Sensia CD20 Manuale utente

Manual No. 20165

Clif Mock

CD20 (230VAC)

Sampler Drive

User Manual

proprietary property of NuFlo Technologies, Inc. Any reproduction or use of these instructions,

drawings, or photographs without the express written permission of an officer of NuFlo

Technologies, Inc. is forbidden.

Printed in the United States of America.

Manual No. 20165011A

April 2004

April 2004 i

Table of Contents

Description ....................................................................................................................1

Installation and Wiring..................................................................................................1

Start-up Procedure........................................................................................................3

Pre-Test Procedure .....................................................................................................3

Repeat Mode Check-Out.............................................................................................3

External Input Pulse Mode Check-Out ........................................................................3

Sample Probe and CD20 Check-Out...........................................................................3

Motor Control Operation...............................................................................................4

Control Card Functions................................................................................................4

Power Board Functions ...............................................................................................4

Troubleshooting............................................................................................................5

Sampler Drive Schematic.............................................................................................7

Bill of Materials..............................................................................................................8

ii April 2004

April 2004 1

Description

The CD20-230VAC Control and Drive Assembly is engineered specifically for use with the True-Cut C-

Series sample probe. It comprises the following components:

•a motor speed control that provides both pulse input (flow-proportional) and repeat (time-

proportional) control of the sample probe. When a “start” pulse is received at the CD20 control card

input, the probe is driven 180 degrees to capture and discharge a single 1.5-ml isokinetic sample. On

a horizontal line, the probe is stopped in the closed position, while on a vertical line, the probe is

stopped in the open position.

•a DC gear motor with a gear ratio of 150:1

•a cam with two high points located opposite each other, mounted on the gear motor output shaft

•a proximity switch mounted in the hub assembly opposite the cam. When a high point on the cam is

opposite the proximity switch, a signal is output to the CD20 motor control electronics that indicates

the sample probe is at the stop and "Hold" position.

•the coupling, jam nut, and hub, which allow the CD20 Control and Drive Assembly to be mounted

directly to the C-Series sample probe. No brackets or supports are required; however, they are

recommended on pipelines with significant vibration.

•an explosion-proof housing which encloses the complete assembly. Two ¾-in.-in. NPT holes allow

connection of the 230VAC line power and input pulse (for flow-proportional sampling). Two ½-in.

breather plugs are installed on opposite sides of the enclosure.

•rotation acknowledgement or verification that the motor has rotated at least 180 degrees.

Installation and Wiring

The CD20 mounts directly to the C-Series sample probe via the DC-2 coupling. The DC-2 coupling

should be hand-tightened to ensure that the internal retaining ring is not pushed out of its groove. If the

DC-2 coupling is over-tightened at the CD20 hub, the motor shaft will not engage the DC-1 coupling on

the probe.

Use the following steps to install field wiring to the CD20-230VAC (Figure 1):

1. Connect 230VAC power to 1TB-1 and 1TB-2.

2. Connect the flow pulse input contact to 1TB-5 and 1TB-6. If an open collector transistor driver is

used, connect the collector to 1TB-5 and connect the emitter to 1TB-6 (common).

Note—The input pulse contact must be closed for at least 5 msec to produce a “start” pulse.

If an electronic square wave input is used, it must have a pulse amplitude of 12VDC. A

5VDC square wave will not work.

3. The on-board jumper E1 selects the source of “start” pulses for the CD20 control logic. For external

pulsed mode, connect jumper E1 to 1TB-3. For the repeat mode (time-proportional sampling),

connect jumper E1 to 1TB-4, as shown in Figure 1.

4. If a signal verifying the rotation of the motor is desired in a control room, connect the transistor

output contact to 1TB-8 (collector) and 1TB-9 (emitter).

Note— A +12VDC output is available at 1TB-7 for powering external flow pulse circuits such as a

turbine meter pre-amplifier. Maximum current from this supply is 50 mA.

2 April 2004

Figure 1—Field wiring of CD20 (230VAC) assembly

Figure 2—CD20 (230VAC) control card (full view)

April 2004 3

Start-up Procedure

The start-up procedure consists of four steps: a pretest, a repeat-mode checkout, an external input pulse

mode checkout, and a sample probe/control drive checkout. Each of these is described below.

Pre-Test Procedure

1. Disconnect the CD20 control and drive assembly from the sample probe.

2. Connect a push button switch across 1TB-5 and 1TB-6 for test purposes.

Repeat Mode Check-Out

1. Connect jumper E1 to terminal 1TB-4.

2. Apply 230VAC input power to the CD20-230VAC control card.

3. The repeat time potentiometer can be adjusted for off-delay times of 3 seconds to 3 minutes. Verify

that the motor rotates 180 degrees and stops for each repeat pulse. Also verify that the PROX

(“Hold”) LED is on while the motor is stopped.

4. Verify that the CD20 output shaft rotates in a clockwise direction as you look at the shaft. The

sample probe will be rotated counterclockwise (CCW) when the CD20 drive is connected to it. If

the direction of motor rotation is wrong, swap the motor armature leads at 2TB-1 and 2TB-2.

5. Verify that the I-LIMIT LED blinks on momentarily during acceleration of the CD20 motor. After

the motor reaches the 12-rpm running speed, the I-LIMIT LED should turn off.

The PROX (“Hold”) LED should be off while the motor is running and should turn on when the motor

stops. It should take about 2.5 seconds for the motor to rotate 180 degrees and stop.

External Input Pulse Mode Check-Out

1. Disconnect the 230VAC input power from the CD20.

2. Move the E1 jumper to 1TB-3 to select the external pulse input mode.

3. Connect a pulse input or switch to 1TB-5 and 1TB-6.

4. Apply 230VAC power to the CD20 control card.

5. Verify that the CD20 output shaft rotates 180 degrees for each external input pulse.

Note—Any input pulses that occur when the CD20 is running are disregarded by the control logic. To be

registered by the control logic, the input pulse must have a duration of 5 msec or longer and it must occur

when the CD20 motor is stopped and the PROX (“Hold”) LED is on.

Sample Probe and CD20 Check-Out

1. Disconnect power from the CD20.

2. Mount the CD20 to the sample probe and hand-tighten the DC-2 coupling.

3. Verify that the product line is full and pressurized.

4. Hold a 100-ml graduated beaker under the probe’s discharge and collect 10 samples. Each sample

should be 1.5 ml in size; therefore, the total volume for 10 samples should be 15 ml.

4 April 2004

Motor Control Operation

The CD20 motor control assembly consists of a control card and power board mounted to a ring, which in

turn, is mounted to the back of the CD20 gear motor. All field connections are to terminal block 1TB on

the control card. The motor and proximity switch connections are made at the factory to terminal block

2TB on the power board.

Control Card Functions

When an input pulse from either the repeat mode timer or an external pulse source is received, a speed

command is output to rotate the motor. Armature feedback controls the speed of the motor at about 12

rpm and current feedback limits motor current to 3 amperes.

The proximity switch input amplifier provides the signal to stop the motor.

The I-LIMIT LED is on when the drive is in current limit mode, which is normal during acceleration.

The PROX (“Hold”) LED is on when the motor is stopped.

Power Board Functions

The CD20 power board provides the following functions:

•Fuse F1 (1-amp, type AGC) provides short circuit protection. It will open if there is a short in the

primary or secondary of transformer T1.

•Transformer T1 converts the 230VAC input to 14 VRMS secondary power when primary jumper W3

is installed.

•Diodes CR2, CR3, CR4, and CR5 provide full-wave rectified DC voltage for use in driving the

motor.

•Transistor circuits including Q1, Q2, and Q4 provide the basic speed control and drive for the CD20

gear motor, which has a 9VDC armature and pm field.

•Power Fet Q3 is on when the RUN/STOP latch is commanding the motor to stop. Q3 provides

electronic braking of the motor to minimize coast past the desired probe stopping point.

•Resistor R5 is the current-sensing resistor for the current limit switch.

•Regulator U1 provides +12VDC for the control card.

April 2004 5

Troubleshooting

Problem Probable Cause Recommended Action

Transformer T1 has an internal

secondary winding or primary

winding short.

Replace T1 or power board. To verify short in

transformer, you must unsolder leads from the

power board and measure winding resistance.

Secondary resistance is 3 ohms. Primary windings

are about 20 ohms each.

Rectifier diode CR2, CR3, CR4,

or CR5 shorted. Check diodes with an ohmmeter and replace or

change power board or CD20 motor control.

Input power fuse F1 is

open.

Input power transformer jumper

is installed incorrectly. Check for jumper across 230VAC to Neutral.

Sample probe jammed or the

motor armature is driving the

probe backwards (CW) against

the cam drop off point.

To isolate the problem, power down and remove

the CD20 from the probe and verify CD20 output

shaft turns CW as you look at it in repeat mode.

Verify sample probe can be turned CCW with a

screwdriver and proper discharge is obtained.

Short across A1 to A2 of CD20

motor output due to a short in

power FET Q3.

Power down, remove motor leads, and verify that

when power is reapplied, the current limit light is

off. Then check motor armature resistance to verify

the short circuit. If motor circuit checks out, replace

CD20 motor control assembly.

Bind-up in gear box. Replace 150:1 ratio gear motor.

Bind-up due to alignment of

adapter plate or hub. Remove adapter plate and hub from gear motor.

Turn on control and see if gear motor will run. If so,

realign and reinstall adapter plate and hub.

Current limit LED is on,

the motor is stopped.

Transistor Q4 or Q2 has failed. Replace CD20 assembly or CD20 power board.

Motor overload. Remove drive from sample probe and run. If the

motor still runs slow, then remove motor from hub

and adapter plate and run.

Current limit LED is on,

motor runs at a slow

speed.

CD20 current limit circuit failure. Replace CD20 motor control.

Input power not on. Check for proper input voltage at 1TB-1 and

1TB-2.

Fuse clips corroded and F1 is

not making contact or fuse F1 is

open.

With power off, check fuse F1 continuity from

1TB-1 through the F1 fuse clips.

Motor does not run.

Jumper E1 is not connected to

1TB-3 or 1TB-4. Connect E1 to 1TB-3 for pulsed mode operation or

1TB-4 for repeat mode operation.

Motor circuit open or leads not

connected to 2TB-1 and 2TB-2. Verify motor wiring. Verify motor impedance by

disconnecting the motor leads and check for an

open armature.

Transistor Q4 or Q2 has failed. Replace CD20 assembly or CD20 power board.

6 April 2004

Problem Probable Cause Recommended Action

Motor does not run

(cont’d). Input pulses are not present at

1TB-5 and 1TB-6. Use a separate switch input to verify the CD20 is

operating correctly in pulse mode. Use a portable

oscilloscope to verify proper pulse input.

In the case of an electronic

driver, the input pulses at 1TB-5

and 1TB-6 do not have a

+12VDC pulse amplitude due to

incorrect wiring.

Check for proper wiring (Figure 1).

Proximity switch is not sensing

the high points on the cam. Check proximity switch and cam alignment.Motor continues to run.

The PROX (“Hold”) LED

never comes on. CD20 motor control failure. Replace CD20 motor control assembly.

Motor runs at full speed

or faster continuously. Output transistor Q4 has failed. Replace Q4 with an MJE 3055 or replace the

CD20 motor speed control.

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