CLIF MOCK CD30A Sampler Drive IOM
Contents
1. De NuFlo Clif Mock CD30A 175VAC Sampler Drive User Manual es INTRINSICALLY SAFE FOR USE IN HAZARDOUS ENVIRONMENTS CLASS I DIV 1 GROUP D de NuFlo Measurement Systems A NuFlo Technologies Company Manual No 20165024 Rev B 2004 NuFlo Technologies Inc All information contained in this publication is confidential and 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 All Rights Reserved Printed in the United States of America Manual No 20165024 Rev B October 2004 Table of Contents RN LION EE EE Eeer EE ee Repeat Time Scaling A ee ee eege ee ie ee ege EE een Installati n and Wiring irs Eeieenbietg Pre Test Procedure E Repeat Mode hee EE eier d e ee el eli weet External Input Pulse Mode Check Out Sample Probe and CD30A Check Out een Motor Control Ope ratio msnccisictcsstacatecnccccdesnaranauciacedeessassnansnaasdduceassceusaauendecccusdavenauncucudus Command Board Functions E Power Board Functions wi eege eege ee ee Interconnect Board PUNCHONS EE PRG Pali S icici acccccitancucnewe A A A E Billek ssaacssiaassistieisnnsahasavouctedcauandaasiustteinanealeimausiudaweunieanmuaabanaresctenwesdatanalsdenenees Sampler Drive Schematic coc cciscssecsseceseceeeesdesntecedewedesneeansasedawedessensevasnsecedacecedednansasndnens2. Singapore 877 891 6540 Calgary 65 6737 0444
3. 1 2 3 4 1 234 9 9 9 9 9 999 An internal sample command is generated when the CD 30A sample command board counts a number of flow pulses equal to the number set on the switches Repeat Time Scaling The repeat mode utilizes a 1 Hz clock signal in lieu of the external flow proportional pulses to pace the sample probe The X1000 X100 X10 and X1 switches allow direct repeat time settings in seconds Some repeat time switch setting examples are shown below Repeat Time Switch Setting Examples Switch Settings Time Between Samples X1000 X100 X10 X1 0 0 0 3 3 Seconds Max Time 0 0 1 0 10 Seconds 0 1 0 0 100 Seconds 1 0 0 0 1 000 Seconds 1 2 3 4 1 234 Seconds 9 9 9 9 9 999 Seconds The repeat mode time proportional sampling can be used as a test mode and a backup for the external input pulse mode flow proportional sampling 2 October 2004 Installation and Wiring The CD30A mounts directly to the C Series sample probe via the DC 2 coupling The DC 2 coupling should be hand tightened only to ensure that the internal retaining ring is not pushed out of its groove If the DC 2 coupling is over tightened at the CD30A hub the motor shaft will not engage the DC 1 not shown coupling on the probe Use the following steps to install field wiring to the CD30A 115VAC 1 Connect 115VAC 50 60 Hz power to 1TB L 2 Connect the neutral wire to 1TB N 3 Connect the ground wire to 1TB G Figure 2 4 Select the pulsed or repeat m
4. in NPT holes allow connection of the 115 VAC 50 60 Hz line power and input pulse for flow proportional sampling A Y in breather plug is installed on one side of the enclosure and a 1 2 in conduit plug is installed on the opposite side of the enclosure The motor speed control unit allows the user to select pulse input flow proportional or repeat time proportional control of the sample probe Figure 1 Figure 1 Red switches labeled X1000 X100 X10 and X1 allow selection of pulse input flow proportional or repeat time proportional control of the sample probe October 2004 1 Pulse Input Scaling The best flow pulse input is an open collector NPN transistor or open drain FET transistor If a relay contact is used as the flow pulse input it must have a low level electronic signal rating A power rated contact will not work reliably over time If a flow pulse input with source current capability is used a signal that has one logic level referenced to DC voltage and the other logic level referenced to common the voltage requirements are e Maximum DC peak voltage 24 VDC e Minimum DC peak voltage 10 VDC The four pulse scaling switches labeled X1000 X100 X10 and X1 Figure 1 allow selection of the desired number of flow pulses per sample Some switch setting examples are shown below Pulse Input Switch Setting Examples X1000 X100 X10 X1 Pulses Per Sample 0 0 0 1 1 0 0 1 0 10 0 1 0 0 100 1 0 0 0 1 000
5. select the repeat mode 3 Set the X1 switch to 5 4 5 Set the X10 X100 X1000 switches to 0 This sets a 5 second repeat cycle time Connect a pushbutton switch customer supplied between 2TB 2 and 2TB 3 for test purposes Make sure the filter jumper is in place between 2TB 1 and 2TB 2 Repeat Mode Check Out 1 2 3 Apply 115VAC input power to the CD30A Verify that the PROX Hold LED is on when the motor is not turning After the CD30A off delay time verify that the output shaft turns in a CLOCKWISE CW direction as you look at the shaft The sample probe will then be rotated COUNTERCLOCKWISE CCW when the CD30A is connected to it If the direction of motor rotation is wrong swap the motor armature leads at 3TB 1 and 3TB 2 Figure 4 Verify that the CD30A output shaft rotates 180 degrees and stops after each off delay period It should take about 2 5 seconds for the motor to rotate 180 degrees and stop The PROX Hold LED should be off while the motor is running and turned on when the motor stops External Input Pulse Mode Check Out 1 2 3 Disconnect AC input power from the CD30A Connect the jumper between 2TB 4 to 2TB 5 to select the external input pulse mode Set switch X1 to 1 October 2004 4 Set the X1000 X100 and X10 switches to 0 This selects a sample output for each input pulse 5 Reapply AC power to the CD30A 6 Push the pushbutton switch to s
6. October 2004 October 2004 Description The CD30A Control and Drive Assembly Part No 50132381535 is engineered specifically for use with the True Cut C Series sample probes The assembly is certified by CSA as intrinsically safe for use in hazardous environments Class I Div 1 Group D 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 CD30A control card input the probe is rotated 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 9VDC 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 the PROX Hold LED will be illuminated This signal indicates the sample probe is at the stop and hold position a coupling jam nut and hub which allow the CD30A Control and Drive Assembly to be mounted directly to the C Series sample probe No brackets or supports are required but they are advisable on pipelines with some vibrations an explosion proof housing which encloses the complete assembly Two 4
7. VE 50142150932 DRIVE COUPLING ASSY DC 2 50142307695 DRIVE SHAFT 50142381667 COUPLING CAM MOTOR ASSEMBLY 50142309906 PROXIMITY SWITCH El 08 01 NACS 50142307686 ADAPTER PLATE 50142304632 PLUG 1 2 CONDUIT 50142307696 SNAP RING 50142382015 TAG ELECTRICAL CD 30A 50025400765 DRIVE SCREW 2 x 3 16 50142307693 BINDER HD SCREW 8 32NC x 1 2 LG 50142307694 WASHER HUB SCREW 8 50142304642 BREATHER 1 2 PLUG 50142200109 CAUTION TAG 50142304858 HUMISORB PACKET 107HX 4 x 4 _ a4 _ k A LI sch October 2004 Command card 19000 1390 Interconnect card 19000 1420 Power wires Motor PROX switch wires Signal wires Interconnect card Mounting plate Power and signal wires Motor wires PROX switch wires A Electrical Warning Route wires as shown in slots and hours provided in mounting plate and interconnect card to prevent electrical shorting to enclosure A Grounding wires G1 G2 and G3 to be 14 AWG min G1 green lug on the housing to the lug on the CD30A bracket G2 soldered internally to ground terminal on 1TB and other end to the lug on CD30A bracket G3 transformer housing to the lug on the CD 30A bracket 8 October 2004 WARRANTY LIMITATION OF LIABILITY Seller warrants only title to the products software supplies and materials and that exce
8. imulate an external input pulse 7 Verify that the CD30A output shaft rotates 180 degrees for each external input pulse Note Any internal coincidence pulses that provide the next start command for the CD30A must occur when the CD30A is stopped and the PROX Hold LED is on The maximum valid flow proportional sampling rate is 2 5 seconds per sample 24 samples min Sample Probe and CD30A Check Out 1 Disconnect AC power from the CD30A 2 Verify that jumper is installed to select the desired mode of operation 3 Mount the CD30A to the sample probe and hand tighten the DC 2 coupling 4 Verify that the product line is full and pressurized 5 Hold a 100 ml graduated beaker or other applicable measuring device under the probe s discharge port and collect 10 samples Each sample should be 1 5 ml in size the total volume for 10 samples therefore should be 15 ml Motor Control Operation The CD30A motor control assembly consists of a command board motor drive and interconnect board mounted to a bracket which in turn is mounted to the back of the CD30A gear motor All field connections are to terminal blocks 1TB and 2TB The motor and proximity switch connections are made at the factory to terminal block 3TB on the interconnect board Command Board Functions The CD30A command board performs the following functions e Components C4 R3 CR1 and a U3 gate provide a 100 msec power up reset e A 1 024 Hz time base i
9. ode of operation as follows a Connect jumper wire between 2TB 5 and 2TB 6 to select the repeat mode Figure 2 b Connect jumper wire between 2TB 5 to 2TB 4 to select the pulsed mode of operation Figure 2 When the pulsed mode is selected the flow pulse input must be wired to 2TB 3 signal and 2TB 2 common If an electronic square wave is utilized it must have a pulse amplitude of 10VDC A 5VDC square wave will not work The jumper between 2TB 1 and 2TB 2 adds filter capacitance to the flow pulse input circuit This jumper must be in place for input flow pulse rates up to 10Hz This jumper must be removed when high frequency flow rate signal inputs 10 to 1000 Hz are to be utilized 115 VAC power Ground Filter Jumper required for input flow rates up to 10 Hz remove jumper for rates of 10 to 1000 Hz Input pulse Mode select pulsed Mode select repeat S606 06 Soe Figure 2 Field wiring of CD30A 115VAC assembly 1TB and 2TB October 2004 3 Figure 3 Terminal block 3TB on interconnect board prewired at factory 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 CD30A control and drive assembly from the sample probe 2 Connect the jumper between 2TB 5 to 2TB 6 to
10. pt as to software the same are free from defects in workmanship and materials for a period of one 1 year from the date of delivery Seller does not warranty that software is free from error or that software will run in an uninterrupted fashion Seller provides all software as is THERE ARE NO WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS OR OTHERWISE WHICH EXTEND BEYOND THOSE STATED IN THE IMMEDIATELY PRECEDING SENTENCE Seller s liability and Buyer s exclusive remedy in any case of action whether in contract tort breach of warranty or otherwise arising out of the sale or use of any products software supplies or materials is expressly limited to the replacement of such products software supplies or materials on their return to Seller or at Seller s option to the allowance to the customer of credit for the cost of such items In no event shall Seller be liable for special incidental indirect punitive or consequential damages Seller does not warrant in any way products software supplies and materials not manufactured by Seller and such will be sold only with the warranties that are given by the manufacturer thereof Seller will pass only through to its purchaser of such items the warranty granted to it by the manufacturer 49 NuFlo Measurement Systems NuFlo Measurement Systems 14450 John F Kennedy Blvd Houston TX 77032 www nuflotech com North America UK 800 654 3760 44 1243 826741 281 582 9500 Houston
11. s generated by R8 R9 C11 and a U2 gate U6 is a divide by 1024 counter which produces the 1 Hz repeat mode time base e An input filter circuit R11 R12 CR4 CR5 C6 and a U3 gate buffer incoming pulses from an external flow measuring device An extra filter capacitor C13 is selected by a jumper between 2TB 1 and 2TB 2 for low frequency contact inputs e An input filter circuit comprised of R7 C7 CR3 CR6 and a U3 gate conditions the repeat or pulsed mode signal prior to the signal being fed to the pulse scaling circuitry e A frequency divider circuit features switch selection of the divide by factor from 1 to 9 999 via SW1 X1 SW2 X10 SW3 X100 and SW4 X1000 The divider circuit utilizes dual decade counters U1 and U2 and diode packages DA1 DA2 DA3 and DA4 Co incidence between the switch setting and decade counters U1 and U2 produces a logical 1 signal at the U3 gate input connected to pull up resistor R2 The co incidence pulse is filtered by R5 and C2 and applied to a U4 gate which provides the logical or function with the power up reset POR October 2004 5 signal prior to application to the dual decade counter reset lines The start pulse also sets the RUN STOP latch US When set by a start pulse the RUN STOP latch USA outputs the speed command voltage to the summing point control amplifier U8A Amplifier U8B provides current feedback to the summing point control amplifier U8A Resistor R26 provides arma
12. tor to minimize coast past the desired probe stopping point Resistor R1 is the current sensing resistor for the current limit circuit Regulator Q1 provides 10 VDC for the sample command card Interconnect Board Functions The CD30A interconnect board performs the following functions Provides separate wiring terminals for power and signal connections Feed through holes in front of the power and signal terminal blocks allow for routing of power cable and signal wires These feed through holes keep the power and signal wires separate and also help prevent wires from contacting the cover which could cause abrasion of the insulation Provides a terminal block and feed through hole for the motor and proximity switch wires Routes all external signals to connector J1 Provides a mounting base for the replaceable electronics assembly consisting of the motor drive and sample command boards October 2004 Repairs If the CD30A assembly fails to perform as described in this manual consult a NuFlo Measurement Systems factory for assistance and or repairs Important Attempts to repair the assembly without consulting the NuFlo Measurement Systems will invalidate product warranties CD30A 115VAC Assembly Part No 50132381535 Parts List QTY CONTROL NO DESCRIPTION 1 1 50142304856 ENCLOSURE 50142381633 SPEED CONTROL 115VAC 50142307700 MOTOR CS CD DRIVE 50142382006 HUB ASSEMBLY CD DRIVE 50142200170 JAM NUT CS CD DRI
13. ture voltage feedback to the summing point control amplifier U8A DS1 is the PROX LED indicator U7A and U7B are the proximity switch amplifiers Note that the voltage across the proximity switch 3TB 3 to 3TB 4 on the power board will be nominally 8 VDC when the proximity switch is sensing metal and 4 VDC when the proximity switch is sensing an absence of metal Latch USB outputs a 500 msec one shot pulse to reset the RUN STOP latch USA when the proximity switch first senses a high point on the cam DS1 is the current limit LED indicator Power Board Functions The CD30A 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 current of transformer T1 or if secondary current is excessive Transformer T1 converts the 115 VAC input to 14 VAC secondary voltage This transformer has a 98 Celsius thermal fuse wired in series with the primary to assure the maximum transformer class B insulation temperature is never reached Diodes CR1 CR2 CR3 and CR4 provide full wave rectified DC voltage to be used to drive the motor and to make the regulated 10 VDC Transistor circuits including Q2 Q3 and Q4 provide the output drive control for the gear motor which has a 0 to 6 3 VDC armature and permanent magnet field Power FET Q5 is on when the RUN STOP latch outputs a motor stop command Q5 provides electronic braking of the mo
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