5. Troubleshooting
Contents
1. such as pressure and temperature instruments conform to the actual conditions 3 Verify operating temperature operating pressure line size and process medium If conditions and specifications are satisfactory then refer to the troubleshooting chart in the back of this chapter for troubleshooting suggestions Troubleshooting the Flow Element Use Tables 5 1 and 5 2 to determine if the flow element is wired correctly or has failed Turn off the input power to the instrument Unplug the control circuit from its socket and measure the resistances below from the terminal block socket If the instrument is set up in remote configuration flow element enclosure seperate from the control circuit enclosure and the ohm readings are incorrect disconnect the flow element cable at the local flow element enclosure Measure the resistance as shown in Table 5 2 If the resistance is correct then the cable between the enclosures is probably bad or not connected properly loose corroded or connected to the wrong terminal Table 5 1 Resistances at Control Circuit Terminal Block Socket NOMINAL CONTROL CIRCUIT RESISTANCE RESISTANCE 1 1 K OHM LUG NUMBER 2 2 K OHM 110 OHM FOR FLT93 S 560 OHM FOR FLT93 F 1 1 K OHM Table 5 2 Resistance at Flow Element Enclosure Terminal Block Remote Applications Only NOMINAL RESISTANCE AT LOCAL ENCLOSURE TERMINAL BLOCK TERMINAL NO RESISTANCE 1TO2 110 OHM FOR FLT93 S 560 OHM FOR FLT932. CHAPTER 5 TROUBLESHOOTING FLUID COMPONENTS INTL 5 Troubleshooting Warning Only qualified personnel should attempt to test this instrument The operator assumes all responsibilities for safe practices while troubleshooting Caution The control circuit contains electrostatic discharge ESD sensitive devices Use standard ESD precautions when handling the control circuit See Chapter 2 Operation for ESD details Tools Needed Digital Multimeter DMM Quick Check Verify that the control circuit is seated firmly LED DS3 should be lit when power is applied and in most cases it should not be blinking Ensure that the jumpers are in the correct position See Chapter 3 for the correct positions The power is factory preset for 220 Vac the customer may need to reset jumpers for other power input Ensure that the CALIBRATE RUN switch is in the RUN position switch S1 positioned toward the heat sink If LED DS3 flashes the heater power is set to high for most applications Check any customer supplied fuses See the troubleshooting chart in Figure 5 1 at the end of this chapter Non maintenance Observations At this point observe the system setup to verify operation No disassembly or testing is required at this time Check Serial Numbers Verify that the serial number of the sensing element and the control circuit are the same number The sensing element and the control circuit are a matched set and cannot be operated independ
3. F 3 TO4 1 1 K OHM 3 TO5 2 2 K OHM 4TO5 1 1 K OHM SHIELD CONNECTED TO CONTROL CIRCUIT SOCKET ONLY NO CONNECTION TO LOCAL ENCLOSURE OR ITS TERMINAL BLOCK Troubleshooting the Flow Transmitter With power applied measure 9 volts DC 2 8 to 10 volts from Plug P1 Pin 1 to Pin 4 See Figure 3 2 for the location of P1 FLTO Series FlexSwitchd 5 2 Doc No 06EN003247 Rev B CHAPTER 5 TROUBLESHOOTING FLUID COMPONENTS INTL 1 Is the Yellow LED ON OFF or BLINKING Mode Switch 3 Signal Voltage Observation Power Supply Check LED ON Although the LED is on it may appear dim This is caused by the unit being supplied with 115 Vac and the Input Power Jumper Configuration set to the default setting of 230 Vac Input power and the jumper configuration OK See Step 2 NOT OK Pull out the control circuit and set the jumpers correctly Reinstall the control circuit and restart the system LED OFF Check the Input Power Jumper Configuration setting and verify the input power OK See Step 4 NOT OK Pull out the control circuit and set the jumpers correctly and verify the input power Reinstall the control circuit and restart the system and check for proper operation If LED is still off go to Step 4 LED BLINKING For Liquid Flow Applications Line is DRY Make sure the line is packed For Gas Flow Applications Heater power set too high Set to lower value For Liquid level Applications Heater power set
4. ed FCI Field Agent There is an extensive list of these representatives at the front of this manual 2 Before contacting the FCI representative please be sure that all the applicable information is near so that a more effective efficient and timely response may be provided 3 Refer to Appendix C for specific Customer Service policy provisions FLTO Series FlexSwitchd 5 4 Doc No 06EN003247 Rev B
5. ently of each other The exception to this is if a removal and replacement have been done for repair purposes All calibrations and jumpers must have been done and set Check Input Power Verify that the correct power source is turned on and connected Verify that the power jumpers are correct for the application See Chapter 3 for the correct positions Check the Instrument Installation Review the information on instrument installation in Chapter 2 to verify correct mechanical and electrical installation Check for Moisture Check for moisture on the control circuit Moisture on the control circuit may cause intermittent operation For normally dry conditions check for moisture on the sensing element If a component of the process media is near its saturation temperature it may condense on the sensing element Place the sensing element where the process media is well above the saturation temperature of any of the process gases Doc No 06EN003247 Rev B 5 1 FLTO Series FlexSwitch FLUID COMPONENTS INTL CHAPTER 5 TROUBLESHOOTING Check Application Design Requirements Application design problems may occur with first time application instruments although the design should also be checked on instruments that have been in operation for some time If the application design does not match field conditions errors occur 1 Review the application design with plant operation personnel and plant engineers 2 Ensure that plant equipment
6. the procedure to check the temp comp settings and balance adjustment Temp Comp Settings are Wrong Perform the Restore Temp Comp Procedure Then perform the sensor Balancing procedure Temp Comp Settings are OK Perform the Balancing procedure Restart the system for proper operation See Step 9 Make sure that the jumpers are set correctly The related settings are the Alarm Duty Alarm Quantity and the Energization Refer to the charts in chapter 3 or the bottom of the control circuit Using the Mode Switch set to Cal check and record the alarm settings Compare these setting to the signals generated by the process and make adjustment if necessary Refer to the Operation chapter for guidelines on setting a switch point in your particular application Figure 5 1 Troubleshooting Chart Spares FCI recommends an extra control circuit to be kept as a spare The control circuit part number is 5294 XXX The dash number can be found on the control circuit the enclosure and on the ordering paper work Defective Parts Before returning any equipment to FCI please obtain an RA number for authorization tracking and repair replacement instructions If a return is required remove defective instrument replace with spare calibrate then return defective instrument to FCI freight prepaid for disposition Customer Service 1 In the event of problems or inquiries regarding the instrument contact the Regional or Country Authoriz
7. too high Set to lower value For Liquid Interface Applications In some cases it is necessary to set the heater power to the maximum value to achieve the maximum signal difference between the two liquids For this application it is normal for the LED to blink if the element goes dry Go to Step 2 Make sure the mode switch is in the RUN position OK See Step 3 Remove the Heater Wattage Control jumper With a voltmeter measure the signal voltage at P1 Terminals 1 and 2 a The voltage is 0 volts 25 mV OK Reinstall the jumper and wait 5 minutes Go to c or d which ever is applicable b The voltage is out of tolerance NOT OK Make sure that the serial numbers on the control board and the sensing element match If the serial numbers are OK then go to the Restoring Temp Comp Adjustments procedure in Appendix D then go to c or d which ever is applicable c The Voltage is between 1 and 6 volts and changes with flow or level changes OK See Step 9 d The voltage is still about 0 volts or the voltage is over 7 volts or the voltage is negative between 1 and 6 volts and changes with flow or level changes Not OK Sensing element may be miswired or is defective Miswiring is more common on remote installations at the initial installation See Step 6 for integral installation Step 7 for remote installations Measure the voltage at P1 terminals 3 to 4 Voltage is 0 volts NOT OK See Step 5 Voltage is 9
8. volts OK See Step 6 for integral installation Step 7 for remote installations Figure 5 1 Troubleshooting Chart Doc No 06EN003247 Rev B 5 3 FLTO Series FlexSwitch6 FLUID COMPONENTS INTL CHAPTER 5 TROUBLESHOOTING Fuse Check Sensor Element Check for Integral Installation Sensor Element Check for Remote Installation Sensor Balance and Temp Comp Settings Check Alarm Switch Point Settings Turn off the power to the FLT and remove the control circuit With an ohmmeter measure the continuity of the fuse F1 Fuse has no continuity NOT OK Replace the fuse and restart the system Check for proper operation Call the factory if the fuse fails again Fuse has continuity OK Control circuit is defective Replace it with a control circuit that has the temp comp adjusted for the particular sensing element Follow the Restoring temperature compensation settings procedure in Appendix D and restart the system Turn off the power and remove the control circuit Follow the Troubleshooting the Flow Element procedure in this chapter Sensor Failure Call the Factory Sensors are OK See Step 8 Turn off the power and remove the control circuit Follow the Troubleshooting the Flow Element procedure in this chapter Remote cable miswired or damaged Repair and restart the system Sensor Failure Call the Factory Sensors are OK See Step 8 Turn off the power and remove the control circuit Follow
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