in the sequence Calibrate / Parameters / CONC(RI) / Parameters / Bias. Comparison with sample determination can decide which one should be corrected. Example: If the Indicating transmitter of A displays CONC% = 63.2% and B displays CONC% = 63.8%, the difference can be eliminated e.g. by lowering B by 0.6%. Read bias from the display of refractometer B. If bias = 52.923 then enter a new bias = 52.323. Due to its digital measurement principle, the readings of the K-Patents Process Refractometer do not drift by time. Frequent recalibrations based on off-line moisture analysis must be avoided, as they will introduce random fluctuations to the refractometer readings. If the concentration reading is noisy, the damping can be increased. Enter Calibrate / Parameters / CONC(RI) / Damping time. The Damping time is the time in seconds for the signal to reach half of its final value after a step change. Increase the damping time in small steps, and wait for the result. 5.2. REFRACTOMETER ACTIVATION FOR DIVERT CONTROL When a refractometer is activated for Divert control, the upper right corner of the display shows alternatively A, a, B, b or ?. If the corner is blank the divert function must be activated by pressing the sequence Calibrate/Parameters/Divert control/Divert control and select "1 Activated". The program has to be version 4.0 or higher, otherwise "8 Divert control" is missing from the CALIBRATE menu. The program EPROM has then to be changed to an up-dated version. The decision to display A (a) or alternatively B (b) is not programmed, it depends on to which SERIAL BUS port in the Divert unit (Figure 3.13) the Indicating transmitter is connected. If a Divert activated refractometer is used in another type of application, the divert function has to be deactivated by selecting "0 Not activated". After de-activation all references to Divert functions disappear except "8 Divert control" in the CALIBRATE menu. Note. If a message DIVERT CONTROL FAULT and a ? appear on the IT-R display, the reason is one of the following: 1.
Cables between the IT-R and the terminals 8-14 on the DD-01 are not properly connected. Reconnect to fix.
2.
Communication 485 component IC 17 (A) or IC 19 C (B) is broken on the PR-7310 board inside the DD-01. Replace board.
3.
Communication 485 component IC 1r is broken on the PR-7010 board inside the IT-R. Replace board.
4.
Dip switch 3. is in the “up” position which means that the PR-7310 card is configured to work in the remote mode. Change the dip switch back to low (=off) position.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
14 5.3. SIGNAL DIFFERENCE ALARM According to BLRBAC, if a difference of 2% solids (absolute value) or greater exists between refractometer readings, an alarm shall be activated. The alarm limit 2% can be changed from the keyboard using the sequence Calibrate/Parameters/Divert control/Ref. difference limit. If the deviation alarm trips seem too frequent, it may help to increase the signal damping, Section 5.1. Note. If the two refractometers have different limit values, the lower value is used by alarm system. 5.4. LOW ALARMS The low alarm limits are set from the keyboard of the Indicating transmitter. Enter sequence Calibrate/Parameters/Divert control. The menu will show “3 Low conc warning limit” and “4 Low conc divert limit”. The latter has a double function: Both LOW SOLIDS ALARM and DIVERT limit. The Indicating transmitter display will carry the messages “Solids warning” and “Solids alarm” when the corresponding alarms occur. Note. The alarm limits are set separately for the two refractometers. Each refractometer gives an alarm according to its own settings. 5.5. REFRACTOMETER MALFUNCTION ALARM The built-in intelligent diagnostics of K-Patents Process Refractometer provides a tight control of the operation. A full test cycle is completed with an interval less than one second. A description of the microprocessor implemented diagnostics is given below. For details consult the Instruction Manual of the refractometer PR01-S. Only errors classified as Equipment malfunctions will cause alarm and removal from the Divert control system. Process related faults will only cause a message in the Indicating transmitter display. See also Section 6.3 for additional diagnostics. The most important test is to check the signal coming from the digital image sensor during measurement. Improper function of light source, optical components, image sensor and sensor driver are recognized by this test. The compensation for temperature measurement is checked, both the temperature element and the A/D converter. The cable between Sensor and Indicating transmitter is checked using a check sum method, thus recognizing short circuits, open circuits and excessive disturbances. The microprocessor system has also a self-checking test program to ensure the proper operation of the CPU and the memories. The constants in the EEPROM memory are tested to be within strict limits of acceptance. The performance of the microprocessor is of critical importance for the measurement control. A separate hardware watch-dog circuit ensures the proper microprocessor operation by checking that the microprocessor regularly sends out a predetermined pulse sequence. Another hardware circuit checks that the supply voltage to the microprocessor is within safe limits, to prevent any brownout stray output pulses. 5.6. PRISM WASH A prerequisite for a proper function of the divert system, is that the prism wash works. The TEST value in the display should increase at least 20 steps during WASH, provided TEST is not close to its maximum value 248. See Sections 8.1, 8.5 and 9.2 in PR-01-S Instruction Manual.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
15 WASH TIMES The wash times can be seen by pressing Display/System configuration/Wash times. The values set at delivery are the following: Preconditioning = 0 seconds Wash time = 3 seconds Recovery time = 30 seconds Interval = 20 min The wash times are changed by pressing the sequence Calibrate/Parameters/Prism wash. Note maximum wash time is 30 seconds and maximum recovery time 30 seconds. WASH CHECK This function can be defined from the prism wash menu: Calibrate/Parameters/Prism wash/Wash test. A prism wash is accepted if: a.
TEST exceeds “TEST limit”
b.
TEST increases more than “TEST difference”
The default values of “TEST limit” and “TEST difference” are zero (0), which makes the wash check inactive. If the wash is not accepted, the diagnostic message will be “Prism wash failure”. A “Wash retries” parameter can also be set to repeat the wash if the wash check fails. The default value is zero (0). WASH STOP Wash stop function can be defined from the prism wash menu. Wash can be prevented when the process temperature is below the set limit, thus indicating that the pipe is not in use. To activate the “wash stop” key sequence: Calibrate/Parameters/1. Prism wash/Wash stop/1. Active and set the temperature limit. The default value for wash stop is inactivate. When the wash is not accepted the diagnostics message is “Wash stop/temp. limit”. EXTERNAL WASH STOP An input switch can be configurated to an external wash stop to prevent the prism wash when the corresponding input switch is connected. “External wash stop”-message will show when automatic wash is activated from the soft keys. The input switch can be set to protect the refractometer e.g. if the process is stopped. AUTOMATIC SINGLE DIVERSION CONTROL DURING PRISM WASH CYCLE Automatic single (one-of-two) diversion control will take place if either of sensors are in prism WASH cycle. 5.7. DIVERT DECISION RULES TWO REFRACTOMETERS IN OPERATION: BLRBAC states the following: For the solids measurements, two refractometers in series must be used. When both refractometers are in service, the requirement for an automatic black liquor diversion can be satisfied by either of the following options: 1.
If either refractometer reads dissolved solids content 58% (default) or below, an automatic black liquor diversion must take place.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
16 2.
When both refractometers read dissolved solids content 58% (default) or below, an automatic black liquor diversion must take place.
Either option is satisfactory. The rules are listed in decreasing order of security. Only rule 1 satisfies the high safety requirements set by BLRBAC, August, 1982. On the other hand, the probability of false trips decreases with decreasing safety. It means that if false trips are too frequent, the rule 2 may be preferred at the cost of safety. The rule 2 has later been accepted by BLRBAC. A third conceivable alternative is to base the decision on only one refractometer (the master) and use the other refractometer (the slave) for comparison only (and difference alarm). Concerning security and false trips, this rule is a compromise between rules 1 and 2. The divert decision rule is selected by the switch SW on the divert control board (Figure 3.13). ON position is upwards.
Switch SW SW1 SW2 OFF OFF ON OFF OFF ON ON ON Table 5.70
Rule One-of-two (BLRBAC) A master, B slave B master, A slave Two-of-Two
Rule 1 Rule 2
Divert decision rule selection.
ONLY ONE REFRACTOMETER IN OPERATION: When only one instrument is IN OPERATION the divert action takes place if this instrument reads 58 % or below. The status of SW (Table 5.70) has no influence on the divert decision in this case. NO REFRACTOMETER IN OPERATION: If both instruments are out of operation (due to malfunction or maintenance), then according to BLRBAC divert action must take place. See also Section 8.7 about external DC supply. REMOTE DIVERT SWITCH CONFIGURATION Switch SW SW 3 OFF ON
Rule DD-01 normal operation Remote divert card activated See Section 8.8.
See Section 5.2 if you have on the screen the message DIVERT CONTROL FAULT.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
17
6. MAINTENANCE As the Divert Control System is a pure digital system, no special maintenance is needed. The LIGHT TEST button on the operator panel (Figure 2.50) sends a signal to the microprocessor, and the microprocessor switches all 11 LED lights on as long as the button is pressed. This way not only the lights but also the processing system is checked. To assist the identification of a faulty component, the information flow and the circuit diagrams are given in Sections 6.1 and 6.2. Also the logic diagrams of Chapter 7 may be of help. 6.1. INFORMATION FLOW The power and information flow of the total Divert system is shown by Figure 6.10. Additional information about the cable connections is found in Figures 3.10, 3.11 and 3.12.
Figure 6.10
Information and power flow.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
18
6.2. DIVERT CONTROL CIRCUIT BOARDS The component lay-out of the divert control circuit board is shown by Figure 3.12 and the circuit diagram by Figures 6.20 to 6.25.
Figure 6.20
Operator panel board, component layout.
Figure 6.21
Operator panel PR-7311 circuit diagram, page 2 of 2
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
19
Figure 6.22
Operator panel PR-7311 circuit diagram, page 1 of 2.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
2
TXD0 RXD0
TXD1 RXD1
INT1
+5V
1
R8
3K32
2
1
10R0
6 WDI 1 2 VCC
+5V
GND 3 48
RESET
C25
2 100n
1
7
10K0
R7
IC18 MAX699
2
RN1 1
+5V
32.0MHz
X1
C26
RN4
1
1 1 1 1 1
2 100n
C24
6 8 7 9 5
1
C22
2 100n 2 100n
1
10K0
RN5 RN5 RN5 RN5 RN5
RN5 2
10K0
RN5
1 RN5 4 1 3
10K0 1 RN4 4 1 6 1 RN4 5 RN4 3 1
C23
+5V
2 100n
1
14 VCC Osc. 1 N.C. OUT 8 7 GND
1
+5V
P2.7 P2.6 P2.5 P2.4 P2.3 P2.2 P2.1 P2.0
INT4 INT3 INT2 INT1 INT0
T0IN T0OUT T1IN T1OUT
HOLD HOLDA NCS ERROR PEREQ
RESIN PDTMR NMI TEST READY
2 22 43 63 VSS 65 84
1 23 VCC 42 64
A19 A18 A17 A16 AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8 AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0
UCS LCS P1.7 P1.6 P1.5 P1.4 P1.3 P1.2 P1.1 P1.0
RESOUT S2 S1 S0 ALE BHE RD WR DEN DT LOCK
83 82 81 80 79 77 75 73 71 69 67 62 78 76 74 72 70 68 66 61
30 29 19 20 21 24 25 26 27 28
38 8 9 10 6 7 4 5 11 16 15
CLOCKOUT 44
80C186EB
51 52 CTS0 TXD0 53 RXD0
49 50 54 56 55 59 58 57
35 34 33 32 31
46 45 48 47
13 12 60 3 39
37 36 17 14 18
41 CLKIN 40 OSCOUT
IC15
16bit MICROPROCESSOR
+5V
AD19 AD18 AD17 AD16 AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8 AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0
SRLY ISOSW SSER2 SDISP
RESOUT
RESET
AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0
AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8
AD19 AD18 AD17 AD16
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
74HC573
1 OC 11 C 2 1D 3 4 2D 3D 5 4D 6 5D 7 6D 8 7D 9 8D
IC10
74HC573
1 OC 11 C 2 1D 3 2D 4 5 3D 4D 6 5D 7 6D 8 7D 9 8D
IC7
74HC573
1 OC 11 C 2 1D 3 2D 4 3D 5 6 4D 5D 7 6D 8 7D 9 8D
IC3
19 18 17 16 15 14 13 12
20 10
19 18 17 16 15 14 13 12
20 10
19 18 17 16 15 14 13 12
20 10
C9
C13
C18
A7 A6 A5 A4 A3 A2 A1 A0
2 100n
1
+5V
A15 A14 A13 A12 A11 A10 A9 A8
2 100n
1
+5V
A18 A17 A16
2 100n
1
+5V
A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
A18
A0
C8 14
HC32
1
IC2
38 37 36 35 34 33 32 31 29 28 27 26 25 24 23 22 21
3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19
11 30
40
11
8
6
O15 O14 O13 O12 O11 O10 O9 O8 O7 O6 O5 O4 O3 O2 O1 O0
27C210
NC A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0
2 20 CE OE 39 PGM
IC8 +5V 1 VPP
13
HC32
1
12
IC2
9
HC32
1
IC2
10
5 7
2 100n 4
1
64K x 16bit EPROM
INSTRUCTION MANUAL FOR DD-01 C14
AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8 AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0
2 100n
1
+5V
A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
1 26 2 23 21 24 25 3 4 5 6 7 8 9 10
IO8 IO7 IO6 IO5 IO4 IO3 IO2 IO1
55257
A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0
IC4
55257
IO8 IO7 IO6 IO5 IO4 IO3 IO2 IO1
IC5
A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0
20 CE 22 OE 27 W
1 26 2 23 21 24 25 3 4 5 6 7 8 9 10
20 CE 22 OE 27 W
32K x 8bit SRAM
Figure 6.23 32K x 8bit SRAM
+5V
AD7 AD6 AD5 AD4 AD3 AD2 AD1 AD0
100n
C10
+5V
AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8
2 100n
C11
+5V 1
AD0-15
A0-9
19 18 17 16 15 13 12 11
14
28
19 18 17 16 15 13 12 11
14
28
RD WR
20
Divert control board PR-7310 circuit diagram. Page 1 of 3.
DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
10 12 14 40 44 46
SSER2 RESOUT
RD WR
A1-3
1 2 3 4 5 6 7 8
2
16 15 14 13 12 11 10 9
R25
EMERGENCY DIVERT
DIVERT RESET
OVERRIDE
1
100n 2
D30
ALARM RESET
1
1
C50
R28
3K3
3K3
SA5.0
LAMP TEST
SW8
SW1
2
1
2
2
R27 2
1
500R
SA5.0 2
D31
1 1N4007
2
D29
1 F4
2
C51
R6
2
1 TP4 2
2 100n
1
1
D28
2
D27
1
1
2
SWGND TEST POINT
R5
R4
C6
+5V
1
R3
C5
1
2
1
C4
1
1
1
C2
R1
2 100R1 1
C3
R2
C42
2 100n
1
C41
2 100n
1
+5V
1
C1
KN6
KN5
KN4
KN3
KN2
KN1
RD
ISOSW
2 2 2 2 2 2 100n 100n 100n 100n 100n 100n
1
1
2
2
+5V
7
VO2 6 GND 5
VO1
VCC
HCPL2731
3 4 22+
1 1+ 2 1-
IC29 8
4 VCC 1 GND
NME0505D
5 VOUT 7 0V
KN1 KN2 KN3 KN4 KN5 KN6
AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 A1 A2 A3
DIP8 DIP7 DIP6 DIP5 DIP4 DIP3 DIP2 DIP1
D0 D1 D2 D3 D4 D5 D6 D7
1
1 74HC05
1
8
9
7
21
2
X2 15 DTR 16 RTS 6 TXD 5 INT 13 RXD RI 10 CTS 14 11 DSR 12 DCD
X1
VSS
VCC
IC23
20 RD 19 18 WR CS 17 RESET
22 A0 23 24 A1 A2
25 26 27 28 1 2 3 4
IC9
20 1 & G1 EN 19 10 G2 18 2 Y1 A1 17 3 Y2 A2 16 4 A3 Y3 15 5 A4 Y4 14 6 A5 Y5 13 7 A6 Y6 12 8 A7 Y7 11 9 A8 Y8 HC541
IC6
1 20 & G1 EN 19 10 G2 18 2 Y1 A1 17 3 Y2 A2 16 4 A3 Y3 15 5 A4 Y4 14 6 A5 Y5 13 7 A6 Y6 12 8 A7 Y7 11 9 A8 Y8 HC541
IC1
82510
AD0-15
J1 J1 J1 J1 J1 J1
1N4007 2 D32 1
X14 2
X14 1
BURNER
X13 2
X13 1
R26 2 1
C40
2 100n
1
RN2
1
1
RN1 1 7
RN2 1
500R 3K32
RN2 1 9
RN1 1 6
7 RN2 1 1
6
RN1 1
4
RN2 1
3
8
5 RN1 1
Opto-isol.
RN2 1
5
RN1 1
RN2 1
4
2
RN2
1 F3
2 1 3K32
2 1 1K
BYPASS
1K
R13 2 R12 1
IC28 DC/DC conv. C7
C12
9
C17
1 74HC05
1
IC23
INT1
2 100n
1
+5V
AD15 AD14 AD13 AD12 AD11 AD10 AD9 AD8
2 100n
1
+5V
AD0-18
AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7
2 100n
1
+5V
8
C16
11
C15
1 74HC05
1
IC23
CTS
RXD
TXD
RTS
1
13 7
100n 2 10
C38
9 12 6 15 5 16 2 19
20 10
2 100n
1
+5V
C31
2 33pF
1
18.432MHz 1 2
X2
C37
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q HC273
2 100n
1
+5V
1D 2D 3D 4D 5D 6D 7D 8D
IC20
1 R CLR 11 C1 CP
AD0 8 AD113 AD2 7 AD314 AD4 4 AD517 AD6 3 AD718
2 33pF
1
HC32
C28 D4
12
HCPL2731
GND
VO2
VO1
VCC
IC26
5
6
7
8
3 24 2+
HCPL2731
GND
VO2
VO1
5
3
1 74HC05
1
IC23
1
IC23 1 74HC05
5 VOUT 7 0V
1 1+ 2 1-
IC24 VCC
3 24 2+
IC23 14
1
2
NME0505D
1 1+ 2 1-
5
6
7
8
+5V
D3
+5V
1k00
IC27 DC/DC conv.
1
2
4 VCC 1 GND
2 100n
1
1 74HC05
1
RN7
1
1K0
3
2
RN1
2
Opto-isol.
WR
5 1 RN7 1 4 RN7 1 3 RN7 1 2
RN3 1 3
RN3 1 2
Opto-isol.
3
RN6
1K0 2 1 RN6 1 4
IC2
C52 2 100u
1
TP3
C33
TXDI
RXDI
11
10
12
6
5
13
C35
4
2
RTSI
1
2 100n
1
5VSER
2 100n CTSI
SA5.0
D9
LTC485
5
6
7
8
C30
C1+
T
T
C2-
C2+
C1-
R
R
VCC +9V -9V OFF GND
8
9
15
14
17 3 7 18 16
2 100n
1
2 100n
IC25 LT1180
DO GND
DE
DO
VCC
C27
1
1
D6
1
1
C34
SGND
SD
RD
UARTS
UACTS
2 100n 2 100n
1
3 K2A
4 J2
1 J2
2 J2
3 J2
6 J2
5 J2
(10)
1 K2A (8)
2 K2A (9)
B
3 K1A (10)
1 K1A (8)
2 100n
1
A 2 K1A (9)
C32
SER1+
D5 2 SA5.0 SA5.0
D8
SER1-
2 SA5.0 SA5.0
C36
2
1
2
D7
SER0+
5
SER0-
6
1
+5V
7
8
+5V
GND
DO
DO
VCC
LTC485
IC17
IC19
DI
DE
RE
RO
4 DI
3
RE
RO
4
3
2
1
1 SGND 2 TEST POINT
2
2 100n
TXD1
2
1
TXD0
RXD0
RTS
D12
1
1
2
1
C39 1
6
4
5 RN3 1 1k00
2 D10
RN6
1
2 10R0 1
1 4
RN3 3 RN6 1 5 1
INSTRUCTION MANUAL FOR DD-01 R11
Figure 6.24 POWER
RESET
21
Divert control board PR-7310 circuit diagram. Page 2 of 3.
DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
.
1
J1 47 J1 49
A (14) K1C 2 B (14) K2C 2
(16) K3 2
(15) K3 1
(11) K2B 1 B (12) K2B 2 (13) K2C 1
P
GND
EXT24V
SR224V
2
VIO24V
11
8
6
3
SR124V
HC32
IC16
13
HC32
1
IC16
14
HC32
1
IC16
12
10 7
(11) K1B 1 A (12) K1B 2 (13) K1C 1
.
2 100n
1 C21
9
5
WR
+5V
4
SDISP
RESET
1
2
HC32
IC16
1
2
AD8 AD9 AD10 AD11 AD12 AD13 AD14 AD15
AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7
AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7
1
2
1
1
2
D17
D16 2 1 1N4007
IC14
1 CLR 11 CP 3 1Q 1D 4 2Q 2D 7 3Q 3D 8 4Q 4D 13 5Q 5D 14 6Q 6D 17 7Q 7D 18 8Q 8D HC273
1 CLR 11 CP 3 1D 1Q 4 2D 2Q 7 3D 3Q 8 4D 4Q 13 5D 5Q 14 6D 6Q 17 7D 7Q 18 8D 8Q HC273
IC11
IC21
1 CLR 11 CP 3 1D 1Q 4 2D 2Q 7 3D 3Q 8 4D 4Q 13 5D 5Q 14 6D 6Q 17 7D 7Q 18 8D 8Q HC273
D11 D13 D14
1
2
1
R16 4K7
SRLY
R9 4K7
. .
.
2
1
2 1 1N4007 1N4007 D18
1 .
1A
.
F1
2 5 6 9 12 15 16 19
20 10
2 5 6 9 12 15 16 19
20 10
2 5 6 9 12 15 16 19
20 10
.
2
.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+
1 C48
.
Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7
1 C49
.
.
+
18 17 16 15 14 13 12 11
18 17 16 15 14 13 12 11
2 2u2 .
SS FRC OSC 15 11 14
1 C43
.
IC30
15K0 1 C46
.
GND
.
.
13 12
FB 10
VOUT 2
2 33n 2 2n2
1 C47
.
4 5
L4962
7 VIN
ULN2803A
D0 D1 D2 D3 D4 D5 D6 D7
RE1 RE2 RE3 RE4 RE5 RE6 RE7 RE8
10 VIO24V DCOM GND 9
IC13
ULN2803A
D0 D1 D2 D3 D4 D5 D6 D7
18 17 16 15 14 13 12 11
VIO24V
DCOM 10 VIO24V GND 9
IC12
ULN2803A
D0 D1 D2 D3 D4 D5 D6 D7
DCOM 10 GND 9
IC22
2 SA26 2 100u 2 33nF
1 D15
.
VIO24V
2 100n
1 C20
.
+5V
.
2 100n
1 C19
.
+5V
.
2 100n
1 C29
.
2
L1 150uH
4K64
.
2 BYV27/50
1 D2
.
+
.
.
.
C45 2 220u
1
1
+
WARN
.
C44 2 220u
1
.
OUT8
OUT7
OUT6
OUT5
OUT4
2
1
TP1 +5V
D1
TEST POINT
1 2
TP2 GND
TEST POINT
1 2
39 J1
38 J1
36 J1
37 J1
35 J1
32 J1
30 J1
28 J1
29 J1
27 J1
26 J1
25 J1
22 J1
20 J1
21 J1
19 J1
SA5.0
+5V
BURNER
VBYPASS
DIVERT
OVERRIDE
SAFE
BOPER
AOPER
MALFUNC
REFRDIF
ALARM
RE1-8
RE8
RE7
RE6
RE5
RE4
RE3
RE2
RE1
VIO24V
2 2 1 R24 4K7
AD0-18
1 R15 2
. .
.
R10 2 4K7 1
1 R14 2
D19
D20
D21
D22
D23
D24
D25
D26 1
8
5
8
12 5
9 8
5
8
5
8
5
8
5
16
1
16
1
16
1
16
1
16
1
16
1
16
8
5
8
1
16
5
. . . .
1 2 2 1 R23 4K7 1 2 2 1 R22 4K7 1 2 2 1 R21 4K7 1 2 2 1 R20 4K7 1 2 2 1 R19 4K7 1 2 2 1 R18 4K7 1 2 2 1 R17 4K7 1
V9 V8 V7
RE8 RE7 RE6 RE5 RE4 RE3 RE2 RE1
2 1 2 1 2
. . . . . .
1 2 1 2 1 2
. . . . . .
1 2 1
V5 V4 V3 V2 P
N
L
V1
INSTRUCTION MANUAL FOR DD-01 . .
Figure 6.25 2 1
+5V
.
F2 1A
V6 2
.
1
3 K4
2 K4
1 K4
2 K5
A WASH
2 K6 1 K5
B WASH
2 K7 1 K6
LINE
SOLIDS WARN.
2 K8 1 K7
SOLIDS ALARM
2 K9 1 K8
DIVERT/NORM
2 K10 1 K9 3 K9
HORN
2 K11 1 K10
REF. DIFF
2 K12 1 K11
NO MALF.
1 K12
22
Divert Control board PR-7310 circuit diagram. Page 3 of 3.
DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
23 6.3. DIAGNOSTIC MESSAGES For diagnostic messages in the Indicating transmitter display, see the PR-01-S manual. The following messages appear only in divert systems: -
"In divert control operation" or "Removed from divert control", Section 2.6.
-
"Solids warning" and "Solids alarm", Section 5.4.
-
** Divert control fault **
This message indicates that there is no communication to the divert control unit, probably cable error, Figure 3.12, cable 2. If the instrument is not applied in a divert control system, de-activate the divert function, see end of Section 5.2. Further the message ** Relay unit fault ** may appear. This indicates that the Relay unit PR-7080 functions are defined, but no Relay unit is connected. Normally a Relay unit is not used in a Divert system because the wash contacts are in the Divert control unit. Clear the relay functions by the key sequence Calibrate/Relay unit and select an "0 Not Defined" for all four relays. For using an optional relay unit, see PR-01-S Manual, section 9.1. 6.4. DIAGNOSTIC LIGHTS The Divert circuit board, Figure 3.12, contains the following diagnostic LEDS: D3
Processor cycles: should flash
D4
Processor reads serial bus: should flash
D10
Serial bus A input: should flash
D11
On if 24 V DC supply from A is OK
D12
Serial bus B input: should flash
D13
On if 24 V DC supply from B is OK
D14
On if external 24 V DC is applied
D19
Wash relay A on
D20
Wash relay B on
D21
Solids warning relay on
D22
Solids alarm relay on
D23
Divert relay on = not DIVERT (Section 2.2)
D24
Horn on
D25
Refractometer difference relay on = difference alarm
D26
Override
D27
Valve to bypass
D28
Valve to burner
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
24
6.5. PUSH-BUTTON ASSEMBLY Before removing the push button or the lockable Override/Automatic switch from the front panel turn the screw 1/4 to the left, Figure 6.50. This will release the contact element.
Figure 6.50
Securing and removal of the contact element.
6.6. FUSES The following fuses are printed on circuit board PR-7130: Fuse F1:
Microfuse IEC 127-3/1
DC Power (24 VDC) main fuse. Protects UL 198G 1A, fast divert electronics againts wrong voltages especially from external DC supply.
Fuse F2:
5 x 20 mm fuse IEC 60127, 1A, fast
AC supply to solenoid valves. Protects cable and coil, if faults appear.
Fuses F3, F4:
Microfuse IEC 127-3/1,
Fuses protect switch of divert valve position UL 198G 63 mA, fast feedback. Any external voltage connected to these circuits causes fuse blow.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
25
7. DIVERT CONTROL LOGIC A logical description of the system is provided as a complement to the previous information about the electronics. 7.1. BLOCK DIAGRAM The block diagram Figure 7.10 shows the connections between the different logical subsystems.
Figure 7.10
Block diagram of the divert control system
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
26 7.2. LOGICAL DIAGRAMS
Figure 7.20
The operation logics.
Figure 7.21
The divert decision logics.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
27
Figure 7.22
The alarm decision logics.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
28
Figure 7.23
The alarm system.
7.3. SAFETY DECISION LOGICS The logical description of the Safety Decision Logics in Figure 7.10 is given by the following tables: - Table 7.30 One - of - two - Table 7.31 A master, B slave - Table 7.32 Two - of - two Note. NOT OPERATING includes the wash cycle. See also Section 5.7. A 58
One-of-two decision rule
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
29
A 58
OPERATING
NOT OP
OPERATING
NOT OP
58 OPERATING
Unsafe
Safe
Safe
Safe
NOT OP
Unsafe
Unsafe
Safe
Unsafe
A master, B slave A 58
OPERATING
NOT OP
OPERATING
NOT OP
58 OPERATING
Safe
Safe
Safe
Safe
NOT OP
Unsafe
Unsafe
Safe
Unsafe
Two-of-two decision rule
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
30
8. OPTIONAL CONFIGURATIONS
8.1. REMOTE DIVERT CONTROL UNIT The remote divert control unit is an option of the digital divert control system DD-01, see Figure 8.20. The remote divert control unit operates as a main unit, which means that the master divert unit is for indication only. If the remote divert control unit is not in operation, the master divert unit in the field operates as a main unit. The remote control unit communicates with the master divert unit in the field through a modem. Connection and wiring is made according to Figure 8.40. For contact terminals see Figure 8.41. Contact terminals 24 and 25 are for communication OK signal. 8.2. EQUIPMENT
Figure 8.20
Complete remote divert control system.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
31 8.3. REMOTE DIVERT CONTROL UNIT IN THE CONTROL ROOM
Figure 8.30
Operator’s panel and functions of the remote divert control in the control room.
The remote divert control unit contains all information for the deviation decision. The operation is clearly indicated with LED lights as follows:
1. A row of four alarms (indicating Black liquor SOLIDS WARNING (at 60%), Black liquor SOLIDS ALARM (below 58%), Refractometer reading more than 2% absolute difference, and Refractometer malfunction). 2. Each refractometer A and B has an OPERATING green light, so the operator knows when he can rely on the refractometer measurement. A refractometer will influence the divert decision only when the green OPERATING light is on. A malfunctioning refractometer is automatically taken out of operation. 3. One green indicator light SAFE% SOLIDS, based on the two refractometers and the divert decision rules. 4. A red OVERRIDE warning light. 5. One red DIVERT light that will be switched on when the SAFE% SOLIDS goes off, providing OVERRIDE is off. The DIVERT light indicates divert status of the divert relay.
INSTRUCTION MANUAL FOR DD-01
6. Two indicator lights for the divert valve status. TO BY-PASS/TO BURNER from microswitches on the valve. For intermediate valve positions both lights are off. 7. A lockable Override/Automatic switch. 8. One RESET push-button for the DIVERT action. The DIVERT action always has to be manually reset. If the override swithc is in automatic position and SAFE% SOLIDS is off, the DIVERT cannot be reset. 9. EMERGENCY DIVERT push-button. 10. A light test button switches all 11 lights on. 11. An alarm reset button resets the alarm lights. 12. Communication to MASTER DIVERT ok, indication light blinking. 13. Power supply ok, indication light on. Note when remote divert in use, master divert unit in the field is for indication only!
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
32 8.4. WIRING AND MOUNTING For wiring of the complete system, see Figure 8.40, which also specifies the cables and connections.
Figure 8.40
Digital Divert Control System with Remote Divert Control Unit Wiring.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
33
Figure 8.41
Remote Divert Control Unit terminals.
Figure 8.42
Digital Divert Control System: Remote Divert Control Unit mounting.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
34 8.5. SERIAL OUTPUT Each Indicating transmitter has a serial output not used by the Divert Control unit. This serial output is selectable RS-232/RS-485 (see PR-01-S Manual) and contains concentration, temperature and error data. It contains also information whether the refractometer is in divert operation or not. Possible uses of the Serial output: To communicate with a computer substituting the Divert Control unit. 8.6. CURRENT OUTPUT SIGNAL Each Indicating transmitter provides a 4-20 mA output concentration signal not used by the Divert system. To calibrate this signal for suitable %Solids range, press Calibrate/Output signal/Current output, see PR-01-S Manual. 8.7. EXTERNAL DC POWER SUPPLY The Divert Control unit may be connected to a DC power supply as a back-up. At AC power failure the refractometers will black-out, but the Divert Control unit will still work. In this case the DIVERT signal can be prevented by turning the key to OVERRIDE. Terminals are 15 (+24VDC) and 16 (ground). The power requirement is 24 VDC, 500 mA. 8.8. DIVERT CONTROL UNIT CARD IN THE REMOTE UNIT In the remote unit the divert control card the third dip switch SW3 must be in the ON position (“up”). See Figure 3.13 and Sections 5.2. and 5.7.
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
35
9. DIVERT CONTROL UNIT PARTS LISTS
9.1. DIVERT CONTROL UNIT AND OPTIONAL REMOTE DIVERT CONTROL UNIT
ltem 1 1.1
Pcs. 1 7
Part No.
2. 3.1 3.2 3.3
1 1 1 1
PR-7310
4 5
1 1
PR-7028 PR-7311
Description Enclosure Conduit hubs 1/2” NPT-Type ST-1 (US) Divert Control Unit Card Modem transformer Modem card Modem cable Ribbon cable LED Display card
INSTRUCTION MANUAL FOR DD-01
Item 6.1 6.2
Pcs. 2 1
Part No. PR-6551 PR-6551
6.3
1
PR-6551
6.4
1
PR-6552
7.
1
PR-6501
Description Switch unit, green Switch unit, red for Emergency divert Switch unit, green for Emergency divert reset Lock unit for Automatic/Override divert operation Divert Fuse set: 9 fuses (3 x Microfuse 1A, fast IEC 1273/1, UL 198G; 3 x 5x20mm Fuse 1A, fast; 3 x Microfuse 63 mA, fast IEC 127-3/1, UL 198G) DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005
36 9.2. REMOTE DIVERT CONTROL UNIT
ltem
Pcs.
Part No.
Description
6.1 6.2 6.3
2 1 1
PR-6551 PR-6551 PR-6551
6.4
1
PR-6552
8.1 8.2 8.3
1
Switch unit, green Switch unit, red for Emergency divert Switch unit, green for Emergency divert reset Lock unit for Automatic/Override divert operation PR-7310-RACK RACK-modem RACK Power 24V
1
INSTRUCTION MANUAL FOR DD-01
DOCUMENT/REVISION: IMD 1/5 Effective: June 20, 2005