Clif Mock
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1. NuFlo Clif Mock CD20A 115 Sampler Drive User Manual 427 NuFlo Measurement Systems A NuFlo Technologies Company iii O 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 20165014A April 2004 Table of Contents assistant Pulse Input Scala neo Repeat Time Scaling Installation and WING naeh St rt Up Proc dure ici Pre TestProced fen un sis A see Repeat Mode Check ad External Input Pulse Mode Check Out n Sample Probe and CD20A Motor ann Control Card FUNCION S actina Power Board FUNCIONS lia e tide tales aara Sampler Drive 2 5 e ae iai April 20042. April 2004 Description The CD20A Control and Drive Assembly is engineered specifically for use with the True Cut C Series sample probes It comprises the following components e 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 CD20A 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 e a9VDC gear motor with a gear ratio of 150 1 e with two high points located opposite each other mounted on the gear motor output shaft e a proximity switch mounted in the hub assembly opposite the cam When 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 e a coupling jam nut and hub which allow the CD20A 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 e anexplosion proof housing encloses the complete assembly Two in NPT holes allow connection of the 115V AC 50 60 Hz line power and input pulse for flow proportional sampling A Y in breather plug is install
3. pulse the RUN STOP latch U4A outputs the speed command voltage to the summing point control amplifier UTA Amplifier U7B provides current feedback to the summing point control amplifier UTA Resistor R18 provides armature voltage feedback to the summing point control amplifier UTA DS1 is the current limit LED indicator DS2 is the PROX Hold LED indicator U8 is the proximity switch amplifier The voltage across the proximity switch 2TB 3 to 2TB 4 on the power board will be nominally 8 VDC when the proximity switch is sensing metal and 4VDC when the proximity switch is sensing an absence of metal Latch U4B outputs a single 500 msec one shot pulse to reset the RUN STOP latch U4A when the proximity switch first senses a high point on the cam Power Board Functions The CD20A power board provides the following functions Fuse Fl 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 115VAC input to 14 VRMS secondary power when primary jumpers W1 and W2 are installed Diodes CR2 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 CD20A 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 bra
4. 142200170 JAM NUT CS CD DRIVE 6 1 50142150932 DRIVE COUPLING ASSY DC 2 7 1 50142307695 DRIVE SHAFT 8 1 50142381667 COUPLING CAM MOTOR ASSEMBLY 9 1 50142309906 PROXIMITY SWITCH El 08 01 NACS 10 1 50142307686 ADAPTER PLATE 11 1 50142304632 PLUG 1 2 CONDUIT 12 1 50142307696 SNAP RING 13 1 50142200101 TAG ELECTRICAL CD DS DRIVE 14 4 50025400765 DRIVE SCREW 2 3 16 15 11 50142307693 BINDER HD SCREW 8 32NC x 1 2 LG 16 11 50142307694 WASHER HUB SCREW 8 17 1 50142304642 BREATHER 1 2 PLUG 18 1 50142400194 JUMPER RDI J4 02 19 1 50142200109 CAUTION TAG CD20 CD20A CD30 DRIVES 20 1 50142304858 HUMISORB PACKET 107HX 4 x 4 April 2004 April 2004 WARRANTY LIMITATION OF LIABILITY Seller warrants only title to the products software supplies and materials and that except 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 sup
5. B 5 Pulse Input Collector X10 Switch gt Repeat E1 jumper 1TB 3 Pulsed for selecting mode X1 Switch gt 115VAC Power PROX Hold LED ls E 4 1 1 115VAC Power Figure 1 Field wiring of CD20A 115VAC assembly 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 CD20A control and drive assembly from the sample probe 2 Connect the El jumper to 1 4 to select the repeat mode 3 Set the X10 and X1 switches to 60 This sets a 60 second repeat time 4 Connect a pushbutton switch across ITB 5 and 1T B 6 for test purposes Repeat Mode Check Out 1 Apply 115VAC input power to the CD20A 2 Verify that the PROX Hold LED is on when the motor is not turning 3 After the CD20A off delay time verify that the output shaft turns in CLOCKWISE CW direction as you look at the shaft The sample probe will then be rotated COUNTERCLOCKWISE CCW when the CD20A is connected to it If the direction of motor rotation is wrong swap the motor armature leads at 2TB 1 and 2TB 2 April 2004 3 4 Verify that the CD20A output shaft rotates 180 degrees and stops after each off delay period It should take about 2 5 seconds for the motor
6. change power board or CD20A motor control Check for jumper across 115VAC to Neutral To isolate the problem power down and remove the CD20A from the probe and verify CD20A 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 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 CD20A motor control assembly Replace 150 1 ratio gear motor 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 Replace CD20A assembly or CD20A power board Remove drive from sample probe and run If the motor still runs slow then remove motor from hub and adapter plate and run Replace CD20A motor control Check for proper input voltage at 1 1 and 1TB 2 With power off check fuse F1 continuity from 1TB through the F1 fuse clips Connect 1 to 1TB 3 for pulsed mode operation or 1TB 4 for repeat mode operation Verify motor wiring Verify motor impedance by disconnecting the motor leads and check for an open armature April 2004 Problem Probable Cause Motor does not run Transistor Q4 or Q2 has failed conta Input pulses are not present at 1TB 5 and 1TB 6 In the case of an electro
7. ed on one side of the enclosure and a Y2 in conduit plug is installed on the opposite side of the enclosure The motor speed control unit allows selection of pulse input flow proportional or repeat time proportional control of the sample probe Pulse Input Scaling The four pulse scaling switches labeled X1000 X100 X10 and X1 allow selection of the desired number of flow pulses per sample Some switch setting examples are shown below Pulse Input Switch Setting Examples 1000 100 10 1 Pulses Per Sample 0 0 0 1 1 0 0 1 0 10 0 1 0 0 100 1 0 0 0 1 000 1 2 3 4 1 234 9 9 9 9 9 999 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 April 2004 1 Repeat Time Switch Setting Examples Switch Settings Time Between Samples 1000 100 10 1 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 Installation and Wiring The CD20A mounts directly to the C Series sample probe via DC 2 coupling The DC 2 coupling should be hand tightened only to ensu
8. in size the total volume for 10 samples therefore should be 15 ml Motor Control Operation The CD20A 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 CD20A gear motor All field connections are to terminal block ITB 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 The CD20A control card performs the following functions e Components C5 R8 CR4 and a US gate provide a 100 msec power up reset e 1Hz time base is generated by C8 R11 R12 a US gate and U6 This time is wired to the pulse scaling circuit when the repeat mode is selected e An input filter circuit at 1TB 5 buffers incoming pulses from an external flow measuring device This circuit has an extra filter capacitor C1 which is selected by a jumper between 1T B 6 and 1T B 7 for low frequency contact inputs 4 April 2004 Jumper El selects start pulses from the external pulse source or the 1Hz time base The selected pulses are applied to the pulse scaling circuit A frequency divider circuit divides the pulses at El by the decimal value on switches SW1 1000 SW2 X100 SW3 X10 and SW4 X1 Any number from 1 to 9999 can be selected A sample start pulse is generated when a number of input pulses equal to the switch settings have been received at El When set by a start
9. king of the motor to minimize coast past the desired probe stopping point Resistor 5 is the current sensing resistor for the current limit switch Regulator U1 provides 12VDC for the control card April 2004 Troubleshooting Problem Input power fuse F1 is open Current limit LED is on the motor is stopped Current limit LED is on motor runs at a slow speed Motor does not run Probable Cause Transformer T1 has an internal secondary winding or primary winding short Rectifier diode CR2 CR3 CR4 or CR5 shorted Input power transformer jumper installed incorrectly Sample probe jammed or the motor armature is driving the probe backwards CW against the cam drop off point Short across A1 to A2 of CD20A motor output due to a short in power FET Bind up in gear box Bind up due to alignment of adapter plate or hub Transistor Q4 or Q2 has failed Motor overload CD20A current limit circuit failure Input power not on Fuse clips corroded and 1 is not making contact or fuse F1 is open Jumper E1 is not connected to 1TB 3 or 1TB 4 Motor circuit open or leads not connected to 2TB 1 and 2 TB 2 Recommended Action 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 Check diodes with an ohmmeter and replace or
10. nic driver the input pulses at 1 TB 5 and 1TB 6 do not have a 12VDC pulse amplitude due to incorrect wiring Motor continues to run Proximity switch is not sensing The PROX Hold LED the high points on the cam never comes on CD20A motor control failure Motor runs at full speed Output transistor Q4 has failed or faster continuously Recommended Action Replace CD20A assembly or CD20A power board Use a separate switch input to verify the CD20A is operating correctly in pulse mode Use a portable oscilloscope to verify proper pulse input Check for proper wiring Figure 1 Check proximity switch and cam alignment Replace CD20A motor control assembly Replace Q4 with an MJE 3055 or replace the CD20A motor speed control April 2004 CAUTION DO NOT CONNECT ANY AC POWER CURRENT or VOLTAGE TO PULSE INPUT TERMINALS UNIT REQUIRES 12 VDC SQUARE WAVE CURRENT SINKING DEVICE NPN or OPEN DRAIN FET OR DRY CONTACT CLOSURE REMOVE JUMPER amp WIRE TAG BEFORE CONNECTING SIGNAL WIRES 29 SERIAL MODEL VOLTS PH HZ April 2004 CD20A 115VAC Parts List CONTROL NO DESCRIPTION 1 1 50142304856 ENCLOSURE 2 1 50142381631 SPEED CONTROL 115VAC 3 1 50142307700 MOTOR CS CD DRIVE 4 1 50142382006 HUB ASSEMBLY CD DRIVE 5 1 50
11. plies 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 27 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 Singapore 877 891 6540 Calgary 65 6737 0444
12. re that the internal retaining ring is not pushed out of its groove If the DC 2 coupling is over tightened at the CD20A 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 CD20A 115VAC 1 Connect 115 50 60 Hz power to 1 1 and ITB 2 2 Select the pulsed or repeat mode of operation as follows a Connect jumper wire El to ITB 4 to select the repeat mode b Connect jumper wire El to ITB 3 to select the pulsed mode of operation When the pulsed mode is selected the flow pulse input must be wired to ITB 5 signal and 1TB 6 common If an electronic square wave is utilized it must have a pulse amplitude of 12VDC A 5VDC square wave will not work The jumper between 1 6 and ITB 7 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 A 12VDC output is available at 1TB 8 for powering external flow pulse circuiting such as a turbine meter pre amplifier Maximum current from this supply is 50 mA 2 April 2004 Jumper required for input flow rates up to 10 Hz remove jumper for rates of 10 to 1000 Hz 1 8 12VDC Output 1000 Switch gt 4 1TB 7 Filter X100 Switch gt 1TB 6 Pulse Input Emitter 1T
13. to rotate 180 degrees and stop 5 Verify the I LIMIT LED blinks on momentarily during acceleration of the CD20A motor After the motor reaches the 16 18 rpm running speed the I LIMIT LED should turn off 6 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 Disconnect AC input power from the CD20A 2 Move the El jumper to 1T B 3 to select the external input pulse mode 3 Set the X1000 X100 and X10 switches to 0 and the X1 switch to 1 This selects a sample output for each input pulse 4 Reapply AC power to the CD20A 5 Verify that the CD20A output shaft rotates 180 degrees for each external input pulse Note Any internal coincidence pulses that provide the next start command for the CD20A must occur when the CD20A 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 CD20A Check Out 1 Disconnect AC power from the CD20A 2 Verify jumper El is connected to either ITB 3 or 1TB 4 to select the desired mode of operation 3 Mount the CD20A to the sample probe and hand tighten the DC 2 coupling 4 Verify that the product line is full and pressurized 5 Hold 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
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